Patent Abstract:
A disposable absorbent article defining an absorbent chassis adapted to wrap around portions of a torso and a pair of side panels adapted to secure the absorbent chassis about the torso during use. The side panels include at least a pair of substantially inextensible zones and a zone of substantial elasticity providing partial extensiblity to the side panels. The side panels may be secured to the chassis at one of the inextensible zones and be provided with a fastener component at another inextensible zone. At least portions of opposed edges of the side panels are shaped into a nonparallel configuration to improve fit, comfort and exudate control of the absorbent article.

Full Description:
RELATED APPLICATION  
       [0001]     This application is a continuation-in-part of U.S. application Ser. No. 10/733,649, filed Dec. 11, 2003. 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates generally to disposable absorbent articles and more particularly to waste worn absorbent articles.  
       BACKGROUND OF THE INVENTION  
       [0003]     Absorbent articles, such as diapers, training pants and incontinence garments, provide a close, comfortable fit about the wearer and contain body exudates when such articles perform properly. Conventional absorbent articles include a front waist portion and a rear waist portion, which are releasably connected about the hips of the wearer during use by fasteners, such as adhesive tape fasteners or hook and loop type fasteners attached to a side panel, such as an elasticized ear, flap, tab or enlarged panel. For example, a conventional fastening system may have a pair of fasteners, such as adhesive tape tabs, located upon an ear or side flap structure, and a complimentary fastener, such as a taping panel, located on the outer surface of the outer cover of the diaper in the front waist portion of the diaper. In a diaper configuration, the absorbent article can be positioned between the legs of the wearer while the wearer is lying down and the adhesive tape tabs then releasably attached to the taping panel to secure the rear waist portion to the front waist portion of the diaper to secure the diaper about the waist of the wearer. In a training pant configuration, the side panels may be substantially larger than typical ears and with panel portions extending, for example, from a waist edge to a leg engaging edge.  
         [0004]     Prior art absorbent articles having side panels and conventional fastening systems have not been completely satisfactory and user needs of comfort, fit and exudate control remain elusive goals. Typical side panels are relatively narrow with generally parallel opposed side edges. Such side panels having generally linear edges can cause skin irritation and/or injury to the user&#39;s skin, as the linear edges have a tendency to focus garment retention forces to relatively narrow regions of the user&#39;s skin. Additionally, the forces exerted on the fastening system are often inefficiently transferred and distributed across the waist region of the diaper. As a result, the fit, comfort and exudate containment of conventional absorbent articles have not been completely satisfactory.  
       SUMMARY OF THE INVENTION  
       [0005]     A disposable absorbent article providing better fit, comfort and exudate control through application of an improved side panel structure. The side panel structure may be utilized, for example, on disposable absorbent articles such as diapers, disposable pull-on garments, and the like. Disposable pull-on garments include training pants, pull-on diapers, disposable underwear, and adult incontinence garments.  
         [0006]     Side panel structures in accordance with the present invention may be embodied as ears, tabs or larger panels extending laterally from side edges of an absorbent chassis near the front waist region, the rear waist region or both.  
         [0007]     Side panel structures in accordance with the present invention address many limitations of the prior art. Advantages provided by contoured or “shaped” panels side panels of the present invention include improved garment fit and comfort. Another advantage of such side panels is the minimization of user skin injury as garment attachment forces are transferred across a relatively wide, contoured side panel.  
         [0008]     A side panel structure in accordance with the invention includes one or more elastic zones providing panel extensibility and a plurality of inelastic zones. Each elastic zone may include one or more elastic members, such as threads, strands, ribbons, nets and films.  
         [0009]     A side panel structure in accordance with the invention is provided in a “shaped” configuration, with a free end, an opposite end attached to the absorbent chassis, and a pair of opposing side edges extending between the ends. At least portions of the opposing edges sides are shaped in substantially nonparallel configuration. Shaped side panels in accordance with the invention may embody opposing side edges having, for example, tapered or concave portions extending across one or more inextensible zones and/or elastic zones.  
         [0010]     The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]      FIG. 1  is a plan view of a disposable absorbent article in the unfolded configuration.  
         [0012]      FIG. 2  is a plan view of a side panel of  FIG. 1 .  
         [0013]      FIG. 3  is a perspective view of the side panel of  FIG. 2  with a cut-out detail to show an elastic construction.  
         [0014]      FIG. 4  is a plan view of a disposable absorbent garment having large “non-shaped” side panels.  
         [0015]      FIG. 5  is a plan view of another alternative disposable absorbent garment having “shaped” side panels.  
         [0016]      FIG. 6  is a plan view of an alternative side panel according to the present invention.  
         [0017]      FIGS. 7-9  are plan view of alternative disposable absorbent garments having shaped side panels.  
         [0018]      FIGS. 10-20  are partial plan views of alternative disposable absorbent articles having shaped side panels in accordance with the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0019]     For purposes of the present description, the term “side panel” is used to refer to a structure that extends laterally away from an absorbent chassis at a rear region, front region or both and being joined to the opposing waist region to allow for fitting of the absorbent article about the waist of the user. Side panels may be embodied, for example, as ear portions, tabs or larger panels. Side panels may be secured to an absorbent chassis at a side margin or may be integrated within the overall absorbent article design and/or construction. Side panels may include multiple plies of material along with one or more elastic elements such as, but not limited to, elastic threads, strands, ribbons, nets and films.  
         [0020]     In  FIG. 1 , an embodiment of an absorbent article in accordance with the invention is shown as garment  110  having a pair of shaped side panels  124 . Disposable absorbent garment  110  is of a type that can be placed against or in proximity to the body of a wearer so as to absorb and to contain various bodily exudates. It should be noted, however, that the present invention is applicable to a variety of disposable absorbent articles and garments, including training pants and a variety of adult incontinence products.  
         [0021]     Garment  110  includes an absorbent chassis which generally defines three main regions aligned along an imaginary longitudinal axis or plane AA. These regions include a first waist region  112  (typically at the front of the user when the garment  110  is worn), a back waist region  114 , and a crotch region  116 . Diaper  110  is also characterized by a front edge  140 , a back longitudinal edge  142 , a first lateral or side edge or side margin  144 , and a second lateral or side edge or side margin  146 . In this embodiment, the absorbent chassis is formed by a liquid permeable inner layer or topsheet  152 , a liquid impermeable outer layer or backsheet (not shown), and an absorbent core  154  sandwiched between the two layers.  
         [0022]     Side panels  124  are secured at or near the side margins  144 ,  146 . Side panels  124  are used to attach the waist regions  112 ,  114  together to secure garment  110  to a user. In this embodiment, side panels  124  are shaped to include a pair of nonparallel opposite side edges  124 d and  124 e. As illustrated, portions of side edges  124 d and  124 e taper inwardly toward each other. In other embodiments of the invention, portions of side edges  124  may taper outwardly, that is, the side edges may expand in relation to the distance from the absorbent chassis. A side edge  124  having an outwardly tapering configuration could be secured at one end to the front waist region of the garment  110 , with the free (wider) end being refastenably connected to the rear waist region during use.  
         [0023]     Garment  110  also has an elastic waistband  130  positioned in this embodiment generally along the back edge  142  to facilitate fastening and to enhance the fit and seal of the garment  110 . When the hourglass-shaped garment  110  is worn, the crotch region  116  fits about the crotch of the wearer, and the front and back waist regions,  112  and  114 , fit about the corresponding waist areas. The shaped side panels  124 , wrap at least partially about the wearer to secure garment  110  during use. In other embodiments of garment  110 , waistband  130  may be provided along the front edge  140 , rear edge  142  or both.  
         [0024]      FIG. 2  depicts shaped side panel  124  removed from the absorbent chassis. Shaped side panel  124  has a central zone  214  in which an elastic construction is situated. Extending laterally from this central elastic or elasticized zone  214  are zones  216  and  218 , which are substantially non-elasticized. Inelastic zone  216  provides a working area on which fastening materials and other accessories or structural attributes of the disposable absorbent garment may be situated. For example, a component of a hook and loop fastening system and/or an adhesive element may be situated within inelastic zone  216 . Inelastic zone  218  may provide an attachment zone within which side panel  124  is secured to the absorbent chassis.  
         [0025]     Shaped side panel  124  has end edges  210   a  and  210   b  and side edges  124   d  and  124   e.  Side edges  124   d,    124   e  include portions which are parallel (along inelastic zone  218 ) and portions which converge (along zone  214  and inelastic zone  216 ). Side panel  124  stretches, in the lateral direction (denoted by arrows XX).  
         [0026]      FIG. 3  provides a perspective view and partial cut-out of shaped side panel  124 . Shaped side panel  124  has a top layer  318  and a bottom or base layer  320 . The two layers  318 ,  320  preferably extend the total width and length of side panel  124 . Both base layer  320  and top layer  318  are preferably a breathable, disposable material such as propylene fabric, breathable polyethylene/polypropylene films, or non-porous films (or combinations of these materials). Base layer  320  and/or tope layer  318  may include woven and/or non-woven fabrics. Base layer  320  and top layer  318  adhere to one another, thereby sandwiching and securing a plurality of elastic elements  322  therebetween. Elastic elements  322  may include, for example, one or more of threads, ribbons, mesh, apertured film and other films. Thread-form elastic elements  322 , as shown in  FIG. 3 , may be substituted, in alternative embodiments, by suitable elastic elements such as elastic strands of different construction, nets, threads, ribbons, and elastic glue beads.  
         [0027]     The elasticized zone  214  of side panels  124  may be implemented in a variety of ways. For example, an elastic zone  214  may contain a single piece of stretchable elastic material or a combination of individual pieces or panels of elastic material. The elastic zone or at the least individual pieces or panels of the elastic zone may comprise elastic composite materials or non-stretchable materials which have been rendered elastically contractible by means known to those skilled in the art. In some embodiments, the elastic zone includes a two-ply stretch panel comprising a top layer, a bottom layer and a plurality of intermediate elastic ribbons. In another configuration, the elastic zone may be provided by a substantially non-elastomeric material, such as polymer films, woven fabrics, non-woven fabrics, or the like such as described above as being suitable for the outer cover or bodyside liner. Such an elastic zone could be modified to render portions elastically contractible to provide the desired elastic properties. In another example, the elastic material may be latent, in which case the elastic material would initially have non-elastomeric properties, but would later be activated to impart elastomeric properties to the stretch panel by any of various means known to those skilled in the art. Additional details of non-shaped side panel construction, including embodiments using aligned elastic threads, are disclosed in U.S. Ser. No. 10/733,649, and U.S. Ser. No. 11/113,114, and each application being incorporated by reference herein.  
         [0028]      FIG. 4 , provided for comparative purposes only, depicts a disposable absorbent garment  410  having a pair of “non-shaped” side panels  414 . Side panels  414  are separately attached to a central body  420  of garment  410 . Side panels  414  include side edges  415 ,  416  that are generally parallel, with side edge  416  defining at least a portion of a waist edge  442  of garment  410  and side edge  415  defining at least a portion of a leg edge. Side panels  414  have a non-elasticized zone  414   b  that is positioned outboard of the side margins  444 ,  446  of the garment  410  and a second non-elasticized zone  414   a,  at least a portion of which is attached inboard of the side margin  444 ,  446 . Thus, a central elastic zone  414 c is situated outboard of the side margin  444 ,  446  and not directly attached thereto. When garment  410  is worn, the central elasticized zone  414   a  allows the side panel to stretch in a lateral direction. Accordingly, during garment use side panels  414  allow for stretching about the waistline of the user. In another embodiment of the invention, another pair of side panels  414  may be secured near the front waist region providing a garment  410  with 4 side panels  414 .  
         [0029]      FIG. 5  depicts an alternative disposable absorbent garment  510  according to the invention. Certain aspects of garment  510  are numbered similarly to corresponding aspects of garment  410 . In comparison to the side edges  415 ,  416  of  FIG. 4 , garment  510  includes side edges  517 ,  518  which are substantially nonparallel across portion of side panels  414 . For example, portions of side edges  517 ,  518  within elastic zone  414   c  and inelastic zone  414   b  are generally tapered resulting in a reduction of side panel  414  width in a transverse direction of garment  510 . While a side panel  414  with generally linear taper is shown in  FIG. 5 , other side panel  414  shapes may include curves or combinations of lines and curves. For example,  FIGS. 8, 12 ,  13 ,  15  and  17  illustrate side panels with portions of side edges extending in nonlinear manners.  
         [0030]      FIG. 6  depicts an alternative embodiment of a side panel  610  suitable for use with embodiments according to the present invention. Side panel  610  illustrated therein differs from the previously described side panels ( 124 ,  210 ,  414 ) in that side panel  610  includes two elasticized zones  614   a  and  614   b.  Elasticized zones  614   a,    614   b  may be equidistantly spaced apart on either side of the longitudinal centerline AA. The spacing of the elasticized regions  614   a,    614   b  creates right and left non-elasticized or dead zones  616 ,  618 , as well as central non-elasticized region  650 . The elasticized regions  614   a,    614   b  imparts elasticity to side panel  610  in the lateral directions XX. Side panel  610  includes side edge  620  which extends in a linear manner across inelastic zones  618 ,  650 ,  616  and elastic zones  614   a,    614   b,  and another side edge  622  which extends in a parallel manner to side  620  within zones  618  and  614   a,  and extends toward side edge  620  in a tapering manner within zones  650 ,  614   b  and  616 .  
         [0031]     Referring to  FIGS. 7 and 8 , a disposable absorbent garment  910  is shown having a central body  920  and ear- and tab-shaped side panels  924  positioned proximate to a waist edge. Side panels  924  have inner and outer nonelasticized zones  924   a,    924   b,  and a central elasticized zone  924   c  situated therebetween.  FIGS. 7 and 8  illustrate side panels  924  having shaped nonelasticized regions  924   a  and  924   b,  as, for example, portions of side edges of side panels  924  converge within the inelastic zone(s)  924   a,    924   b.  In both designs, portions of the side edges of the outer nonelasticized regions  924   b  are rounded or curved.  
         [0032]     Now turning to  FIG. 9 , yet another variation of side panel  924  is shown applied to a training pant  910 . In this embodiment, side panel  924  is substantially larger than ear-shaped side panel  924  of  FIGS. 7 and 8 , and includes a waist edge and a leg engaging edge  930 . Side panel  924  is defined by nonelasticized zones  924   a  and  924   b  having different geometries.  
         [0033]      FIGS. 10-20  illustrate further aspects of the present invention. In each example, a disposable absorbent garment is shown having a central body and side panels in the form of ears, tabs or even larger panels. While these illustrated embodiments have side panels with inner and outer nonelasticized regions and a central elasticized region situated therebetween, other side panel embodiments may have a plurality of both elasticized and nonelasticized regions, configured for example as shown in  FIG. 6 .  
         [0034]     The exemplary embodiments of  FIGS. 10-20  illustrate a variety of differently configured side panels, in ear, tab or even larger form.  FIGS. 10-17  represent side panels which are generally symmetrical about an axis perpendicular to a longitudinal axis of the absorbent chassis. Opposite side edges of side panels of these embodiments would align if folded about the center axis. In comparison,  FIGS. 18-20  represent side panels which are asymmetric about a center axis.  
         [0035]     Turning to  FIG. 10   a,  the side panel  1010  is shown applied at a side margin  1046  of a disposable absorbent article near waist edge  1040 . Side panel  1010  has nonelasticized regions  1012 ,  1014  of different geometries. In the embodiment of  FIG. 10 , the nonelasticized regions  1012 ,  1014  have side edges which are generally parallel, while the side edges of elasticized region  1016  taper inwardly toward outer nonelasticized region  1012 . A fastening component  1018 , such as a hook and loop component is affixed or defined within nonelasticized region  1012 . Fastening component  1018  may extend generally between the side edges of the side panel, or alternatively, may extend within only a portion of nonelasticized region  1012 .  
         [0036]      FIG. 10   a  illustrates a side panel  1010  in a “tab” configuration, while  FIG. 10   b  shows a side panel  1010  with a substantially larger area extending generally from the waist edge to a leg edge and adapted to engage a user&#39;s leg during use.  
         [0037]     Now turning to  FIG. 11 , a side panel  1110  is shown applied at a side margin  1146  of a disposable absorbent article near waist edge  1140 . Side panel  1110  has nonelasticized regions  1112 ,  1114  of different geometries. In the embodiment of  FIG. 11 , the outer nonelasticized regions  1112  as well as in inward portion of nonelasticized region  1114  have side edges which are generally parallel, while the side edges of elasticized region  1116  and an outer portion of nonelasticized region  1114  taper inwardly toward outer nonelasticized region  1112 .  
         [0038]      FIG. 11   a  illustrates a side panel  1010  in an “ear” or “tab” configuration, while  FIG. 11   b  shows a side panel  1110  with a substantially larger area extending generally from the waist edge and having a leg edge adapted to engage a user&#39;s leg during use.  
         [0039]     Now turning to  FIG. 12 , a side panel  1210  is shown applied at a side margin  1246  of a disposable absorbent article near waist edge  1240 . Side panel  1210  has nonelasticized regions  1212 ,  1214  of different geometries. In the embodiment of  FIG. 12 , the nonelasticized region  1214  has side edges which are generally parallel, while the side edges of elasticized region  1216  and nonelasticized region  1212  taper inwardly. Similar to the embodiments of  FIGS. 10   b  and  11   b,  side panel  1212  (and the side panels of  FIGS. 13-20 ) can also be implemented as a substantially larger panel having, for example, a waist edge and a leg engaging edge.  
         [0040]     Now turning to  FIG. 13 , a side panel  1310  is shown applied at a side margin  1346  of a disposable absorbent article near waist edge  1340 . Side panel  1310  has nonelasticized regions  1312 ,  1314  of different geometries. In the embodiment of  FIG. 13 , the inward portion of nonelasticized region  1314  has side edges which are generally parallel, while the side edges of elasticized region  1316 , an outer portion of nonelasticized region  1314 , and nonelasticized region  1312  taper inwardly, in a concave manner.  
         [0041]      FIG. 14  illustrates a side panel  1410  applied at a side margin  1446  of a disposable absorbent article near waist edge  1440 . Side panel  1410  has nonelasticized regions  1412 ,  1414  of different geometries. In the embodiment of  FIG. 14 , the inner nonelasticized region  1414  has side edges which are generally parallel, while the side edges of elasticized region  1416  and outer nonelasticized region  1414  taper inwardly. Fastening component  1418  may extend generally between the side edges of the side panel or alternatively, may extend within only a portion of nonelasticized region  1412 .  
         [0042]      FIG. 15  illustrates a side panel  1510  as applied at a side margin  1546  of a disposable absorbent article near waist edge  1540 . Side panel  1510  has nonelasticized regions  1512 ,  1514  of different geometries. In the embodiment of  FIG. 15 , the inward portion of nonelasticized region  1514  has side edges which are generally parallel, while the side edges of elasticized region  1516 , an outer portion of nonelasticized region  1514 , and nonelasticized region  1512  taper inwardly, in a convex manner.  
         [0043]      FIG. 16  shows a side panel  1610  as applied at a side margin  1646  of a disposable absorbent article near waist edge  1640 . Side panel  1610  has nonelasticized regions  1612 ,  1614  of different geometries. In the embodiment of  FIG. 16 , the nonelasticized region  1614  and elasticized region  1616  have side edges which are generally parallel, while the side edges of nonelasticized region  1612  taper inwardly.  
         [0044]      FIG. 17  shows a side panel  1710  as applied at a side margin  1746  of a disposable absorbent article near waist edge  1740 . Side panel  1710  has nonelasticized regions  1712 ,  1714  of different geometries. In the embodiment of  FIG. 17 , the nonelasticized region  1714  and elasticized region  1716  have side edges which are generally parallel, while the side edges of nonelasticized region  1712  taper inwardly, in a concave manner.  
         [0045]      FIG. 18  shows a side panel  1810  as applied at a side margin  1846  of a disposable absorbent article near waist edge  1840 . Side panel  1810  has nonelasticized regions  1812 ,  1814 . In the embodiment of  FIG. 18 , the nonelasticized regions  1812 ,  1814  have side edges which are generally parallel, while one of the side edges of elasticized region  1816  tapers inwardly.  
         [0046]      FIG. 19  shows a side panel  1910  as shown applied at a side margin  1946  of a disposable absorbent article near waist edge  1940 . Side panel  1910  has nonelasticized regions  1912 ,  1914  of different geometries. In the embodiment of  FIG. 19   a,  the nonelasticized region  1914  has side edges which are generally parallel, while one of the side edges of elasticized region  1816  and one of the edges of nonelasticized region  1912  taper inwardly. In comparison,  FIG. 19   b  shows a side edges which are parallel across zone  1914  and a portion of zone  1916  and then taper inwardly across the balance of zone  1914  and zone  1912 .  FIG. 19   b  represents an elastic zone  1916  having both parallel and non-parallel side edges.  
         [0047]      FIG. 20  shows a side panel  2010  as shown applied at a side margin  2046  of a disposable absorbent article near waist edge  2040 . Elastic composite band  2010  has nonelasticized regions  2012 ,  2014  of different geometries. In the embodiment of  FIG. 20 , a portion of nonelasticized region  2014  and nonelasticized region  2012  have side edges which are generally parallel, while one of the side edges of elasticized region  2016  and another portion of nonelasticized region  2014  tapers inwardly.  
         [0048]     Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Technology Classification (CPC): 0