CZ20004264A3 - The device allows for uniform distribution of the medium from a single inlet duct (1) to nineteen outlets regularly spaced along the circular surface of the bottom of the fermentation tank. Six structurally identical pipe branches come from the central distributor (2). Their leading segment (4) at a uniform distance from the reactor axis turns to the bottom and passes into a lateral distribution pot (7), from which three congruent constricting segments emerge at 120 ° - two marginal (5) and one centreline (6) , which, at a uniform distance from the side distributor (7), is turned by its outlet (9) to the bottom opposite the distribution cones (10). The central outlet segment (3) extends directly from the central distributor (2), incorporates a pressure loss compensating loop (8), and is turned in its outlet (9) against the distribution cone (10) at the center of the tank bottom. - Google Patents

Abstract

The disposable diaper has a front region (26), a back region (28) and a crotch region (30) between the front region (26) and the back region (28). The disposable diaper includes a body (41) and connecting edges (12, 13). The body (41) comprises a top fabric (24) and a back fabric (22) which is joined to the top fabric (24) and an absorbent core (25) which is sandwiched between the top fabric (22). The body (41) has a central panel having side edges and a waist edge and an ear panel (10, 11) extending laterally outwardly from each side edge of the central panel in the front region (26) and the back region (28). The ear panel (10, 11) is expandable so as to form an expandable ear (46, 48). The expandable ear (46, 48) has a higher edge end (46A, 48A), a lower edge end (46B, 48B), an inner side edge (46C, 48C) and an outer side edge (46D, 48D). The outer side edge (46D, 48D) is not parallel to the inner side edge (46C, 48C) and is not parallel to the longitudinal centerline (100) of the diaper and intersects laterally outwardly the nearest higher edge end. The lateral width (L2) of the expandable ear (46, 48) between the inner side edge (46C, 48C) and the outer side edge (46D, 48D) is greater at the nearest higher edge end (46A, 48A) than at the nearest lower edge end (46B, 48B). The connecting edges (12, 13) connect each ear panel (10, 11) along the outer side edge (46D, 48D) to a corresponding portion on the opposite region of the disposable diaper to form one waist opening (36) and two leg openings. The connecting edge (12, 13) is not parallel to a parting line (100) running through the center of the diaper.

Description

Technical field

The present invention relates to disposable underwear. Examples of such disposable clothing items include disposable underwear items, disposable diapers including pull-on diapers and sports pants, and disposable menstrual panties. More specifically, the present invention relates to disposable underwear with increased stretch around the waist opening.

State of the art

Infants and other incontinent individuals use disposable undergarments such as diapers to capture and contain urine and other body exudates. Pull-on undergarments with fixed sides (such as nursing pants or pull-on diapers) have become popular. To contain body exudates and accommodate a wide range of body shapes and sizes, the undergarment must fit snugly around the wearer's waist and legs without sagging, sagging, or slipping from its position on the torso, and it must fit larger wearers without irritating the skin due to excessive tightness.

Many types of pull-on undergarments use conventional elastic elements secured in an elastically shrinkable state around the waist and leg openings. For example, pull-on undergarments known as "balloon-type" pants are shrunk in specific zones of the product by elastic bands, while the remaining material tends to bulge. Examples of such pull-on undergarments are described in U.S. Patent 5,171,239, issued 1992-12-15, and U.S. Patent 4,610,681, issued 1986-09-09. These undergarments accommodate a range of waist and leg volume sizes due to the fact that the shrunk elastic portion around the openings can be expanded to fit a wide variety of wearers. However, the range of sizes is limited because the elastic elements that allow for such dimensional variability have a limited degree of extensibility. Narrow elastic bands used around the waist and leg openings also tend to concentrate all forces into a narrow zone on the wearer's body, leading to increased indentations on the wearer's skin.

Another type of pull-on undergarment utilizes side panels. Examples of this type are described in U.S. Patent 4,940,464 of 1990-07-10, U.S. Patent 5,246,433 of 1993-09-21, U.S. Patent 5,545,158 of 1996-08-13, U.S. Patent 5,591,155 of 199701-07, and in EP 0 526 868 A1 published 1993-02-10. This undergarment has side panels that extend outwardly at the sides at both the front and back of the undergarment. The side panels have an inner side edge and an outer side edge, each of which is parallel to each other and to the longitudinal centerline of the undergarment. The garment is also provided with joints to connect the outer side edges of the side panels to form one waist opening and two leg insertion openings. Since the side edges are parallel to each other and are also parallel to the longitudinal centerline of the undergarment, each elastic edge incorporated in the side panel has the same width in the lateral direction or the same available amount of elastic material on the side panel between the waist opening and the leg openings. Therefore, this garment is not sufficiently stretchable around the waist circumference, it only has a uniform degree of stretchability around the waist circumference and the leg openings. Therefore, if the garment fits the wearer around the leg openings and provides sufficient fit around the legs, the wearer may feel tightness around the waist circumference, which may lead to the appearance of indentations on the wearer's skin. In addition, since this garment does not have sufficient stretchability, it cannot provide a wider use, for example, it is not suitable for wearers with a larger waist circumference. This leads to difficulties in using pull-on diapers.

Thus, none of the existing types of laundry offer all the advantages and benefits of the present invention.

The essence of the invention

The present invention is directed to disposable undergarments. The disposable undergarment has a front portion, a back portion, and a portion including a crotch region between the front portion and the back portion. The disposable undergarment comprises a body and edge edges. The body comprises a top fabric and a back fabric joined to the top fabric and an absorbent core sandwiched between the top and back fabrics. The body comprises a central panel with side edges and a waist edge and an ear-shaped panel extending laterally outwardly from each side of the central panel in the front region and the back region. The ear-shaped panel is made of an extensible material to form an extensible ear. The extensible ear has a higher edge end, a lower edge end, an inner edge side, and an outer edge side. The outer edge side is not parallel to the inner edge side and is not parallel to the longitudinal centerline of the undergarment and extends laterally outwardly nearest the higher edge end. The lateral width of the expandable tab between the inner side edge and the outer side edge is greater at the nearest higher end of the edge than at the nearest lower end of the edge. The hems connect each tab-shaped panel along the outer side edge to a corresponding portion on the opposite region of the disposable garment to form a waist opening and two leg openings. The connecting hem is not parallel to the longitudinal centerline.

These and other features, aspects and advantages of the present invention will be apparent to those skilled in the art from the present description of the invention.

Clarification of drawings

While the specification includes claims which particularly point out and clearly define the claims for patent protection, it is believed that the following description of preferred embodiments, taken in conjunction with the accompanying drawings, will provide a better understanding of the invention. The drawings contain reference numerals which are used to designate substantially identical elements and in which:

Fig. laundry on configuration;

is a top view of a preferred embodiment of a pull-on portion of a disposable undergarment according to the present invention in a typical, used

Fig. 2 is a simplified drawing of a pull-on portion of a disposable undergarment in a flat, unshrunk, and unjoined condition at its edges, illustrating the various panel portions of the undergarment;

Fig. 3 is a simplified drawing of the embodiment shown in Fig. 1 in its flat, unshrunk and unbonded state;

Fig. 4 is a schematic simplified drawing of the embodiment according to Fig. 3, showing the body of the article formed from an upper fabric, a lower fabric and an absorbent core inserted between these fabrics, the other elements of the pull-on garment being omitted;

Fig. 5 is a cross-sectional view of the preferred embodiment taken along section line 4-4 in Fig. 3;

Fig. 6 is a schematic simplified drawing of the embodiment of Fig. 3, showing a disposable pull-on garment with an expandable ear-shaped panel and an expandable waistband;

Fig. 7 is a cross-sectional view of the preferred embodiment taken along section line 6-6 of Fig. 3;

Fig. 8 is a cross-sectional perspective view of an elastic element of a preferred embodiment.

Fig. 9 is a fragmentary enlarged side view of the elastic element shown in Fig. 5;

Fig. 10 is a graphical representation of two consecutive cycles of hysteresis arcs of an elastomeric material in a preferred embodiment;

Fig. 11 is an enlarged, partially segmented, perspective view of an alternative embodiment of an elastomeric material;

Fig. 12 is a cross-sectional view of an alternative embodiment taken along section line 6-6 in Fig. 3;

Fig. 13 is a front view of the embodiment shown in Fig. 1;

Fig. 14 is a front view of an alternative embodiment of a disposable pull-on garment;

Fig. 15 shows a pressure versus expansion curve of an infinite zone around the waist of a disposable garment according to the present invention;

Fig. 16 shows the modulus of elasticity versus expansion curve obtained from the pressure versus expansion curve of Fig. 15;

Fig. 17 is a perspective view of a standard torso section used to measure skin contact pressure;

Fig. 18 is a side view of the standard fuselage section shown in Fig. 17;

Fig. 19 is a top view of the standard fuselage section of Fig. 17.

Detailed description of the embodiment according to the invention

References to all cited documents are incorporated herein in their entirety. References to documents relating to the prior art do not limit the specification to the claimed invention.

The term "pull-on underwear" as used herein refers to underwear that is provided with a waist opening and openings for a pair of legs and that is pulled onto the wearer's body by inserting the legs into the leg openings and pulling the underwear around the waist. The term “disposable” is used herein to refer to undergarments that are not intended to be washed or reused or renewed as underwear (i.e., they are intended to be discarded after a single use and should preferably be recycled, composted, or otherwise disposed of in an environmentally compatible manner). “Integral” undergarments refer to undergarments that are composed of individual parts joined together to form a compliant whole, but the ear panels are not separate elements attached to a separate body, but rather the ear panels are formed such that at least one layer also forms the middle panel or body of the undergarment (i.e., the undergarment does not require separate manipulable panels such as a separate body and separate ear-shaped panels). The pull-on garment is also preferably of the "absorbent type that absorbs and retains various body exudates. A preferred embodiment of the pull-on garment according to the invention is a disposable, absorbent type pull-on garment that forms a unitary, pull-on diaper 20, which is shown in Fig. 1. The term "pull-on diaper" as used herein refers to a pull-on undergarment that is generally worn by infants and incontinent individuals to absorb and retain urine and feces. However, the present invention is also applicable to other types of pull-on garments such as sanitary pants, incontinent briefs, feminine hygiene underwear or panties, and the like. As used herein, the terms "attached" or "attached" refer to a configuration in which an element is attached to another element by firmly attaching the element directly to the other element, and a configuration in which an element is indirectly attached to another element by firmly attaching the element via an intermediate member or members on the other side connected to another element.

Referring to Figures 1, 2 and 3, the diaper 20 has a front region 26, a back region 28 and a crotch region 30 between the front region 26 and the back region 28. The diaper 20 also has two centerlines; a longitudinal centerline 100 and a transverse centerline 110. The term “longitudinal” as used herein refers to a line, axis or direction in the plane of the diaper 20 that is generally aligned with (i.e. approximately parallel to) a vertical plane that bisects a standing wearer into left and right halves when the diaper 20 is worn. The terms “transverse” and “lateral” as used herein are interchangeable and refer to a line, axis or direction that lies within the plane of the diaper and is generally perpendicular to the longitudinal direction (which divides the wearer’s body into two halves, front and back). The pull-on diaper and its component materials also have a body-adjacent surface that, in use, contacts the wearer's skin and an outer surface that is on the opposite side of the body-adjacent surface.

* < · · · · · » · · • « · · · · · · ··· ··· ·· ·· ·· ··· ···

Fig. 2 is a simplified plan view of the diaper 20 of Fig. 1 in a flat, unshrunk state, showing the various panels and their relative positions. The term "panel" is used wherever it refers to a region or feature of the diaper or a strip zone. (While a panel is typically a distinct region or feature, a panel may also coincide (functionally correspond) to an adjacent panel to some extent.) The diaper 20 has a crotch region 30 formed from a main panel 2 and a pair of leg flap panels 4; a front region 26 formed by a center panel 8, a strip panel 6 at the waist, ear panels 10, and connecting panels 12; and a back region 28, which is formed by a central panel (9), a waist band panel 7, ear panels H and connecting panels 13. The crotch region 30 is the part of the pull-on diaper 20 from which an endless band (other panels) extends. The absorbent core is typically located within the main panel 2, as exudates typically emerge in this region, and the absorbent core is typically spread in a band into the central panels 8 and 9. A leg flap panel 4 extends typically laterally outwardly from and along each side edge 2B of the main panel 2. Each leg flap panel 4 is typically at least partially formed of an elastic material. The continuous belt (front region 26 and back region 28) extends generally longitudinally outwardly from each side edge 159 of the crotch region 30 (main panel 2 and leg flap panel 4) and along these edges 159. In the front region 26, a middle panel 8 (i.e., a central panel) extends generally longitudinally outwardly from and along the lateral edge 159 of the crotch region 30. The middle panel 8 has a waist-adjacent edge 190 and side edges 191. The ear-shaped panels 10 each extend generally transversely outwardly from and along the side edge 191 of the middle panel 8. The ear-shaped panel 10 has a waist edge 161 and a side edge 171. The longitudinal waist-adjacent panel 6 extends generally longitudinally outwardly from and along the waist edge 190 of the middle panel 8 and the waist edge 161 of the ear panel 10. The waist-adjacent waist panel 6 is provided with side edges 175. Connecting panels 12, each of which extends generally transversely and outwardly from and along the side edge 171 of the ear panel 8 and the side edge 175 of the waist-adjacent stripe panel 6. In the back region 28, the middle panel 9 (i.e., the middle panel) generally extends longitudinally outwardly from and along the opposite lateral edge 159 of the crotch region 30. The middle panel 9 has a waist-adjacent edge 192 and side edges 193. Ear panels 11, each of which projects generally laterally outwardly

from and along the side edge 193 of the middle panel 9 (i.e., the central panel). The ear panel H has a waist-adjacent edge 163 and a side edge 173. The waist-adjacent waist panel 7 extends generally longitudinally outwardly from and along the waist-adjacent edge 192 of the middle panel 9 and the waist-adjacent edge 163 of the ear panel H. The waist panel 7 has side edges 177. Each connecting panel 13 generally extends laterally outwardly from and along the side edge 173 of the ear panel H and the side edge 177 of the waist-adjacent waist panel 7. The front region 26, in addition to its panels, also has a waist edge 151, leg-adjacent edges 153 and side edges 154. The back region 28, in addition to its panels, also has a waist edge 155, leg-adjacent edges 156 and side edges 157. The crotch region 30 has leg-adjacent edges 158.

The pull-on diaper 20 primarily comprises a body 41, a waist elastic material (not shown in Figures 1, 2 and 3), a side elastic material (not shown in Figures 1, 2 and 3), and connecting edges 32. The pull-on diaper 20 may be provided with opening tabs 31, the location of which is interconnected with the connecting edges 32 and elastic cuffs 52 around the legs including inner barrier cuffs 54. The side elastomeric material allows for the extensibility of at least a portion of the ear-shaped panels 10 and H, thereby creating extensible gripper ears 46 and 48. The elastomeric material around the waist assists in the extensibility of at least a portion of the waist panels 6 and 7 adjacent the waist, thereby creating an uninterrupted extensible belt 57 and 59 around the waist. The side elastomeric material together with the waist elastomeric material are separate elements and are placed so that in the longitudinal direction of the pull-on diaper 20 they do not overlap each other. This allows for a much more independent behavior of the waist and side elastomeric materials and allows for a better fit in terms of extensibility, pressure and the like. The extensible tabs 46 and 48 and the continuous extensible waist band 57 and 59 are extensible at least in the lateral direction. The joint 32 connects the connecting seam panel 12 in the front region 26 to the connecting seam panel 13 in the back region 28, with the tab panel 10 being connected to the tab panel H thereby creating one opening 36 adjacent the waist and two openings 34 adjacent the legs. In the configuration in which the ear panel 10 is connected to the ear panel H, the continuous extensible waist band 57 and 59 form a continuous extensible waist definition 60 around the waist opening 36. Furthermore, the continuous waist zone 38 extends into the front region 26 and the back region 28.

The body 41, as shown in Figures 3 and 4, is formed from an absorbent core 25 and a number of layers disposed in connection with the absorbent core 25, such as a topsheet 24 and a backsheet 22 that is connected to the topsheet 24. The absorbent core 25 is sandwiched between the topsheet 24 and the backsheet 22. The body 41 may further include one or more interposed additional layers that are interconnected with the absorbent core 25. The topsheet 24 has a surface that faces the body and, in use, fits the body of the wearer. The backsheet 22 has an outer surface that is disposed on the opposite side. Preferably, the back fabric 22 includes an inner barrier film 68 and a nonwoven outer cover 23. Since the body 41 is defined by the front region 26, the back region 28, and the crotch region 30, it also has the corresponding regions and panels defined previously. (For simplicity, these regions and panels are designated in the drawings by the same reference numerals as the corresponding regions and panels on the pull-on diaper shown in Fig. 2.)

The topsheet 24 and the inner barrier film 68 of the backsheet 22 are typically longer and wider in dimension than the absorbent core layer 25. The topsheet 24 and the inner barrier film 68 extend beyond the side edges and ends of the absorbent core 25 to form the periphery of the body 41. The topsheet 24 extends longitudinally between the edge 151 and 155 that abuts the waist of the diaper 20. The topsheet 24 has waist end portions 24A and side portions 24B. The waist end portions 24A (i.e., end portion 24A) of the topsheet 24 extends into the waist portion of the waistband panels 6 and 7 of the diaper 20. The inner barrier film 68 has waist end portions 68A and side portions 68B. The inner barrier film 68 is slightly shorter in the longitudinal direction than the top fabric 24 and slightly wider in the lateral direction than the top fabric 24. The inner barrier film 68 is of unequal width in the lateral direction, such that it forms a first portion 94 in at least a portion of the crotch region 30 and a second portion 96 in at least a portion of the front or back region 26 or 28. The lateral width of the inner barrier film 68 gradually tapers toward the end portions 68A at the waist, such that the lateral width dimension of the second portion 96 is less than the lateral width dimension of the first portion 94. The inner barrier film 68 preferably does not extend into the waist panels 6 and 7 in order to reduce the bulkiness of the waist panels 6 and 7. Additionally, by not extending into both ear panels 10 and 11, the effective lateral longitudinal extensibility is increased and the bulkiness of these ear panels 10 and 11 is reduced. The inner barrier film 68 also does not extend into the waist panels 6 and 7 with a view to reducing their bulkiness. Additionally, by not extending into both ear panels 10 and 11 and ·· *· ·· » β · « • * · * « · · · · · ·· • *··« · · · * **·· ··· · * * * · · · « ····»· * · ··· · While the surface fabric 24, the inner barrier film 68, the absorbent core 25, can be assembled in a variety of known configurations, exemplary body configurations are generally described in U.S. Patent 3,860,003 entitled "Shrinkable Side Panels for Disposable Diapers," issued January 14, 1975 to Kenneth B. Buell; and in U.S. Patent 5,151,092 entitled "Absorbent Article with Elastically Expandable Waistband Provided with Flexible Bendable Attachment," issued September 29, 1992 to Kenneth B. Buell.

Preferably, the nonwoven outer cover 23 covers substantially all of the outermost portion of the pull-on diaper 20. The nonwoven outer cover 23 may have generally the same shape as the pull-on diaper 20. The nonwoven outer cover 23 has a waist end 23A and a side portion 23B. The nonwoven outer cover 23 also has side extensible portions 23C in the front region 26 and side extensible portions 23D in the back region 28. The waist end 23A (i.e., the portion extending toward the end 23A) of the nonwoven outer cover 23 extends into the waist belt panels 6 and 7, and the side extensible portions 23C and 23D of the nonwoven outer cover 23 extend into the ear panels 10 and 11. Alternatively, the nonwoven outer cover 23 may be eliminated and the inner barrier film 68 may have generally the same shape as the pull-on diaper 20 and may extend into both the ear panels 10 and 11 and the waist belt panels 6 and 7.

The absorbent core 25 can be any absorbent element that is generally compressible, comfortable, non-irritating to the wearer's skin, and capable of absorbing and retaining fluids such as urine and certain other body exudates. The absorbent core 25 can be made in a wide variety of sizes and shapes (e.g., rectangular, hourglass, "T"-shaped, asymmetrical, etc.) from a wide variety of fluid-absorbent materials commonly used in the manufacture of disposable diapers and other absorbent articles such as mixed wood pulp, commonly referred to as felt. Examples of other suitable absorbent materials are crepe cellulose filling; meltblown polymers including coform; chemically stiffened, modified, or crosslinked cellulose fibers; webs including tissue paper and laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gels; or other equivalent materials or combinations of materials.

The configuration and construction of the absorbent core 25 may be variable (i.e., the absorbent core 25 may have different callipers, a hydrophilic gradient, a superior absorbency gradient, or lower average density and lower average basis weight of the incremental zones; or may include one or more layers or structures). Furthermore, the size and absorbent capacity of the absorbent core 25 may also be variable according to the needs of wearers, from infants to adults. However, the overall absorbent capacity of the absorbent core 25 should be compatible with the proposed load and anticipated use of the diaper 20.

The absorbent core 25 in the preferred embodiment has an asymmetrical, modified hourglass shape provided with handles in the front and rear waist regions 26 and 28. Other examples of absorbent structures suitable for absorbent core 25 that have achieved widespread use and commercial success are described in U.S. Patent No. 4,610,678 entitled "High Density Absorbent Structures", assigned to Weisman et al., issued September 9, 1986; U.S. Patent No. 4,673,402 entitled "Absorbent Articles with a Dual Layer Core", assigned to Weisman et al., issued June 16, 1987; U.S. Patent No. 4,888,231 entitled "Absorbent Core Provided with a Wipeable Layer" assigned to Angstadt, issued December 19, 1989; and in U.S. Patent No. 4,834,735 entitled "High Density Absorbent Materials with Lower Density and Lower Basis Weight Incremental Zones", issued to Alemany et al. on 1989,05,30.

The body 41, as shown in Fig. 5, may further include an acquisition or distribution core 84 of chemically strengthened fibers that is positioned over the absorbent core 25 to form a dual core system. Preferred dual core systems are described in U.S. Patent No. 5,234,423, entitled "Absorbent Articles with Elastic Waistband and Increased Absorbency", issued to Alemany et. al., on August 10, 1993; and in U.S. Patent No. 5,147,345, entitled "High Performance Absorbent Articles for Incontinence Care", issued to Young, LaVon and Taylor on September 15, 1992. In a preferred embodiment, the acquisition/distribution core 84 comprises a material of chemically treated strengthened cellulose fibers, which are available from Weyerhaeuser Co. (U.S.A) under the trade name CMC.

• · φ · φ φ φ ·· φ • ♦ · · · · · φ φ · φ φ φ φφφφ φφφ φ φφφφ φφφφ φ • · φφφ φφφ φφφφ φφφφ φφφφ φφφφ «

More preferably, the body 41 may further include an acquisition/distribution layer 82 between the top fabric 24 and the acquisition/distribution core 84 as shown in Fig. 5. The acquisition/distribution core 82 is provided to help reduce the surface moisture tendency of the top fabric 24. The acquisition/distribution layer 82 preferably comprises a carded, resin-bonded nonwoven material such as the material available under code number FT-6860 from Polymer Group, Inc., North America (Landisivelle, New Jersey, USA), which is made from 6 dtex polyethylene terephthalate fibers and has a basis weight of about 43 g/m ² .

The top fabric 24 is preferably loose, soft, and non-irritating to the wearer's skin. Furthermore, the top fabric 24 is fluid-permeable, allowing rapid fluid penetration. Suitable top fabric 24 can be made from a variety of woven or nonwoven materials; polymeric materials such as molded mesh thermoplastic films, mesh plastic films, and hydraulically formed thermoplastic films; porous foams; mesh thermoplastic films; and thermoplastic scrims. Suitable woven and nonwoven materials can be made from natural fibers (e.g., wood or cotton), synthetic fibers (e.g., polymeric fibers such as polyester, polypropylene, or polyethylene fibers), or a combination of natural and synthetic fibers. The topsheet 24 is preferably made of a hydrophobic material that isolates the fluid that has permeated the topsheet 24 and is contained in the absorbent core 25 from the wearer's skin (i.e., to prevent rewetting). If the topsheet 24 is made of a hydrophobic material, it is preferred that at least the top surface of the topsheet 24 be treated to be hydrophilic and to allow fluid to pass through the topsheet more rapidly. This reduces the likelihood that body exudates will drain down the topsheet 24 rather than penetrate through the topsheet 24 and be absorbed by the absorbent core 25. A hydrophilic topsheet 24 can be obtained by treating it with a surfactant. Typical methods for treating the topsheet 24 with surfactants include spraying the topsheet 24 with a surfactant and dipping the material in a surfactant solution. A more detailed discussion of such treatment and the achievement of hydrophilicity is contained in U.S. Patent No. 4,988,344 entitled “Absorbent Articles with Multiple Absorbent Layers” issued to Reising et al. on January 29, 1991 and in U.S. Patent No. 4,988,345 entitled “Absorbent Articles with Fast-Acting Absorbent Cores” issued to Reising on January 29, 1991. The topsheet 24 may be compatible with the provision of

• 9 · « · · » « ·♦♦· 9999 99 99 99 999 breathability during design or during the process, particularly along the waist panel 6 and 7 at the waist and in other parts of the pull-on diaper 20.

In preferred embodiments, the topsheet 24 is a nonwoven fabric that reduces the surface tendency to wet; and subsequently aids in retaining urine absorbed by the absorbent core 25 and separating it from the user's skin after wetting. One preferred topsheet material is a thermally bonded carded fabric available under the code "Code No. P-8" from Fiberweb North America, Inc. (Simpsonville, South Carolina, USA). Another preferred topsheet material is the material available under the code "Code No. S-2355" from Havix Co., Japan. This material is a two-layer composite material and is made from two types of synthetic bicomponent fibers treated with a surfactant using a carding and spinning manufacturing process. Another preferred material for the upper fabric is a thermally bonded carded web, available as a material designated "Code No. Profleece Style 040018007 from "Amoco Fabrics, Inc. (Gronau, Germany).

Another preferred topsheet 24 is an apertured sheet. Apertured sheets are suitable for topsheet 24 because they are permeable yet nonabsorbent and are capable of retaining liquid from re-penetration, thereby preventing rewetting of the wearer's skin. Thus, the surface of the apertured sheet that comes into contact with the body remains dry, reducing body soiling and creating a more comfortable feel for the wearer. Suitable shaped sheets are described in U.S. Patent No. 3,929,135 entitled "Absorbent Structures with Narrowed Capillaries", which issued to Thompson on December 30, 1975; in U.S. Patent No. 4,324,246 entitled "Disposable Absorbent Articles with Soil Resistant Topsheet", which issued to Mullane et al. on April 13, 1982; in U.S. Patent No. 4,342,314 entitled “Elastic Plastic Fabric, Exhibiting Properties Similar to Fibers”, issued to Radel et al. on August 3, 1982; in U.S. Patent No. 4,463,045 entitled “Macroscopically Stretchable Three-Dimensional Plastic Fabric Exhibiting a Non-Gloss Surface and a Fabric-Like Tactile Impression”, issued to Ahr et al. on July 31, 1984; and in U.S. Patent No. 5,006,394 entitled “Multilayer Polymeric Film” issued to Baird on April 9, 1991.

• ···· · · · · 9 • · 9 9 9 9 9 9

9999 9999 99 999 99 999

The backsheet 22 preferably includes an inner barrier film 68 and a nonwoven outer cover 23. The inner barrier film 68 is preferably impermeable to liquid (e.g., urine) and is preferably made of a thin plastic film. The inner barrier film 68 has a body-facing surface 79 and an outer facing surface 77. The plastic film is suitably permeable to vapors emerging from the diaper 20. In a preferred embodiment, a microporous polyethylene film is used for the inner barrier film 68. A suitable microporous polyethylene film is manufactured by Mitsui Toatsu Chemicals, Inc., Nagoya, Japan and is commercially available as Espoir No. 100. Preferably, the backsheet 22 is compatible with breathability and the design or construction of the side seams. An adhesive tape may be further attached to the outer surface of the backsheet.

A suitable plastic film for the inner barrier film 68 is a thermoplastic film having a thickness of about 0.012 mm (0.5 mils) to 0.051 mm (2.0 mils), preferably comprising polyethylene or polypropylene. Preferably, the plastic film has a basis weight of about 5 g/m ² to 35 g/m ² . However, other flexible, liquid-impermeable materials may also be used. As used herein, the term "flexible" refers to materials that are pliable and that readily conform to the shape and contours of the wearer's body. The moisture and vapor transmission rate of the plastic film may be between 3,000 and 4,000 g/m ² /24 hours, as measured by a foam test.

The nonwoven outer cover 23 is bonded to the adjacent surface of the inner barrier film 68 to form a laminate (i.e., the backsheet 22). The nonwoven outer cover 23 is disposed on the outermost portion of the pull-on diaper 20 and covers at least a portion of the outermost portion of the diaper 20. The nonwoven outer cover 23 may be bonded to the inner barrier film 68 by any suitable bonding means known in the art. For example, the nonwoven outer cover 23 may be bonded to the inner barrier film 68 by a continuous uniform layer of adhesive, a layer of patterned adhesive, or a series of discrete lines, spirals, or dots of adhesive. Suitable adhesives include hot melt adhesives available from Nitta Findley Co., Ltd., Osaka, Japan as H-2128 and hot melt adhesives available from H.B.Fuller Japan Co., Ltd., Osaka, Japan as JM-6064.

In a preferred embodiment, the nonwoven outer cover 23 is a carded nonwoven fabric, manufactured, for example, by Havix Co., LTD., Gifu, Japan as E-2341.

The nonwoven outer cover 23 is made of bicomponent fibers of polyethylene (PE) and polyethylene terephthalate (PET). The PE/PET ratio is about 40/60. The PE/PET bicomponent fiber has a dimension of 2 decitex x 51 mm. Another preferred carded nonwoven fabric is available from Vchisso Corp., Osaka, Japan. The nonwoven outer cover 23 is also made of bicomponent fibers of polyethylene (PE) and polyethylene terephthalate (PET). The PE/PET ratio is about 30/70.

Another suitable embodiment of the nonwoven fabric is a nonwoven fabric, which is available, for example, from Mitsui Petrochemical Industries, Ltd., Tokyo, Japan. The nonwoven fabric is made of bicomponent fibers consisting of a polyethylene (PE) coating and a polypropylene (PP) core. The PE/PET ratio is about 80/20. The PE/PET bicomponent fiber has a thickness of about 2.3 decitex.

The backsheet 22 is preferably positioned adjacent the outer surface of the absorbent core 25 and is preferably joined together therewith by any suitable known attachment. For example, the backsheet 22 may be joined to the absorbent core 25 by a uniform continuous layer of binder, a patterned layer of binder, or a series of discrete lines, spirals, or dots formed of binder. Suitable binders have been found to be products of the H.B. Fuller Company of St. Paul, Minnesota under the designation HL-1258. An example of a suitable binder that forms an open patterned network of fibers is the binder described in U.S. Patent No. 4,573,986 entitled "Disposable Undergarments," which issued to Minetola et al. on March 4, 1986. Other suitable joining means that form multiple lines of binder fibers twisted into a spiral pattern are illustrated by the apparatus and methods of U.S. Patent No. 3,911,173, issued to Sprague, Jr. on October 7, 1975; in U.S. Patent No. 4,785,996, issued to Ziecker, et al. on November 22, 1978; and in U.S. Patent No. 4,842,666, issued to Werenicz on July 27, 1989. Alternatively, the joining means may be heat bonding, pressure bonding, ultrasonic bonding, dynamic and mechanical bonding, or any other suitable joining means or combination of such joining means known in the art.

To provide greater extensibility in the front region 26 and the back region 28, in an alternative embodiment, the absorbent core 25 is not attached to the back fabric 22 and/or the top fabric 24.

Elastic leg cuff 52 for improved containment of fluids and other body exudates. The elastic leg cuff 52 can be constructed in a number of different ways to prevent leakage of body exudates into the leg area. (A leg cuff can be and is sometimes referred to as a bandage, flap, barrier cuff, or elastic leg cuff). U.S. Patent No. 3,860,003 describes a disposable diaper that features a pull-down leg opening and side flap and one or more elastic elements for providing elasticity to the leg opening (sealing cuff). U.S. Patent No. 4,909,803 entitled "Disposable Absorbent Articles with Elastic Flaps" issued to Azis et al. on March 20, 1990, describes a disposable diaper with a leg cuff that provides a dual function, including a sealing cuff and a barrier cuff. U.S. Patent No. 4,704,115, entitled "Disposable Security Undergarment," issued to Buell on November 3, 1987, describes a disposable diaper or incontinent garment having side edge flaps that are configured to retain fluid within the garment.

Although each elastic panty cuff 52 may be formed similarly to the above-described waistbands, side flaps, elastic panty cuffs, it is preferred that each elastic panty cuff 52 include an inner barrier cuff 54, a barrier flap 56, and separation means 58 (as shown in Fig. 5) as described in the aforementioned U.S. Patent No. 4,909,803. The inner barrier cuffs 54 may have an interposed inner element that is highly impermeable, but preferably breathable. In a preferred embodiment, the elastic panty cuff 52 additionally includes an elastic sealing cuff 62 with one or more elastic bands 64 disposed outside the barrier cuff 54 as described in the aforementioned U.S. Patent Nos. 4,695,278 and 4,795,454. The elastic bands 64 are typically located in the leg flap panel 4 and are attached to the leg by any means such as hot melt adhesive, in a pre-tensioned state. The elastic bands 64, prior to attachment, may be pre-tensioned by up to 30% to 200%, preferably 50% to 150%. Suitable elastic bands 64 are those manufactured by Fulflex International Company under the designation 9312.

The pull-on diaper 20 has a front expandable tab 46 and a rear expandable tab 47.

48. Referring to Fig. 5, the extensible ear 46 and 48 preferably have a lateral elastic element 70 provided with a lateral elastomeric material 124 (shown in Fig. 8), ···· ··· ··· ... ·· ,,, a lateral extensible portion 23C of the nonwoven outer cover 23, and an extensible portion 72 of the inner barrier cuff 54 (Fig. 5 only shows the structures in the front region 26, the structures in the back region 28 are preferably the same or similar to those in the front region 26). Preferably, at least one of the front and back extensible ears 46 and 48 is elastically extensible in at least a lateral direction. More preferably, both the front and back extensible ears 46 and 48 may be elastically extensible in at least a lateral direction. In an alternative embodiment, the front and rear extensible tabs 46 and 48 are elastically extensible in both directions, both laterally and longitudinally. As used herein, the term “extensible” refers to a material that is capable of being stretched in at least one direction to some degree without tearing. As used herein, the terms “elastic” and “elastically extensible” refer to an extensible material that has the ability to return to approximately its original dimension upon removal of the force that is stretching the material. Herein, any material or element referred to as “extensible” may also be elastically extensible unless otherwise specified. The extensible tab 46 and/or 48 provides more comfort and conformability to body contours by providing an internal, comfortable fit to the wearer of the diaper and assists in this fit during wear when the diaper has become filled with exudates, as the extensible tab 46 and/or 48 allows the sides of the diaper to expand and contract.

The expandable ear 46 and 48 are preferably breathable. The moisture vapor permeability of the ear panels in conjunction with the overall vapor permeability of the remaining portions of the diaper is important for reducing the incidence of sweat glands and other skin problems associated with moisture and temperature in the interior of the diaper. With a view to reducing moisture and temperature inside the diaper, the expandable ear 46 and 48 preferably have a weight total vapor transmission rate of at least about 2,000 g/m ² /24 h, more preferably at least 4,000 g/m ² /24 h. The entire diaper preferably has a weight total vapor transmission rate of at least from 2,000 g/m ² /24 h to 8,000 g/m ² /24 h.

The wet vapor transmission ratio is measured by the method described below. A known amount of CaCl ₂ is placed in a dish. The sample is placed on top of the dish and secured firmly with a sealing ring. The whole is then weighed and recorded as the initial weight. The whole is placed in a room with a constant temperature (40°C) and humidity (75% RH) for 5 hours. The whole is then removed from the room and allowed to equilibrate for at least 30 minutes at room temperature in another room.

··

The whole is then weighed and the final weight recorded. The moisture vapour transmission ratio (MVTR) is calculated and expressed in g/ ^m2 /24h using the following formula.

MVTR (final weight - initial starting weight) x 24.0 sample area in meters x 5.0 (time in room)

In Fig. 6, as in Fig. 3, the extensible ear 46 forms a side elastic element 70 with an upper edge end 46A, a lower edge end 46B, a side edge 46C, and an outer side edge 46D. The rear extensible ear 48 forms a side elastic material 70 with an upper edge end 48A, a lower end 48B, an inner side edge 48, and an outer edge 48D. Also, the configuration of each element, part, etc., in the front region 26 may be different from the same element in the back region 28 (such as the configuration of the front expandable ear 46 and the configuration of the back expandable ear 48, or the configuration of the bottom edge 46B and the configuration of the bottom edge 48B), those elements, parts, components, etc. that correspond to each other in the front region 26 and in the back region 28. may be described concurrently for ease of discussion. In the preferred embodiment, the ear panel 10 and 11 are formed to be expandable over the entire area of the ear panel 10 and H so as to form the expandable ear 46 and 48 on the side of the elastic material 70. According to the embodiment in Fig. 3, the side elastic material 70 extends into the portion of the hem 12 and 13 such that the front extensible tab 46 and the rear extensible tab 48 are mutually engaged in the connecting hem 32, and the side elastic material 70 in the front region 26 and the side elastic material 70 in the rear portion 28 are engaged in the connecting hem 32 (Fig. 5 also shows the side elastic member 70 extending into the hem 12 and 13, although the hem 12 and 13 are not shown in Fig. 5). Alternatively, the ear panel 10 and 11 may be extensible only in a portion of the area of the ear panel 10 and H. The extensible ear 46 and 48 is the portion of the ear panel 10 and 11 that is extensible by being connected to the side elastic member 70 and subjected to mechanical stretching. In the preferred embodiment, the inner side edge 46C and 48C extends generally along the longitudinal centerline 100 of the pull-on diaper 20. The outer side edge 46D and 48D do not follow the inner side edge 46C and 48C and do not follow the longitudinal centerline 100. The outer side edge 46D and 48D project the adjacent top edge 46A and 48A laterally at the outer edge. Therefore, the outer side edge 46D and 48D distances the inner side edge 46C and 48C adjacent to the ...

top edge 46A and 48A. The expandable ear 46 and 48 has a lateral width L1 between the inner side edge 46C and 48C and the outer side edge 46D and 48D adjacent the lower end edge 46B and 48B and a lateral width L2 between the inner side edge 46C and 48C and the outer side edge 46D and 48D adjacent the upper end of the edge 46A and 48A. The lateral width between the inner side edge and the outer side edge is the width between the inner side edge 46C and 48C and the outer side edge 46D and 48D in the lateral direction perpendicular to the longitudinal centerline 100. Therefore, the lateral width between the inner side edge and the outer side varies in the range R where the inner side edge 46C and 48C and the outer side edge 46D and 48D cooperate in the longitudinal direction of extensibility. The lateral width L2 is greater than the lateral width L1, therefore, the sufficient quantity of elastomeric material in the lateral direction of the extensible ear 46 and 48 is greater at the upper edge 46A and 48A than at the lower edge 46B and 48B. Because the outer side edge 46D and 48D intersects the adjacent top edge 46A and 48A, which extends laterally outward, the amount of elastomeric material at the top edge 46A and 48A is increased. The amount of elastomeric material varies in a direction from the top edge 46A and 48A toward the bottom end edge 46B and 48B as the lateral width of the expandable ear 46 and 48 gradually changes in that direction. This results in a variation in the force or force gradient across the surface of the expandable ear that allows for adjustment. The inner side edge 46C and 48C also need not follow the longitudinal centerline 100 and projects laterally inward at the top end 46A and 48A as the lateral width L2 gradually increases relative to the lateral width L1. Alternatively, the inner side edge 46C and 48C may intersect slightly adjacent top ends 46A and 48A extending laterally outwardly such that the lateral width L2 is still greater than the lateral width L1.

The expandable tabs 46 and 48 may be formed from individual elements of the diaper 20 (that is, they are not separately manipulable elements that are attached to the diaper 20, but rather are expandable portions formed from one or more different layers of the diaper). In a preferred embodiment, the expandable ear 46 and 48 is a member that projects from the body 41. Preferably, the expandable ear 46 and 48 comprises at least one unitary member or continuous sheet material that forms a part of the body 41 and extends uninterruptedly into the expandable ear 46 and 48. Alternatively, the expandable ear 46 and 48 may be a separate member that does not include any unitary member that forms a part of the body 41. The expandable ear 46 and 48 may be formed by attaching a separate member to a side portion of the body 41.

A lateral elastic member 70 is interposed between the extensible portion 72 of the inner barrier cuff 54 and the lateral extensible portions 23C and 23D of the nonwoven outer cover 23 in the region of the extensible tab 46 48. The lateral elastic member 70 is operatively connected to at least one of the extensible portions 72 of the inner barrier cuff 54 and the lateral extensible portions 23C and 23D of the nonwoven outer cover 23. Preferably, the lateral elastic member 70 is operatively connected to both of the extensible portions 72 of the inner barrier cuff 54 and the lateral extensible portions 23C and 23D of the nonwoven outer cover 23, in the absence of tension (in a zero-load condition).

The lateral elastic element 70 may be operatively connected to the inner barrier cuff 54 and the nonwoven outer cover 23 by any intermittent connection configuration or by a substantially continuous connection configuration. As used herein, the term "intermittent" bonded laminate web means a laminate web in which the layers are internally bonded to each other at point intervals, or a laminate web in which the layers are substantially unbonded to each other in separate areas spaced apart from each other. Conversely, a "substantially continuous" bonded laminate web means a laminate web in which the layers are internally bonded to each other substantially continuously throughout their entire surfaces facing each other. Since it is preferred that the elastic laminate be bonded as a whole or a significant portion of the elastic laminate such that the non-elastic fabric (i.e., the nonwoven fabric of the inner barrier cuff 54 of the nonwoven outer cover 23) is stressed in tension without tearing, and the layers of the elastic laminate are preferably bonded in a configuration that maintains all layers of the elastic laminate in relatively close adhesion to each other in the event of incremental mechanical stress, the lateral elastic element and the other layers of the elastic laminate are substantially continuously bonded together by a binder (adhesive). In a particularly preferred embodiment, the selected binder is applied in a spiral pattern (as shown in U.S. Pat. No. 3,911,173 (Sprague. Jr.) and in U.S. Pat. No. 4,842,666 (Werenicz)) and at a basis weight of about 0.116 g/m ² . The spirals are about 1.9 cm (0.75 inches) wide and are positioned closely together or slightly overlapping (less than 2 mm). The adhesive is preferably one available from Findley Adhesives under the designation H2120.

**·· ···· Φ· ··· «φ

Alternatively, the lateral elastic element and any other component of the elastic laminates may be intermittently or continuously connected to each other by thermal bonding, pressure bonding, ultrasonic bonding, mechanical bonding, or other methods known in the art.

After operatively attaching the lateral elastic element 70 to the extensible portion 72 of the inner barrier sleeve 54 and to the lateral extensible portions 23C and 23D of the nonwoven outer cover 23, at least a portion of the resulting composite elastic laminate is then subjected to a mechanical stress sufficient to permanently extend the non-elastic components, such as the extensible portion 72 of the inner barrier sleeve 54 and the lateral extensible portions 23C and 23D of the nonwoven outer cover 23. The composite elastic laminate is then returned to its substantially unstressed state. The extensible tabs 46 and 48 are thus formed into the elastic laminate at "zero stress." (Alternatively, the lateral elastic element 70 could be operatively attached in a tensioned state and then subjected to mechanical tension.) As used herein, the term "zero-tension" elastic laminate refers to a laminate that is comprised of at least two layers of material that are attached to each other along at least a portion of their mutually extended surfaces in a condition that is substantially untensioned ("at zero tension"); one of the layers comprises a material that is extensible and elastomeric (i.e., will return substantially to its untensioned size upon release of the applied tensioning force) and a second layer that is capable of elongation (but is not necessarily elastomeric) such that upon tensioning, the second layer will be permanently elongated by at least one degree, i.e., will not fully return to its original undeformed configuration upon release of the applied tensioning forces. The resulting elastic laminate is thus made elastically extensible at least to the point of initial tension in the direction of the internal mechanical tension. Preferred methods and apparatus used to produce elastic laminates employ, in particular, meshed corrugated rollers or plates to mechanically elastically tension the components. Preferred apparatus and methods are described in U.S. Patent No. 5,167,897 (Weber et al., issued December 1, 1992); U.S. Patent No. 5,156,793 (Buell et al., issued October 20, 1990); U.S. Patent No. 5,143,679 (Weber et al., issued September 1, 1992); and European Patent Application No. 98108290, entitled "Methods and Apparatus for Actuating a Moving Fabric," filed May 7, 1998 (Christoph J. Schmitz et al.).

The lateral elastic element 70 is preferably attached, and more preferably directly attached, to the lateral portions 68B of the inner barrier film 68 by an adhesive 76, as shown in Fig. 5. In a preferred embodiment, the lateral elastic element 70 is attached to the lateral portions 68B of the inner barrier film 68 to an outer adjacent surface 77. In an alternative embodiment, the lateral elastic element 70 may be attached to the lateral portions 68B of the inner barrier film 68 to a surface that is adjacent to the body 79. The adhesive 76 is preferably applied in the form of a drop. The adhesive 76 may be applied as a spiral. In a preferred embodiment, the adhesive 76 is a flexible adhesive with an amorphous and a crystallizable component. Such a suitable adhesive is available from Findley Adhesive Company under the designation #H9224. Alternatively, the lateral elastic element 70 may be attached to the lateral portions 68B of the inner barrier film 68 by any other known attachment means, for example, thermal bonding, pressure bonding, ultrasonic bonding, mechanical bonding, or a combination of these.

The lateral elastic element 70 used for the expandable ear 46 and 48, according to Fig. 8, is formed of a lateral elastomeric material 124. The lateral elastic material 70 may further comprise one, preferably both, of the primary cover layers 122 and the second cover layer 126. Alternatively, the lateral elastic material 70 may not comprise any additional layers.

The side elastic material 124 has a first surface 150 and a second surface 152 opposite the first surface 150 and a first cover layer 122 that is connected to the first surface 150 of the side elastic material 124. In a preferred embodiment, the first cover layer 122 is connected to the first surface 150 of the side elastic material 124 by an adhesive 160, as shown, for example, in Fig. 9. The side elastic material 70 more preferably further includes a second cover layer 126 that is connected to the second surface 152 of the side elastomeric material 124 by an adhesive layer 164. The side elastomeric material 124 provides a good fit by creating an optimal holding force on the sides of the wearer. Preferably, the side elastomeric material 124 is extensible in at least one direction, particularly in the direction of the portion oriented in the lateral direction, to provide retention at a force that is optimal for preventing the pull-on diaper 20 from sagging, sagging, or slipping from its proper position on the torso without causing indentations on the wearer's skin.

• ·

The side elastomeric material 124 can be formed into various sizes, shapes, and forms. In a preferred embodiment, the side elastomeric material 124 is in the form of an endless planar layer. A preferred embodiment is an endless planar layer comprising a mesh, perforated film (formed with apertures), woven or nonwoven elastomers, and the like. In an alternative embodiment, the side elastomeric material 124 is in the form of strips (or bands) that are not interconnected to form an endless planar layer. The endless planar layer can be in any shape that is suitable for forming ear panels. Preferred forms of an endless planar layer include a quadrilateral, a rectangle, a square, a trapezoid, and other polygons.

Elastomeric materials that have been found to be particularly suitable for the side elastomeric material 124 are styrenic block copolymer based foams, perforated (or apertured) elastic films, webs, preferably about 0.05 mm to 1.0 mm (0.002 inches - 0.039 inches) thick. Other suitable elastomeric materials for the side elastomeric material 124 are synthetic natural rubber, other synthetic or natural resin foams, elastomeric films (including heat shrinkable elastomeric films), elastomeric woven and nonwoven webs, elastomeric compositions, and the like.

The extensibility of the side elastomeric material 124, such as the first cycle extensibility at 100% stretch (hereinafter PCR 100%), the first cycle extensibility at 200% stretch (PCR 200%), the second cycle recovery at 50% stretch (DCO 50%), and the 50% sustained load after 10-12 hours, are important aspects in the manufacture of disposable garments. The property of the side elastomeric material 124 is preferably extensibility within the range defined herein. PCR 100% and PCR 200% are measures of the overall perceived "shrinkage" during use/removal of the disposable garment. These two properties also affect the ability of the product to achieve a suitable degree of tension during use. A side elastomeric material 124 with a relatively high PCR 100% and PCR 200% may lead to difficulties in applying the disposable garment to the wearer. On the other hand, the side elastomeric material 124 with a relatively low PCR of 100% and PCR of 200% may not achieve an appropriate level of fit/comfort on the wearer's body. The DCO of 50% also closely relates to the fit/comfort of the disposable garment on the wearer's body. The side elastomeric material 124 with a relatively high DCO of 50% has

tend to cause reddened marks on the wearer's skin and the disposable garment may be uncomfortable during use. The side elastomeric material 124 with a relatively low DCO characteristic of 50% may not provide sufficient elasticity to retain the diaper on the wearer's body or may not provide a good fit to the body. The 50% sustained load evaluates the force of disintegration over time. The result will be a limit or significant decrease.

PCVR 100%, PCR 200% and DCO 50% can be measured using a tensile test. The tensile test apparatus includes an upper gripping device (jaw) and a lower gripping device that is located below the upper jaw. The upper jaw is movable and is connected to a tensile force measuring device. The lower jaw is attached to a plate (or floor). A test specimen (i.e., the elastomeric material to be tested) measuring about 2.54 cm (1.0 in) wide and about

A 12.75 cm (5 inch) length is prepared and clamped between the upper jaw and the lower jaw under conditions where no tensile force is applied, the test specimen being at its original unstretched length. Apparatus suitable for performing the tensile test described herein is available from Instron Corporation (100 Royall Street, Canton, MA02021, USA) as product code number Instron 5564.

Fig. 10 shows the elongation and recovery curve of one preferred example for two hysteresis cycles of the lateral elastomeric material 124. Curve E1 shows the first cycle elongation force, while curve R1 shows the first cycle recovery force. Curve E2 (shown in dashed line) shows the second cycle elongation force, while curve R2 shows the second cycle recovery force. The ability to stretch and recover forces is measured as follows.

For the first cycle, the test specimen is subjected to an initial tensile force at a crosshead expansion rate of 25.4 cm/min (10 in/min) at 23°C and is held for 30 seconds at 200% span. The test specimen is then allowed to rest for the same period of time in the non-tensile state. The test specimen remains in the non-tensile state for one minute before being subjected to a second tensile force (in the second cycle) at the same rate and under the same conditions.

In preferred embodiments, the PCR of 100% of the side elastomeric material 124 is at least about 100 grams/inch. More preferably, the PCR of 100% is between 120 to 220 grams/inch, most preferably between about 150 grams/inch and 190 grams/inch. The PCR of 200% is preferably between about 160 grams/inch and about 450 grams/inch, more preferably between about 180 grams/inch and about 300 grams/inch, and even more preferably between about 200 grams/inch and about 240 grams/inch. The DCO of the 50% side elastomeric material 124 is preferably between about 40 grams/inch and about 130 grams/inch, more preferably between about 65 grams/inch and about 105 grams/inch, and more preferably between about 75 grams/inch and about 95 grams/inch. The sustained load at 50% is preferably between about 40 grams/inch and about 130 grams/inch, more preferably between about 65 grams/inch and about 105 grams/inch, and more preferably between about 75 grams/inch and about 95 grams/inch.

In the preferred embodiment shown in Fig. 8, the elastomeric mu, 124 has a plurality of first bands 125 and a plurality of second bands 127. The plurality of first bands 125 intersect the plurality of second bands 127 at the nodes 130 at a predetermined angle σ to form an open network-like structure with a plurality of apertures 132. Each aperture 132 is defined by at least two adjacent first bands and at least two adjacent second bands such that the apertures 132 are substantially rectangular in shape. Other configurations of apertures 132, such as parallelograms, squares, or circular sectors, may also be provided. Preferably, the first and second bands 125 and 127 are substantially straight and substantially parallel to each other. Preferably, the first bands 125 intersect the second bands 127 at the nodes 130 such that the angle α is about 90 degrees. The first and second strips 125 and 127 are preferably connected or joined at nodes 130. A preferred elastomeric sheet 124 is manufactured by Conwed Plastics Company under the designation XO2514. This material has about 12 elastic strips per inch in the construction direction D (in the direction of the second strips 127).

According to another preferred embodiment, which is shown in Fig. 11, the elastomeric material 124 may comprise a macroscopically expandable porous, three-dimensional elastomeric fabric 172. The fabric 172 has a continuous surface 174 and a discontinuous second surface 176 spaced from the first surface 174. The elastomeric fabric 172 preferably comprises a formed sheet having at least two polymer layers, at least one of which is an elastomeric layer 178 and at least one of the other layers is a substantially less elastic surface layer 182. The elastomeric fabric has a plurality of primary apertures 184 in the first surface 174 of the fabric 172, the primary apertures 184 being provided in the plane of the first surface 174 in a continuous network of one another. interconnected members 186. Each interconnected member 186 is concave in shape along its length in the perpendicular direction. The interconnecting members 186 are substantially coterminous with each other and form second openings 188 in the plane of the second surface of the fabric. Details of such a structure and a method of making it are described in U.S. Patent Application Serial No. 08/816,106, filed March 14, 1997. A suitable porous elastomeric material 124 is manufactured by Tredegar Film Products under the designation X25007. The primary openings 184 may have any shape. Preferably, the primary opening 184 has a shape having a major axis and a minor axis perpendicular to said major axis, such as an oval shape, and the major axis is oriented generally orthogonal to the applied unidirectionally oriented artificial tensile forces.

In the embodiment of Fig. 8, the lateral elastic element 70 is formed by first and second cover layers 122 and 126, and the lateral elastomeric material 124 is sandwiched between the first and second cover layers 122 and 126. The first cover layer 122 has an inner surface 142 and an outer surface 144. The inner surface 142 of the first cover layer 122 is the surface that is adjacent to the lateral elastomeric material 124. The second cover layer 126 also has an inner surface 146 and an outer surface 148. The inner surface 146 of the second cover layer 126 is the surface that is adjacent to the lateral elastomeric material 124. The lateral elastomeric material 124 also has two planar surfaces, a first surface 150 and a second surface 152, each of which is parallel to the planes of the first and second cover layers 122 and 126.

The first surface 150 is that planar surface of the side elastomeric material 124 that closely abuts the inner surface 142 of the first cover layer 122. The second surface 152 is that planar surface of the side elastomeric material 124 that most closely abuts the inner surface 146 of the second cover layer 126.

Since the lateral elastic member 70 will be subjected to mechanical contraction before and during use, the first and second cover layers 122 and 126 preferably have high elongation at break and are preferably capable of shrinking or elongating, more preferably capable of stretching (but not necessarily elastomeric), without cracking or tearing. Furthermore, the first and second cover layers 122 and 126 can be made from a wide variety of materials such as felt films, apertured plastic films, woven or nonwoven fabrics made of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., fibers made of polyolefins, polyamides, polyester, polyethylene, or polypropylene), or combinations of natural and/or synthetic fibers, or coated woven or nonwoven fabrics.

Preferably, each of the first and second cover layers 122 and 126 is an identical nonwoven material. An example of a suitable nonwoven material is a product of the FiberWeb Company under the designation DAPP-S tex with a weight in the range of 18-35 g/m ^{2 .} The nonwoven material may be reinforced or unreinforced. Preferably, the nonwoven is unreinforced and is suitable as a cover layer for an elastomeric mulch. This material has a basis weight in the range of 18-35 g/m ² before reinforcement and a basis weight in the range of about 40-70 g/m ² after reinforcement. The term "basis weight" as used herein is the weight of one square meter of planar textile material.

Alternatively, nonwoven materials capable of high tensile strength may be used. Alternatively, the first and second cover layers 1222 and 126 may also not be of identical material as long as the material meets the desired performance requirements such as elasticity, softness, conformability, breathability, and durability. As used herein, the term "reinforced nonwoven" refers to a nonwoven material that has been assembled or subjected to transverse contraction under mechanical tension in the structural direction D, such that the material can be elongated in the structural direction D under the application of a low tensile force.

Fig. 9 is a fragmentary enlarged side view in the structural direction B of the laminate 120 (lateral elastic element 70). When the laminate 120 is bonded or otherwise secured such that the lateral grip zones A are formed, it has been found that such laminate 120 is both highly resilient and substantially free of delamination and shifting, providing very good performance characteristics in all categories without any change in the desired characteristics. The lateral attachment is preferably accomplished by lateral bonding using a spot-positioned adhesive to attach the lateral elastomeric material 124 between the cover layers 122 and 126 as part of the lamination process. Alternatively, the lateral attachment may be accomplished by sewing, heat bonding, ultrasonic bonding, needle punching, alternatively by an adhesive process, or by any method known in the art. Another alternative is to laterally bond the layers of the laminated structure after the elastomeric and cover components have been laminated. Preferably, the laminate 120 should provide a very good soft feel to the wearer and user. This is important because consumers value softness. In conventional laminates, attempts to eliminate slip have simultaneously required an unacceptable reduction in softness, often accompanied by an unacceptable decrease in actuation ability. This is because such previous attempts (which were insufficient to reduce slip) to apply an additional hot melt adhesive, often in a general coating pattern, have resulted in an attempt to reinforce the joints. This has generally resulted in an undesirable overall stiffening of the laminate. However, the laminates of preferred embodiments provide for the elimination of slippage without losing the softness desired by the consumer and without compromising the actuation capability.

Referring to Fig. 9, a first adhesive 170 is applied to the inner surface 146 of the second cover layer 126 at locations corresponding to each of the outer portions 180 of the laminate structure 120. The first adhesive 170 may alternatively or additionally be applied to the inner surface 142 of the first cover layer 122. For ease of explanation, the description and figures relate only to the application of the second cover layer 126.

This pattern creates lateral zones A for attachment that substantially eliminate delamination and slippage associated with previously known laminates and that allow the laminate 120 to withstand higher stresses without slipping or delamination. It has also been found that by locally confining the first binder 170 to the edge regions 180 of the laminate structure 120, it is possible to prevent imminent stretching of the laminate 120 and also to prevent tearing of the cover layers 122 and 126. Preferably, the first binder 170 is applied as a series of points 168, as shown in Fig. 9. Preferably, the first binder 170 is a flexible binder with an amorphous and a crystallizable component. Such a suitable binder is manufactured by Findley Adhesive Company under the designation H9224.

Preferably, the laminate 120 includes a second binder 164. The second binder 164 is preferably applied to the second surface 152 of the side elastomeric material 124, but alternatively may be applied to the first surface 150 of the elastomeric material 124. The second binder 164 is preferably applied by spraying in a spiral pattern 166, thereby creating bonding points 167b that are more concealed than those formed by linear spraying. Without being bound by theory, it is believed that a greater portion of the second binder 164 so sprayed aligns in the structural direction D. It has therefore been found that spraying in a spiral results in very good activation capabilities. The term "activation" as used herein refers to shrinkability.

It has been found that spraying a layer of second binder 164 directly onto the second surface 152 of the side elastomeric material 124 is more advantageous than applying the second binder 164 to the opposing (i.e., second) cover layer 126. The reason is that the second binder 164 tends to permeate through residual processing agents (or oils) that may adhere to the surface of the side elastomeric material 124. Such residual materials, if left on the side elastomeric material 124, can weaken the attachment points and thus the laminate structure 120 over time. For example, if these residual materials are left intact, the bonds that are used to form the laminate 120 may weaken over time before the product is sold.

The separation values of the individual layers of material 120 in the areas where a spiral binder is used are typically higher when the spirals 166 are applied directly to the side elastomeric material 124 than when they are applied to the opposing (i.e., second) cover layer 126. As used herein, the term "separation values" refers to the amount of force required to separate the two layers of cover material 122 and 126 from each other. Higher separation values typically indicate less potential for delamination during use.

The third binder 160 may also be preferably applied to the inner surface 142 of the first cover layer 122. Preferably, the third binder 160 is an elastomeric binder. The first binder 160, in the same manner as described in connection with the spiral application of the second binder 166, is preferably sprayed in a spiral pattern 162, thereby creating bonding points 167 that are more concealed than those that would be created by linear spraying. Without wishing to be bound by theory, it is believed that the majority of the first binder 160 so sprayed is aligned in the structural direction D.

• φφφ φφ • φφφ « φ « φ φφφ φ φφφφ φ φ φ φ •φφφφφφφ φφ φ

It is recommended that the second and third binders 160 and 164 be the same elastomeric binder. A recommended binder suitable for the second and third adhesive spiral sprays 162 and 166 is manufactured by Findley Adhesive Company under the designation H2120. The addition level for each second or third spiral spray 162 and 166 is about 0.062 to 0.185 g/m ² , preferably about 0.124 g/m ² .

Referring to Fig. 1, the diaper 20 is provided with a characteristic endless extensible feature 60 around the waist. The endless extensible band 60 around the waist circumference improves the fit, eases use and control. The endless extensible band 60 around the waist circumference is that portion or zone of the diaper 20 which is intended to be elastically expandable and contractible to dynamically conform to the waist of the wearer. The endless extensible band 60 extends along the waist panel 6 and

7. Preferably, the endless extensible belt 60 is formed of two separate elements; one endless extensible waistband 57 located in the front region 26 and the other endless extensible waistband 59 located in the back region 28, other pull-on diapers may also be formed with a single endless extensible waistband. Similarly, according to Fig. 7, the endless extensible waistband 57 and 59 may preferably include an elastic waistband member 80 with a waist elastomeric material 200 (shown in Fig. 8) and a protruding portion of at least one of several layers that are connected to the absorbent core 25, such as the topsheet 24 and the backsheet 22 (although Fig. 7 only shows the structures in the front region 26, the structures in the back region 28 are preferably the same or similar to those shown in the front region 26). Preferably, the endless extensible waistband 57 and 59 is elastically extensible at least in the lateral direction, more preferably in both the lateral and longitudinal directions. In a preferred embodiment, the waist panel 6 and 7 is configured to be extensible at least along the entire lateral length of the waist panel 6 and 7 to form the endless extensible waistband 57 and 59 by the waist elastic member 80. In the embodiment of FIG. 3, the waist elastic member 80 may extend to the connecting edges 12 and 13 such that the endless extensible waist band 57 and the endless extensible waist band 59 are secured to each other in the connecting edge 32 and the waist elastic material 80 of the front region 26 and the elastic material 80 of the back region 28 are secured in the edge 32 (Fig. 7 also shows the waist elastic member 78 which extends to the connecting panel 12 and 13, although the connecting panel 12 and 13 is not shown in Fig. 7). The endless extensible waist bands 57 and 59 form • 9 • · · · « · ··· · ··· ··· ··· »» · in the assembled configuration, the endless extensible waist perimeter panel 60 of the pull-on diaper 20 shown in Fig. 1.

The endless extensible waist panels 57 and 59 may be formed as unitary elements of the diaper 20 (that is, they are not separately manipulable elements attached to the diaper 20, but rather are formed from one or more different layers of the diaper and are extensible portions). In a preferred embodiment, each of the endless extensible waist panels 57 and 59 forms a protruding member of the torso panel 41. Preferably, the endless extensible waist panel 57 and 59 comprises at least one unitary element or continuous web of material that forms a portion of the torso 41 and extends uninterruptedly into the endless extensible waist panels 57 and 59. Alternatively, the endless extensible waist panels 57 and 59 may be concealed members that do not comprise a unitary element forming a portion of the torso 41. The endless extensible waist panel 57 and 59 may be formed by joining concealed members to the waist portions of the torso 41.

The endless extensible waist panel 57 and 59 includes a waist elastic member 80 and an extensible portion of one or more layers adjacent to the absorbent core 25, such as the topsheet 24 and the backsheet 22. If an additional layer, such as an inner barrier cuff 54 or an additional liquid-absorbing silk layer, is added and joined to the absorbent core 25, the additional layer may form part of the endless extensible waist panel 57 and 59. In the preferred embodiment of FIG. 7, the side portion 57B of the endless extensible waist panel 57 includes a laminate of the extended portion 72 of the inner barrier cuff 54, the end extended portion 23A of the nonwoven outer cover 23, and the side portion of the waist elastic member 80. The central portion 57A of the extensible waist panel 57 includes a laminate of the end extended portion 24A of the top fabric 24, the end extended portion 23A of the nonwoven outer cover 23, and the central portion of the waist elastic member 80 (although FIG. 7 only shows the structures in the front region 26. Preferably, the structures in the back region 28 are the same or similar to those depicted in the front region 26). However, in an embodiment, the inner barrier film 68 does not extend into the endless extensible waist panel 57. Alternatively, the inner barrier cuff 54, top fabric 24, and/or nonwoven outer cover 23 may not extend into the endless extensible waist panel 57. Extended portion 72 ·· · ·· • ·

9 9 9 9 9

9 9 9 9

999 99 9 the inner barrier cuff 54 also does not need to extend into the endless extensible waist panel 57. If both the top fabric 24 and the nonwoven outer cover 23 do not extend into the endless extensible waist panel 57, the endless extensible waist panel 57 may form an elongated portion of the inner barrier film 68 and the waist elastic member 80,

The waist elastic member 80 is concealed within the innermost body-facing surface of the pull-on diaper 20. The waist elastic member 80 may be operatively connected to the protruding portions 72 of the inner barrier cuffs 54, to the end extended portion 23A of the nonwoven outer cover 23, and to the end extended portion 24A of the topsheet 24. The waist elastic member 80 may be operatively connected using either an intermittent connection configuration or a substantially continuous connection configuration.

In a particularly preferred embodiment, the selected binder is applied in a spiral (as shown in U.S. Patent No. 3,911,173 (Sprague, Jr.) and U.S. Patent No. 4,842,666 (Werenicz)) at a basis weight of about 0.116 g/m ² . The width of the spirals is about 1.9 cm (0.75 inches) and they are placed closely adjacent to each other or slightly overlapped (less than 2 mm). The binder is preferably a binder available from Findley Adhesives under the designation H2120.

Alternatively, the waist elastic member and any other components of the shrinkable laminates may be joined together in a discontinuous manner or in a continuous manner by thermal bonding, pressure bonding, ultrasonic bonding, dynamic-mechanical bonding, or any other method known in the art.

The total unstretched length of the waist elastic member 80 is preferably prestretched in the lateral direction before being attached to the extensible portions 72 of the left and right inner barrier cuffs 54, to the end of the extensible portion 24A of the top fabric 24, and to the end of the extensible portion 23A of the nonwoven outer cover 23. The total unstretched length of the waist elastic member 80 is prestretched in the lateral direction at least up to the initial original length of the waist panels 6 and 7 of the body 41. The total unstretched length of the waist elastic member 80 may be further prestretched up to the connecting hem portions 12 and 13. In an embodiment, the waist panels 6 and 2 of the body 41 form the extensible portions 72 of the left and right inner barrier cuffs 54, the end extensible portions 72 of the left and right inner barrier cuffs 54, and the end extensible portions 24A of the top fabric 24, and the end extensible portions 23A of the nonwoven outer cover 23. 9 »999 * · 9 · 9 9 » ········ 99 999 99 <

the portion 24A of the top fabric 24 and the end extensible portion 23A of the nonwoven outer cover 23. The term "initial length" as used herein refers to the length of the individual material or composite material before it is processed into a material that is elastically extensible and before being mechanically processed into a material that is permanently shrinkable. The term "pre-stretched total length" as used herein represents the total length of the elastic material in a state where a portion or the entire length of the elastic material is pre-stretched in the lateral direction. In embodiments, the initial length of the waist panels 6 and 7 is typically the same as the combined length of the extensible portions 72 of the left and right inner barrier cuffs 54 and the end extensible portion 24A of the top fabric 24 in the assembled configuration prior to attachment of the elastic waist member 80. The initial length of the waist panels 6 and 7 is also typically the same as the length of the end extensible portion 23A of the nonwoven outer cover 23 prior to attachment of the elastic waist member 80. The elastic waist member 80 is preferably pre-tensioned to a range of from 20 to 100% of its untensioned length (i.e., in a non-tensioned state). More preferably, the elastic waist member 80 may be pre-tensioned to a range of from 40 to 80%. After the pre-tensioned elastic member 80 has been attached, the elastic waist member 80 may return to an untensioned state along with other components such as the extensible portions 72 of the inner barrier cuff 54, the end extensible portion 24A of the top fabric 24, and the end extensible portion 23A of the nonwoven outer cover 23, which are connected to the waist elastic member 80. Thus, an endless extensible waist panel 57 and 59 is formed, which is capable of stretching to an extent corresponding to the unstretched length of the waist elastic member 80 at least up to the initial length of the waist panels 6 and 7 of the torso 41.

Alternatively, only a portion of the waist elastic member 80 may be pre-tensioned prior to operative attachment to the extensible portion of at least one of the plurality of layers such that the pre-tensioned overall length of the elastic waist member 80 in the condition where the portion of the waist elastic member 80 is pre-tensioned is generally the same as the initial length of the waist panels 6 and 7 of the torso 41. Preferably, only a portion of the waist elastic material 80 that extends along the lateral width X (shown in FIG. 3) of the absorbent core 25, the portion adjacent the waist elastic member 80, may be pre-tensioned.

Examples of stretchable materials are described in U.S. Patent No. 2,075,189 issued to Galligan on March 30, 1937; U.S. Pat. No. 3,025,199 33 . ♦ · ··» · · · *·· ··· ··· ·· ·· ·· ··

Harwood, 13/03/1962; US Patent No. 4,107,364 and 4,209,563 - Sisson, 08/15/1978 and 06/24/1980; US Pat. No. 4,834,741 - Sabee 05/30/1989 and US Pat. No. 5,151,092 - Buell et al, 09/29/1992.

The endless extensible panel 57 and 59 is configured to be extensible from the unstretched length of the waist elastic member 80 to at least the initial length of the waist panels 6 and 7 of the body 41. However, the waist elastic member 80 is typically attached to an extensible portion of at least one of several layers adjacent to the absorbent core 25, such as the topsheet 24 and the backsheet 22, which are substantially non-elastic.

Therefore, the extensibility of the waist elastic member 80 can only range between the unstretched length of the waist elastic member 80 and the initial length of the waist panels 6 and 7 of the torso 41, that is, it cannot exceed the limitation given by the initial length of the waist panels 6 and 7 of the torso 41. This defines an upper limit to the range of extensibility of the endlessly extensible waist panels 57 and 59 (that is, the ability to stretch an infinite circumference around the waist 60), even if the waist elastomeric material 80 itself is capable of stretching beyond the initial length of the waist panels 6 and 7 of the torso 41 or to the total pre-stretched length of the waist elastomeric material 80. This definition of the upper limit of the range of extensibility does not provide sufficient extensibility for the endlessly extensible waist panels 57 and 59. Therefore, when the pull-on diaper 20 is used in an extended state, the pull-on diaper 20, may not always provide sufficient size for the waist circumference, or the user must use considerable effort when putting on the diaper 20 to achieve the stretchability of other stretchable materials used in the pull-on diaper 20 to achieve sufficient size around the waist. This can cause difficulties in using the pull-on diaper.

Therefore, the endless extensible waist panel 57 and 59 is configured to be elastically extensible to provide a greater range of extensibility (i.e., range of extensibility) beyond the initial length of the waist panel 6 and 7 of the torso 41 or beyond the prestressed overall length of the waist elastic member 80. Namely, after the waist elastic member 80 has been operatively connected in a prestressed state to the inner barrier cuff 54, to the top fabric 24, and to the nonwoven outer cover 23 and before returning to the unstressed state, at least a portion, preferably all of the resulting composite shrink laminate (i.e., the endless extensible waist band 57 and 59) is formed to be elastically extensible.

59) is then subjected to mechanical contraction sufficient to permanently extend the non-elastic components that are part of the extensible portions 72 of the left and right inner barrier cuffs 54, the end extensible portion 24A of the top fabric 24, the end extensible portion 23A of the nonwoven outer cover 23, and the cover layers (if any) that constitute part of the waist elastic member 80. The composite shrinkable laminate can then return to its substantially unstretched state. Therefore, the waist elastic member 80 is extensible from an unstretched length beyond the initial length of the waist panels 6 and 7 of the torso 41 to at least the permanently extended length of the non-elastic components. This provides a greater range of extensibility for the endlessly extensible waist panels 57 and 59 and is beneficial for ease of use. Alternatively, the waist elastic member 80 may be attached to the inner barrier cuffs 54, the top fabric 24, and the nonwoven outer cover 23 in a substantially untensioned state to create a "zero tension" shrinkable laminate. Preferred devices and methods are described in U.S. Patent No. 5,167,897 to Weber et al, issued Dec. 1, 1992; U.S. Patent No. 5,156,793 to Buell et al, issued Oct. 20, 1990; U.S. Patent No. 5,143,679 to Weber et al, issued Sep. 1, 1992; and in EP application No. 98108290 entitled "Methods and Apparatus for Actuating a Movable Fabric" filed May 7, 1998 (Christoph J. Schmitz et al.).

The waist elastic member 80 is formed of a waist elastomeric material 200, which may be the same material/structure as the side elastomeric material 124. Alternatively, the waist elastomeric material 20 may employ a material/structure different from the side elastomeric material 124. The waist elastic member 80 may further include one or both of a first 202 and a second 204 cover layer. The structure of the waist elastic member 80 may be the same or similar to that used on the side elastic member 70. The structure, materials, and/or properties of the cover layers 202 and 204 may be the same or similar to, or different from, those forming the cover layers 122 and 126. Furthermore, the method of attaching the waist elastomeric material 200 to the cover layers 202 and 204 may be the same or similar to, or different from, the method of attaching the ear panel elements 70 described above. In a preferred embodiment, the waist elastic member 80 is formed of a waist elastomeric material 200 and a single layer of cover layer 202 or 204.

In such a case, the waist elastomeric material 200 is adjacent to the inner barrier cuffs 54 and the top fabric 27 and the cover layer 202 or 204 and is positioned to contact the wearer's body so that the wearer's skin is not directly compressed by the waist elastomeric material 200, thereby reducing the formation of indentations on the skin.

Fig. 12 shows another preferred embodiment of an endless extensible waist panel 57 and 59. In this embodiment, the waist elastic member 80 is concealed within the nonwoven outer cover 23. Preferably in the side portions 57B of the endless extensible waist panel 57, the waist elastic member 80 is sandwiched between the extensible portions 72 of the inner barrier cuffs 54 and the end extensible portions 23A of the nonwoven outer cover 23. In the central portion 57A. The waist elastic member 80 is interposed between the end extensible portions 24A of the top fabric 24 and the end extensible portion 23A of the nonwoven outer cover 23. The waist elastic member 80 may be operatively connected to the extensible portions 72 of the inner barrier cuffs 54, to the end extensible portion 23A of the nonwoven outer cover 23, and to the end extensible portion 24A of the top fabric 24. In another embodiment, the waist elastic member 80 may comprise a waist elastomeric material 200 and a single layer of overlay materials 202 or 204. In the case where the waist elastomeric material 200 is adjacent to the inner barrier cuffs 54 and the top fabric 27, the overlay layer 202 or 204 faces the nonwoven outer cover 23. This overlay layer arrangement tends to to limit the waist elastomeric material 200 . is visible from the outside because one layer (cover layer) is added by interposing between the waist elastomeric material 200 and the nonwoven outer cover 23. In another case, the waist elastomeric material 200 is adjacent to the nonwoven outer cover 23 and to the cover layer 202 or 204, adjacent to the inner barrier cuffs 54 and to the top fabric 27. This cover layer arrangement tends to reduce the occurrence of red marks on the skin because one layer (cover layer) is added by interposing between the waist elastomeric material 200 and the wearer's skin. In both cases, since one of the cover layers is eliminated (compared to two layers of cover layers), the bulkiness of the n portion of the endless extensible waist circumference 57 is reduced. Furthermore, the breathability of the endless extensible waistband 57 is increased because there is less material therein. In addition, the endless extensible waistband 57 provides more stretchability. The endless extensible waistband 57 is formed by a waistband elastic member 80 that includes a waistband elastomeric material 200 that is pre-tensioned and then returned to its original untensioned state, in the preferred embodiment. When the waistband elastomeric material 200 returns to its original untensioned state, • ·

other components attached to the waist elastomeric material 200 tend to restrict the waist elastomeric material 200 from returning to its original unstretched length. Therefore, the waist elastomeric material 200 cannot utilize the full range of extensibility. However, in the embodiment described above, if the bulkiness of the endless extensible waist band 57 is reduced, the waist elastomeric material 200 can return as closely as possible to its original unstretched length. Therefore, the waist elastomeric material 200 is capable of greater extensibility.

Alternatively, the waist elastic member 80 may comprise a single layer of waist elastomeric material 200 without any cover layer. In the side portion 57B of the extensible waistband 57, the waist elastomeric material 200 is inserted and connected directly between the extensible portions 72 of the inner barrier cuffs 54 and the end extensible portion 23A of the nonwoven outer cover 23. In the middle portion 57A, the waist elastomeric material 200 is inserted and connected directly between the end extensible portion 24A of the top fabric 24 and the nonwoven outer cover 23. This structure is also used to reduce bulk, increase breathability, and to provide greater extensibility in the extensible waistband 57.

The side elastic member 70 and the waist elastic member 80 are comprised of separate elements, and both members 70 and 80 are preferably disposed so as not to overlap each other in the longitudinal direction. However, both members 70 and 80 are preferably disposed so as not to have a gap therebetween, such that the members 70 and 80 form a composite elastomeric network in the expandable ear panels 46 and 48. As used herein, the term "composite elastomeric network" refers to a zone or region where two (or more) separate elastomeric materials are substantially continuous without interruption between the elastomeric materials or with predetermined intervals to thereby create an extensible capability as a single elastomeric material. Preferably, both members 70 and 80 are disposed without interruption. Therefore, it should be understood that the extensible ear panels 46 and 48 and the side portion 57B and 59B of the endless extensible waistband 57 and 59 form an endless single elastomeric material between the waist circumference 36 and the leg openings in the assembled configuration of the pull-on diaper 20. The side elastic member 70 and the waist elastic member 80 are comprised of separate elements, therefore the side elastomeric material 124 and the waist elastomeric material 200 are also comprised of separate elements. The structure of the separate separate parts allows

ΦΦ φ φ φ φ «« φφφφ·φ«·

ΦΦ « φ φ ΦΦ φ designing the side elastomeric material 124 and the waist elastomeric material 200 using different materials for each component, so that this allows for different extensibility properties such as force versus extensibility curve for different parts of the diaper 20. The structure of the separate parts also allows for the use of the side elastomeric material 124 and the waist elastomeric material 200 under different conditions, such as in a pre-tensioned state or in an untensioned state. This allows for differentiation of the forces required to stretch different parts of the diaper 20 to the same length, or equalization of the forces required to stretch different parts to different lengths, while adjusting the pressure on the wearer's skin. For example, the pull-on diaper 20 may have a waist stretch material 200 with a high degree of stretchability at a low force, such that the endless stretchable circumference 60 is easily stretched with a low force exerted by the wearer to easily apply the pull-on diaper 20. The pull-on diaper 20 may have a side elastomeric material 124 generating the force necessary to hold the stretchable tabs 46 and 48 in place without causing pressure marks on the wearer's skin. In one embodiment, the endless waistband 60 comprising the waistband elastomeric material 200 is designed to have an extensibility of at least 100%, while the extensibility of the tabs 46 and 48 comprising the elastomeric material 124 is designed to have an applied force of between 40 g/inch and 130 g/inch when the extensible tabs 46 and 48 are in a 50% expanded state (specification at 50% DCO).

Both the side elastic member 70 and the waist elastic member 80 are disposed so as not to overlap each other in the longitudinal direction, therefore the side elastomeric material 124 and the waist elastomeric material 200 also do not overlap. Since the side elastic member 70 and the waist elastic member 80 do not overlap in terms of structure, each member 70 and 80 comprises a single material in terms of extensibility, therefore having substantially homogeneous extensibility properties. This allows the user to stretch the pull-on diaper 20 smoothly, without feeling a change in pressure during stretching when using the pull-on diaper.

The joints 32, each of which connects the connecting edges 12 and 13, thereby connecting corresponding portions of the expandable tabs 46 and 48, thereby forming two leg openings 34 and one waist opening 36. The front and rear expandable tabs 46 and 48 are connected, preferably along the outer side edges 46D and 48D, in an overlapping manner ···· ··· ··· φφφ φφ φ and form an overlapped joint structure. Alternatively, the front and rear expandable tabs 46 and 43 may be connected by a butt joint (not shown in the figures). Bonding of the U32U joints may be accomplished by any suitable means known in the art for the specific materials represented in the front and back ear stretch panels 46 and 48. Ultrasonic bonding, heat bonding, pressure bonding, adhesive bonding, or cohesive bonding, sewing techniques, autogenous bonding, and the like may also be suitable techniques. Preferably, the joining edges 12 and 13 are joined according to a predetermined template by heat/pressure or ultrasonic welds that will withstand the forces and stresses exerted by the pull-on diaper 20 during wear. The joints 32 also connect the endless extensible waist bands 57 and 59 to form an endless extensible waist circumference 60 around the waist opening 36. When the side elastic member 70 and the waist elastic member 80 engage the connecting panels 12 and 13, the joints 32 secure the side elastic member 70 in the front region 26 to the side elastic member 70 in the back region 28 and secure the waist elastic member 80 in the front region 26 to the waist elastic member 80 in the back region 28. Examples of joints are disclosed in U.S. Patent No. 5,569,234 - Buell et al, October 29, 1996, in U.S. Patent No. 5,607,537 - Johnson et al., March 4, 1997, in U.S. Patent No. 5,662,638 Johnson et al, September 2, 1997 and US Patent No. 5,685,874 - Buell et al, November 11, 1997. Suitable joints are described in EP application No. 96118654.1 entitled "Thermal Bonding of Fabrics" filed November 21, 1996 (Christoph J. Schmitz).

In a preferred embodiment, the outer side edge 46D and 48 is not parallel to the inner side edge 46C and 48C and is not parallel to the longitudinal centerline 100. The outer side edge 46D and 48D intersects laterally in an outward direction the nearest higher end edge 46A and 48A. The expandable tabs 46 and 48 have a lateral width L2 between the inner side edge 46C and 48C and the outer side edge 46D and 48D closest to the higher end edge 46A and 48A has a lateral width greater than the lateral width L1 between the inner side edge 46C and 48C and the outer side edge closest to the lower end edge 46B and 48B. Therefore, the amount of elastomeric material in the lateral direction of the expandable ear panels 46 and 48 is greater closer to the upper end edge 46A and 48A than at the lower end edge 46B and 48B. The expandability at the higher end edge 46A and 48A is greater. In addition, because both expandable ear panels 46 and 48 have a greater lateral width (i.e., contain a greater amount of elastomeric material) at the higher end edge 46A and 48A, the lateral width (available ·· • · · * » · · ··*· ··· »· ·«* ·· · amount of elastomeric material) is further increased at the upper end edge 46A and 48A by combining the expandable ear 46 and the expandable ear 48.

With respect to the configuration in which the width at the upper end edges 46A and 48A is greater, the pull-on diaper has a greater amount of elastomeric material around the waist circumference. Therefore, the pull-on diaper does not exert high pressure on the skin that would lead to negative problems around the waist circumference while maintaining proper fit around the leg openings. It further allows for easy application. In the configuration where the expandable ear 46 and the expandable ear 48 are connected, the joint 32 is not parallel to the longitudinal centerline 100 as shown in Fig. 13, the joint 32 intersects laterally in an outward direction the nearest higher portion 32B of the joint 32. In Fig. 13, the waist elastic member 80 is connected to the waist panels 6 and 7 of the body 41 in a tensioned (pre-tensioned) state and returned to a substantially untensioned state, while the side elastic member 70 is connected to the extensible ear 46 and 48 in an untensioned state. Therefore, the circumference along the endlessly extensible waist opening 60 contracts slightly. As the elastomeric material 200 is further pre-tensioned, the circumference along the endlessly extensible waist circumference 60 becomes smaller than the circumference of the pull-on diaper 20 through a portion of the extensible ear 46 and 48, as shown in Fig. 14. However, because the original configuration of the extensible ear 46 and 48 has a larger lateral width closest to the upper end edge 46A and 48A, the pull-on diaper 20 shown in Fig. 14, has an increasing amount of elastomeric material at the higher end edges 46A and 48A.

As used herein, the term "circumferential direction" refers to the direction along the circumference of the waist in the assembled configuration of the pull-on diaper. As used herein, the term "circumference" refers to the length of the pull-on diaper along the circumferential direction.

The endless waistband zone 38 is formed by front and rear extensible tabs 46 and 48, a body portion 41, and an uninterrupted extensible waist circumference, as shown in Fig. 1. The endless waistband zone, or belt-like zone, is that portion of the pull-on diaper that is extensible so that the circumference of the endless waistband zone is stretched for application of the pull-on diaper 20. The endless waistband zone 38 is that portion that is capable of being stretched. The endless waistband zone 38 in the assembled configuration of Fig. 1, includes the waist edge 151 and 155 of the pull-on diaper 20, the edges around the leg openings 153 and 156, the lateral edge 159 of the crotch area 30 in the front 26 and in the back 28. The endless waist zone 38 has the lowest height typically found in ear panels. In the embodiment of Fig. 1, the lowest height of the endless waist zone 38 also has an uninterrupted lowest line 35 that is not interrupted by the leg openings 34 and is closely adjacent to these openings 34. The endless waist zone 38 has two parts; an uninterrupted waist zone in the form of a belt 37, in which an endless extensible waist circumference 60 extends; and an uninterrupted lower waist zone 39, in which the extensible ears 46 and 48 and the torso portion 41 extend. In a preferred embodiment, the uninterrupted belt-shaped zone 37 around the waist corresponds to the uninterrupted extensible waist circumference 60.

In one preferred embodiment, where the pull-on diaper of Fig. 3 , when assembled in the configuration shown in Fig. 1 , the initial circumference of the endless waistband zone 38 along the waist end edges 151 and 155 may be in the range of 220 mm to 520 mm in the untensioned state, preferably from 270 mm to 420 mm. The circumference of the endless waistband zone 38 along the waist end edges 151 and 155 extends to at least 650 mm, preferably at least 700 mm, more preferably at least 750 mm (when the circumference is extended). The circumference of the endless waistband zone 38 along line 35 may be from 300 mm to 530 mm, preferably from 380 mm to 480 mm. The minimum height of the endless waist zone 38 measured along the seams 32 may be from 50 mm to 150 mm, preferably from 80 mm to 120 mm. The height of the endless waist zone 37 (continuous extensible waist circumference 60) may be from 5 mm to 40 mm, preferably from 15 mm to 30 mm. The combined lateral width of the extensible ear panels 46 and 48 on one side of the pull-on diaper 20 along line 35 is from 50 mm to 120 mm, preferably from 60 mm to 100 mm.

The diaper assembly shown in Fig. 3 reduces pressure on the wearer's skin locally, particularly around the waist 34 because the expandable ears 46 and 48 have a greater lateral width (a sufficient amount of elastomeric material in the lateral direction) near the upper end edges 46A and 48A. If necessary, the waist elastomeric material 200 can utilize a low DCO 50% strength material to further reduce pressure around the waist 36. However, reducing the DCO 50% strength around the waist 36 can lead to a loss of fit throughout the diaper. Therefore, increasing the pressure around the leg openings 34 can be a necessary condition for proper fit of the diaper as a whole. This can be achieved by prestressing only the side elastomeric material 124, prior to attachment of the ear panels 10 and

11. Additionally, the side elastomeric material 124 may utilize a material with a higher DCO 50% • · · · · · · · · · · · · · · · · · · · · · · «««· · · * * • · * · · · · · · · · · · · · · · · · · · · 99 · strength to further increase the pressure around the leg openings 34. These force distribution combinations allow the pull-on diaper to achieve sufficient retention and adhesion around the leg openings without causing skin indentations around the waist. Alternatively, a pull-on diaper with the configuration shown in Fig. 3 may provide retention and adhesion around the waist circumference and prevent skin indentations around the leg openings. This may be accomplished, for example, by utilizing a material with a lower DCO 50% strength for the side elastomeric material 124 to reduce pressure around the leg openings 34. The waist elastomeric material 200 may utilize a material with a higher DCO 50% strength. Furthermore, the waist elastomeric material 200 may be pre-stressed before being attached to the waist panels 6 and 7.

The continuous belt zone 38 contributes to the generation of dynamic forces required to conform the diaper 20 to the wearer's body, to maintain the diaper on the wearer's body. Although the higher force generated by the endless belt zone 38 is recommended for retaining and conforming the diaper, the endless belt zone 38, which exerts higher pressure, leads to difficulties in using the diaper, since the wearer of the diaper must use higher forces when donning it, i.e., to stretch the endless belt zone 38 to provide a wider opening around the waist and wider openings around the legs. Since the endless belt zone 38 includes a side elastomeric material 124 and a waist elastomeric material 200, both elastomeric materials must be stretched during donning the diaper. Therefore, the extensibility, as a property of the endless waistband zone 38 including the side and waist elastomeric material, is more important than the intrinsic characteristic of the endless extensible waistband 60 and/or the intrinsic characteristic of the separate extensible tabs 46 and 48, although, the extensibility, as a property of the intrinsic characteristic of the endless extensible waistband 60 and/or the separate extensible tabs 46 and 48 is still important. Part of the prior art is U.S. Patent 5,601,547, issued February 11, 1997 to Kato, et al., which describes an elastic waistband system with improved modulus of elasticity for children's sanitary panties that provides greater comfort, fit, and ease of use. However, this publication is directed only to the improved elastic waistband system.

The endless band zone 38 is expandable to a range from its initial state (i.e. 0%). The expandability is calculated according to the formula: ((expanded circumference - initial circumference) / initial circumference) x 100 and expressed in % (percentage unit).

• · ········

The initial circumference of the endless waist zone 38 is the circumference in a state where the endless waist zone 38 is not stretched. The expanded circumference is the circumference when the endless waist zone 38 is in an expanded, stretched state. The wider range of expansion allows for a wider waist circumference and wider leg openings when using the pull-on diaper 20. The circumference of the endless waist zone 38 is the circumference measured along the waistline on the unbroken waist zone 38 (along the waist edges 151 and 155 of the endless expandable waist circumference 60).

In order to ensure ease of use of the diaper (this involves achieving a wider waist opening and wider leg openings), the initial circumference of the endless waist zone 38 of the diaper can be between about 220 mm and 500 mm and the expanded circumference of the endless waist zone 38 of the diaper at least about 650 mm. More specifically, the initial circumference of the endless waist zone 38 of the diaper designed to fit infants weighing about 9 kg to about 14 kg is between 240 mm to 480 mm, preferably between about 270 mm and about 380 mm. The initial circumference of the endless waist zone 38 of the diaper designed for infants weighing 13 kg or more is between 260 mm and 500 mm, preferably between about 290 mm and about 400 mm. The circumference when stretched of the endless waist zone 38 of a pull-on diaper designed for toddlers weighing from 7 kg to about 10 kg is at least about 650 mm, preferably about 700 mm. The circumference when stretched of the endless waist zone 38 of a pull-on diaper designed for toddlers weighing from 9 kg to about 14 kg is at least about 700 mm, preferably about 750 mm. The circumference when stretched of the endless waist zone 38 of a pull-on diaper designed for toddlers weighing about 13 kg and above is at least about 750 mm, preferably 800 mm. The pull-on diaper has a stretch range of at least about 125%, preferably about 135%, preferably at least 150%

The endless web zone 38 also has a force versus elongation curve over the range of elongation and a modulus of elongation over the range of elongation. The force versus elongation curve represents the relationship between the force required to stretch the endless web zone 38 and the elongation of the endless web zone 38. The modulus of elongation represents the rate of force changes to the change in elongation and is expressed in units of g/% elongation (grams/percentage of elongation). The modulus of elongation is based on the force versus elongation curve. A higher modulus of elongation means a higher rate of force changes required to stretch the endless web zone 38. When a dramatic • · • · 9 4 4 v * • ·· 4 · ώ »· • 4 · 4 4

4 4 4 4

44444444 44 44 high modulus of elasticity, the user will experience a limitation in the elasticity of this portion. Conversely, a lower modulus of elasticity means a smaller amount of force change required to stretch the endless belt zone 38. This allows the endless belt zone 38 to be stretched without much effort and the user will not experience a limitation in elasticity. Therefore, it is advantageous for the user of the pull-on diaper that the endless belt zone 38 has a lower modulus of elasticity at the stretched circumference. In addition, the lower force required to stretch the pull-on diaper to the stretched circumference is advantageous when applying the pull-on diaper.

To ensure easy application of the pull-on diaper (to achieve stretching during application of the pull-on diaper, less force and a lower modulus of elasticity are required at 125% extension, which is not greater than about 150 g/extension, more preferably not greater than about 120 g/% extension, more preferably not greater than about 100 g/% extension. The modulus of elasticity in the range of extension up to 125% is preferably not greater than a factor of 150 g/% extension, more preferably not greater than a factor of 120 g/% extension. The modulus of elasticity at 135% is not greater than a factor of 200 g/% extension. More preferably not greater than a factor of 175 g/% extension, more preferably not greater than a factor of 150 g/% extension. The modulus of elasticity in the range of extension up to 135% is not greater than a factor of 135%, preferably not greater than 200 g/% elongation, more preferably not greater than 175 g/% elongation. Modulus of elongation at 150% elongation preferably not greater than 300 f/% elongation, more preferably not greater than 250 g/% elongation. Force required to stretch to 125% preferably not greater than 5,000 g, more preferably not greater than 4,500 g. Force required to stretch to 135% preferably not greater than 6,000 g, more preferably not greater than 5,500 g. Force required to stretch to 150% preferably not greater than 9,000 g, most preferably not greater than 8,000 g.

Fig. 15 shows a preferred example of a force versus stretch curve of the endless belt zone 38 of a pull-on diaper. Fig. 16 shows a modulus of extensibility versus stretch curve for the example shown in Fig. 15. The methods for obtaining the force versus stretch curve of the endless belt zone 38 and the modulus of extensibility versus stretch curve are determined as follows:

The force versus stretch curve of the endless belt zone and the modulus of elasticity versus stretch curve are determined as follows. This method is a modification of the ultimate tensile test method included in the Sintech TestWorks software package for force versus stretch curve measurements. This measurement is essentially designed to simulate the wearer's experience of wearing a pull-on diaper and utilizes an Instron force tester and two horizontal bars at the jaw attachment points from 0 g to 10,000 g, or until the diaper ruptures. This force then represents the ultimate force applied to the endless belt zone. The method provides a "force versus stretch" curve from the untensioned state to the ultimate tension of the diaper. The force versus elongation data obtained by the method described above can then be converted to "elastic modulus versus elongation".

The following describes the preparation of the test sample for this test method.

(1) The diaper sample to be tested should be taken from the back.

(2) Measure the circumference of the diaper at the waist edge inside the diaper using a tailor's tape measure in an unstretched state, without the shrinking circumference being taut during measurement.

This test method requires the following equipment.

(1) Instron Model 5564 Cyclic Stress Testing Equipment (2) Sintech TestWorks version 3.0 operating software (3) Instron Static Loadcel, 100N load cell (4) Jaw mount 20 mm diameter x 150 mm long, Teflon coated rod, mounted horizontally to the upper and lower jaws.

This method is implemented using the following settings.

(1) Testing method: Tension (2) Progress speed: 20 inches/minute (3) Measuring length: the distance from the center of the top bar and the bottom bar is calculated as follows (Measuring length) = (untensioned diaper circumference)/2 - 30 mm

9 9 • 9 • · * 9 9 • · • 9 • • • 9 9 9 9 • • ♦ • • 9 9 • « · · • • · · · • • • · • • · · Λ 9 4 9 9

(4) # of cycles: 1 cycle (5) Tear sensitivity: 75% (6) Load limit: 10,000 g (7) Calculation input: Diaper circumference in unstretched state, Load point at 500 g, 1,000 g, 2,000 g, 3,000 g, 4,000 g, 5,000 g, 6,000 g (8) Calculation results: Diaper circumference at 0 g (=unstretched state), Stretch at load point at 500 g, at 1,000 g, at 2,000 g, at 3,000 g, at 4,000 g, at 5,000 g, at 6,000 g, at peak load, load at maximum, circumference at peak load. The circumference of the diaper at a certain point of peak load is calculated as follows: (Diaper circumference) = (Diaper circumference in the unstretched state) + (stretch) x 2 The stretch at a certain point of load is calculated as follows: (Stretch) = (Expanded diaper circumference - Diaper circumference in the unstretched state)/(Diaper circumference in the unstretched state).

The test is performed as follows.

(1) Prepare diaper sample and measurement data (2) Set up Instron load cell and slow shift to follow Istron settings, then calibrate load cell (3) Log in to TestWork (4) Select tension test method from method list in tool menu, then load panel, load measurement, stretch measurement and HS listed at top of screen.

(5) Enter the unstretched diaper circumference into the measured length in the input calculation data (6) Set the measured length using the rules described above for setting the measured length, (example: Unstretched diaper circumference = 380 mm -> measurement length = 380/2-3= 160 mm) (7) Re-adjust the load to the load measuring device and stretch to the tension measuring device (8) Determine the weight of the test product by placing it on the top bar, then re-adjust the load « · (9) Place the diaper sample on the sliding device and ensure that the elastic leg cuff does not stick to the bar (10) After placing the diaper on the sliding device, the load measurement cannot be re-adjusted.

(11) Click “Run” to start the measurement.

(12) After the measurement is completed, the slide returns to its original position (13) Click “File” to save the data and remove the diaper (14) Repeat step 6-13 for another sample

The data is evaluated in the following way.

(1) After completing all the samples, export the data to an appropriate advanced computer program (such as Microsoft Excel). (2) The “Force versus Stretch Curve” is obtained by plotting the force in grams against the stretch of the diaper in percent. (3) The “Modulus of Stretch” is obtained by finding the ratio, dividing the difference in force between two consecutive data points by the difference in stretch between those same points. (4) The “Modulus of Stretch versus Stretch Curve” is obtained by plotting the modulus of stretch obtained in step (3) against the stretch of the diaper in percent.

As stated above, the endless waistband zone 38 provides the force necessary to adhere the pull-on diaper 20 to the wearer's body so that the pull-on diaper 20 is held against the wearer's body. The endless waistband zone 38 further includes a zone of extensibility that includes elastic materials such as the side elastomeric material 124 and the waist elastomeric material 200. The zone of extensibility must further include an elastomeric material around the leg openings. The elastomeric material for the edges of the leg openings is an elastomeric material such as the elastic bands 64 shown in FIG. 3. The elastomeric material for the legs may comprise the material used for the side elastomeric material 124 or the waist elastomeric material 200. As used herein, the term "zone of extensibility" refers to an infinite area or infinite zone of the pull-on diaper made extensible by means of an elastomeric material that is in the form of an endless planar layer with or without an opening, or in the form of strips that are not connected to each other.

φ φφφ

The extensibility zone is that portion of the endless belt zone 38 that substantially creates pressure contact with the skin in the endless belt zone 38. The pressure contact with the skin created by the extensibility zone helps to maintain the pull-on diaper on the wearer (supports the fit of the pull-on diaper). The pressure contact with the skin in the extensibility zone may not be the same everywhere. For example, the pressure contact of the skin of the extensibility zone between approximately the waist opening and approximately the leg openings may differ from each other. Finally, the pressure contact with the skin around the edge circumference of the diaper or the circumference around the legs may be different for the diaper.

In the extensibility zone, the elastic component of the elastomeric material (such as the first plurality of strips 125 and the second plurality of strips 127 of the elastomeric mule 124 shown in FIG. 8 ) that compresses the skin typically generates a higher pressure contact than the rest of the extensibility zone area (such as the series of holes 132 of the elastomeric mule shown in FIG. 8 ). Therefore, the less pressure contact with the skin of the elastomeric material that compresses the skin results in a reduction in the formation of local indentations on the skin.

The skin contact pressure of the elastomeric material (side elastomeric material and/or waist elastomeric material) compressing the skin should be no less than about 0.1 psi, more preferably no less than about 0.2 psi, more preferably no less than about 0.3 psi, to maintain the pull-on diaper 20 on the wearer's body. The skin contact pressure of the elastomeric material (side elastomeric material and/or waist elastomeric material) compressing the skin so as not to cause indentations on the skin in the extensibility zone should be no greater than about 0.75 psi, more preferably no greater than about 0.65 psi, more preferably no greater than about 0.55 psi. Any combination selected from the above range of skin contact pressure of the elastomeric material pressing against the skin is effective in providing a pull-on diaper with reduced risk of sagging, sagging or slipping from position on the wearer, with reduced risk of indentations in the extensibility zone, and with reduced risk of indentations caused by the elastomeric material. The skin contact pressure of the elastomeric material (the elastomeric material at the leg openings) pressing against the skin to maintain the pull-on diaper 20 on the wearer should be no less than 0.1 psi, more preferably no less than 0.2 psi, more preferably no less than 0.3 psi. The skin contact pressure of the elastomeric material (the elastomeric material at the leg openings) pressing against the skin to maintain the pull-on diaper 20 on the wearer should be no less than 0.1 psi, more preferably no less than 0.2 psi, more preferably no less than 0.3 psi.

9 9 9 9 9 9 9 9 9

9 9 9 9 9 9 9

9999 9999 99 99 99 999 feet) compressing the skin, so as not to cause skin indentations in the zone of extensibility, should be no greater than about 0.75 psi, more preferably no greater than about 0.65 psi, more preferably no greater than about 0.55 psi. A method for determining the skin contact pressure of an elastomeric material that compresses the skin is as follows.

The contact pressure of the elastomeric material compressing the skin in the zone of extensibility around the waist circumference to ensure the adhesion of the pull-on diaper to the waist circumference may be higher than the contact pressure of the elastomeric material compressing the skin in the remaining parts of the area in the zone of extensibility. The contact pressure of the elastomeric material compressing the skin in the zone of extensibility around the leg openings to ensure the adhesion of the pull-on diaper around the leg openings may be higher than the contact pressure of the elastomeric material compressing the skin in the remaining parts of the area in the zone of extensibility. The contact pressure of the elastomeric material compressing the skin in the zone of extensibility around the waist circumference and around the leg openings within the zone of extensibility may be higher than the contact pressure of the elastomeric material compressing the skin in the remaining parts of the area within the zone of extensibility. The difference between the highest contact pressure of the elastomeric material compressing the skin within the zone of extensibility and the lowest contact pressure of the elastomeric material compressing the skin should be less than about 0.65 psi, preferably less than about 0.45 psi, more preferably less than about 0.25 psi. As the difference approaches zero, the contact pressure of the elastomeric material compressing the skin within the zone of extensibility approaches uniformity throughout. This further contributes to reducing the occurrence of indentations on the skin caused by differential pressure.

The diaper 20 further includes additional elastomeric material such as padding means 58 of the inner barrier cuff 54. It is preferred that the additional elastomeric material incorporated into the diaper 20 provide a contact pressure of the additional elastomeric material compressing the wearer's skin of no greater than about 0.75 psi. Preferably, the contact pressure of the additional elastomeric material compressing the wearer's skin is no greater than about 0.65 psi, more preferably no greater than about 0.55 psi.

The method for measuring the contact pressure of an elastomeric material on the skin within the extensibility zone is as follows. The method named “AMI Air49 φ · φ ♦ * · · • φφφ ♦ φ ·♦ · ♦ • φ · φ · · · φ φφφφ · * φ · φ φ φ · · * · φφφφφφφφ φφ Φ·· «· pack - type surface contact pressure measurement system” is commercially available from AMI Co., Ltd for measuring the surface contact pressure generated between soft materials. This method is modified to measure the contact pressure between the diaper and the wearer’s body. The indicated air pressure represents the surface contact pressure from which the force absorbed by the material’s compliance is derived. The sensing part is composed of an air pack made of a very soft thin film, a tube introduced into the main unit, and the measured values are converted into a DC output (10mV=1gf/cm ² ).

This test method requires sample preparation as described.

(1) The diaper sample to be tested should be taken from the back.

(2) Measure the width of the actual elastomer component of the elastomer material (e.g., elastic bands) at a 50% shrinkage state and calculate the percentage area of the elastomer component.

This test method, called “AMI Air-pack - Type Contact Pressure Measurement System on Surface”, requires the following equipment.

(1) Air package (2) Main unit (3) Optional unit (4) Air cylinder (5) Calibration kit (6) Data collector (7) Data conversion software

AMI CO., Ltd Mode, 0 15 mm AMI Co., Ltd AM, 3037-2 AMI Co., Ltd AMI 3037-2B AM, Co., Ltd AMI Co., Ltd

ANSITSU METER Co., Ltd. AM-7052 ANRITSU METER Co., Ltd.

DATA COLLECTOR System

AMS7006WIN ver.2.0 for Windows

This test equipment, described above, requires the following setup.

(1) Connect the output cable to the output connector of the main unit and connect the opposite side of the output cable to the data collector.

(2) Power on (3) Use the gear, insert the air cylinder head to the end in the shortest length (4) Connect the air pack to the air cylinder (5) Insert the pin into the blue head on the gear, rotate the gear until the pin is inserted to the end, wait for 3 seconds (6) Press the release lever to create air cylinder pressure, which should be the same as the surrounding pressure, wait for 3 seconds.

(7) Insert the pin into the gear hole that matches the color of the air pack, and rotate the gear until the pin reaches the end.

(8) Remove the air pack from the air cylinder, rotate the gear until the pin reaches the end (9) Check whether the output signal from the main unit is close to zero with a deviation of 5mV (0.5 gf/cm ² ).

(10) Connecting the air pack to the main unit (connection should be done once. If the connection is renewed, the internal volume of the air pack must be changed) (11) Pressing the air pack with the palm or finger to remove all the air from the air pack, checking the output signal transmitted from the main unit, it is necessary to carefully check whether this signal is the maximum measured value and whether the system has measured some values reaching the maximum of the maximum measured value. If the contact surface is too curved, and if the output signal from the main unit reaches + 20mV (2gf/cm ² ), it is necessary to connect the air cylinder and press the release lever (12) For standard measurement, it is necessary to prepare 2 air packs.

This method requires a standard dummy as described above.

The standard dummy 350 shown in Figures 18 and 19 is modeled after the body shape in a sitting position. The shape and dimensions of the standard dummy 350 should be based on the body size data of the actual diaper wearer. The standard dummy 350 has a top portion 352 and a bottom portion 354. The top portion 352 and the bottom portion 354 are divided by a bottom line 380 passing through the torso. The bottom line 380 passing through the torso is a circumferential line passing through the top of the pubic bone. The top portion 352 includes

torso portion 353. Torso portion 353 has a top surface 355 (shown in Fig. 19) surrounded by a waistline 357, which is a circumferential line around the top of torso portion 353 at the waist. Torso portion 353 has a height that is defined by the height between waistline 357 and bottom torso line 380. The circumference of torso portion 353 gradually increases from waistline 357 toward bottom torso line 380. Bottom portion 354 includes a hip portion 356 at the rear of bottom portion 354 and leg portions 358 extending from hip portion 356 at the front of bottom portion 354. Hip portion 356 and leg portions 358 are separated by a crotch fold line 359 along a flat fold at the front of the body. The two leg portions 358 have a crotch angle 362 that is the opposite angle between the thighs 364. The leg portion 358 has a thigh line 366 that is a circumferential line around the thigh on the leg portion 358. The top surface 355 has a shape surrounded by a waist line 357 that includes straight lines and curved lines. Fig. 19 shows a preferred example of the shape of the top surface 355. which is conditionally based on the actual dimensions of the wearer. The standard mannequin is made of vinyl chloride.

The current dimensions of the standard dummy for designing diapers to be worn by users weighing around 7.0 kg to 10.0 kg are listed below.

Waist circumference:

Circumference at the lower torso line: Circumference at the crotch crease line: Circumference at the crease line:

Torso height:

Crotch angle:

460 mm 470 mm 310 mm 275 mm 75 mm around 60 degrees

The current dimensions of the standard diaper design dummy, which should fit a wearer weighing from around 9.0 kg to around 14.0 kg, are listed below.

Waist circumference:

Circumference at the lower torso line: Circumference at the crotch crease line: Circumference at the crease line:

Torso height:

Crotch angle:

495 mm 505 mm 330 mm 290 mm 78mm around 60 degrees

The current dimensions of the standard diaper design mannequin, which should fit a wearer weighing around 13.0kg or above, are listed below.

Waist circumference:

Circumference at the lower torso line: Circumference at the crotch crease line Circumference at the crease line:

Torso height:

Crotch angle:

520 mm 530 mm 350 mm 305 mm 85 mm around 60 degrees

Measurements are for the waist elastomer material and are listed below for the side elastomer material.

Point P1 is the point of the minimum radius of the curved line around the waist on the right side of the torso part. Point P2 is the point of the minimum radius of the curved line around the waist on the left side of the torso part. Point P3 is a point in the middle of the torso at the back. Point P4 is a point in the middle of the torso at the front. The points P1, P2, P3, and P4 for measurement should be attached about 10 mm below the waist line and should be completely covered by the waist material of the diaper sample. Point P5 is the point of the right leg part at the front and point P6 is the point of the left leg part at the front. The air packs for measuring points P5 and P6 should be attached under the elastomeric material that contacts the leg parts of the dummy.

The measurement points for the elastomer material on the legs are the points where the elastomer material presses against the skin of the standard mannequin.

This method is performed as follows.

(1) Setting up the pressure measurement system according to the above settings (2) Preparing the diaper sample and attaching the diaper to the standard dummy (3) Placing two air packs at points E1 and P2 and measuring the pressure.

• · (4) Record the measured pressure data and check that the pressure signal recovers close to zero with a deviation of 5 mV (0.5 gf/cm ² ) (5) Place two air packs at points P3 and P4 and measure the pressure (6) Record the measured pressure data and check that the pressure signal recovers close to zero with a deviation of 5 mV (0.5 gf/cm ² ) (7) Place two air packs at points P5 and 56 and measure the pressure (8) Record the measured pressure data and check that the pressure signal recovers close to zero with a deviation of 5 mV (0.5 gf/cm ² ) (9) Repeat steps 2 to 8 for 1 diaper sample

The data is evaluated in the following way.

(1) The “Local Total Skin Contact Pressure within the Extensibility Zone” can be obtained by converting the measured voltage to psi (10mV = 1 gm/ ^cm2 ) (2) The “Skin Contact Pressure of the Skin Compressing Elastomeric Material” can then be obtained in psi by dividing the “Local Total Skin Contact Pressure within the Extensibility Zone” indicator given above by the area ratio in percent of the elastomeric component.

It is understood that the examples and embodiments described herein are provided for illustrative purposes only and that various modifications or changes that will be suggested to those skilled in the art are within the scope of the present invention.

Claims (10)

PATENT CLAIMS Disposable undergarments having a front region (26), a back region (28) and a crotch portion (30) between the front and back regions, the disposable underwear comprising: a torso (41) comprising an outer fabric (24) ), a backsheet (22) associated with the topsheet and an absorbent core (25) interposed between the topsheet (24) and the backsheet (22), the hull (41) having a central panel having side edges and waist edges and panels in the topsheet. an ear shape (10 and 11) that protrudes laterally outward from each lateral edge of the central panel in the front region and the rear region, the ear panel being extensible to form an extensible gripping ear, the extensible ear having a top end of the rim, the lower end of the edge, the inner side edge and the outer side edge, wherein the outer side edge is not parallel to the inner side edge and is not parallel to the longitudinal centerline and extending laterally outwardly the nearest higher end of the edge, wherein the lateral width of the extensible ear between the inner side edges and the outer side edges is greater closest to the higher end edge than the nearest lower end edge and the seams (12 and 13). ) attach each ear panel along the outer side edge to a respective portion on the opposing disposable garment so as to form one waist opening and two leg openings, wherein the connecting rim is not parallel to the longitudinal centerline. Disposable garment according to claim 1, characterized in that the ear panel is provided with a waist edge, the fuselage (41) having a waist panel in the form of a strip (6 and 7) extending longitudinally out of each waist edge of the middle a panel and a waist edge of the ear panel in the front region and in the rear region, the waistband panel being extensible to form an extensible waistband. • · · · · · · · · · · · · · · · · · · · · · · · · · 3. The disposable undergarment of claim 1, wherein the extensible ear is a lateral elastomeric material. 4. The disposable undergarment of claim 2 wherein the expandable waist panel is a waist elastomeric material. The disposable garment of claim 1, wherein the extensible ear is a side elastomeric material and the expandable waistband panel is a waist elastomeric material, wherein the waist elastomeric material and the side elastomeric material are separate elements and are positioned such that do not overlap each other. 6. The disposable garment of claim 4, wherein the belt-shaped waist panel before the elastomeric material is attached thereto is of an original length, wherein the extensible waist panel web is made extensible. so that the expandable belt-shaped waist panel extends beyond the original length of the belt-shaped waist panel. The disposable undergarment of claim 6, wherein at least a portion of the waist elastomeric material is pre-tensioned prior to attachment to the ear-shaped waist panel. 8. The disposable undergarment of claim 3, wherein the extensible handle is formed of a &quot; zero strain &quot; The disposable undergarment of claim 3, wherein the side elastomeric material is in the form of an endless planar layer. • · The disposable undergarment of claim 3, wherein the side elastomeric material is in the form of belts that are not joined to each other.