ABSORBENT ARTICLES WITH UNITARY HOOK FASTENERS, AND METHODS OF MAKING SUCH ARTICLES

Abstract

This disclosure includes embodiments of disposable absorbent articles and methods of making disposable absorbent articles that include closures with a web of material and hook fasteners that are unitary with the web. For example, some of the present disposable absorbent articles include diapers or briefs with closure members, such as back ears or front ears, defined at least in part by a nonwoven web with hook fasteners that are unitary with the nonwoven web. Use of such unitary hook fasteners allows simpler construction of such articles and/or softer closure members for improved fit and user comfort, and/or other benefits. Certain embodiments of the present methods can manufacture such absorbent articles with fewer manufacturing steps or processes and/or fewer raw materials, relative to those required to manufacture prior art absorbent articles with hook fastener patches that are added by application of a separate piece of material that includes the hook fasteners.

Claims

1. A disposable absorbent article comprising: a chassis having opposing front and rear waist portions, a crotch portion extending longitudinally between the front and rear waist portions, a body facing surface configured to face a wearer during use of the article, and an outer surface configured to face away from a wearer during use of the article; two closure members each having a first end, a second end, and a width extending between the first and second ends, each of the closure members having an elasticized portion and a nonwoven panel with at least one fastener region on a body facing side of the nonwoven panel, each fastener region comprising a plurality of hook fasteners that are unitary with the nonwoven panel; where the first end of each closure member is bonded to the rear waist portion of the chassis, and the second end of each closure member is configured to overlap and be releasably coupled to the front waist portion to define a closed configuration in which: the front and rear waist portions cooperate with the closure members to encircle and define a waist opening, a left side of the chassis defines a first leg opening, and a right side of the chassis defines a second leg opening.

2. The article of claim 1, where each fastener region comprises a plurality of distinct sub-regions of the hook fasteners.

3. The article of claim 1, where the elasticized portion of each of the closure members is defined by an elastic panel having a first end defining the first end of the closure member, a second end, and a width extending between the first and second ends, and the nonwoven panel of each of the closure members defines a fastener tab having a first end bonded to the elastic panel, and a second end defining a second end of the closure member such that the width of the closure member extends from the first end of the elastic panel to the second end of the fastener tab.

4. The article of claim 1, where the nonwoven panel of each of the closure members includes the respective elasticized portion.

5. The article of claim 4, where the nonwoven panel of each of the closure members includes a plurality of the fastener regions spaced along a portion of the width of the closure member.

6. The article of claim 5, where the fastener regions of each of the closure members comprise a first fastener region having a first height, and a second fastener region having a second height and disposed between the elasticized portion and the first fastener region, and the second height is greater than the first height.

7. The article of claim 5, where the fastener regions of each of the closure members are closer to the second end of the closure member than to the first end of the closure member.

8. The article of claim 1, where a landing portion of the outer surface on the front waist portion of the chassis is configured to be releasable engaged by the fastener portions of the closure members.

9. The article of claim 8, where the portion of the outer surface is defined by an anchoring member bonded to a backsheet of the chassis.

10. The article of claim 9, where the anchoring member comprises a loop fastener material.

11. The article of any of claims 1-10, where at least a portion of the fastener regions are spaced inward from a peripheral edge of the respective closure member.

12. The article of claim 1, further comprising; two nonwoven front-ear members each having a first end, a second end, and a width extending between the first and second ends, each of the front-ear members having at least one fastener region on an outward-facing side of the front-ear member, each fastener region comprising a plurality of hook fasteners that are unitary with the nonwoven front-ear panel; where the first end of each front-ear member is bonded to the front waist portion of the chassis, and the second end of each closure member is configured to be overlapped by and be releasably coupled to a body-facing side of a corresponding one of the closure members when the closure members are coupled to the front waist portion.

13. The article of claim 12, where the at least one fastener region of each of the front-ear members includes a plurality of the fastener regions spaced along a portion of the width of the front-ear member.

14. The article of claim 13, where the fastener regions of each of the front-ear members are closer to the second end of the front-ear member than to the first end of the front-ear member.

15. The article of any of claims 12-14, where at least a portion of the fastener regions of the front-ear members are spaced inward from a peripheral edge of the respective front-ear member.

16. The article of any of claims 1-15, where the front waist portion, rear waist portion, and crotch portion are defined by corresponding regions of a common chassis member.

17. The article of any of claims 1-15, where the chassis comprises a topsheet, a backsheet bonded to the topsheet, and an absorbent core disposed between the topsheet and the backsheet.

18. A disposable absorbent article comprising: a chassis having opposing front and rear waist portions, a crotch portion extending longitudinally between the front and rear waist portions, a body facing surface configured to face a wearer during use of the article, and an outer surface configured to face away from a wearer during use of the article; two nonwoven front-ear members each having a first end, a second end, and a width extending between the first and second ends, each of the front-ear members having at least one fastener region on an outward-facing side of the front-ear member, each fastener region comprising a plurality of hook fasteners that are unitary with the nonwoven front-ear panel; two closure members each having a first end, a second end, and a width extending between the first and second ends, each of the closure members having an elasticized portion and a nonwoven panel with at least one fastener region on a body facing side of the nonwoven panel, each fastener region comprising a plurality of hook fasteners; where the first end of each closure member is bonded to the rear waist portion of the chassis, and the second end of each closure member is configured to overlap and be releasably coupled to the front waist portion to define a closed configuration in which: the front and rear waist portions cooperate with the closure members to encircle and define a waist opening, a left side of the chassis defines a first leg opening, and a right side of the chassis defines a second leg opening; and where the first end of each front-ear member is bonded to the front waist portion of the chassis, and the second end of each closure member is configured to be overlapped by and be releasably coupled to a body-facing side of a corresponding one of the closure members when the closure members are coupled to the front waist portion.

19. The article of claim 18, where each fastener region comprises a plurality of distinct sub-regions of the hook fasteners.

20. The article of claim 18, where the elasticized portion of each of the closure members is defined by an elastic panel having a first end defining the first end of the closure member, a second end, and a width extending between the first and second ends, and the nonwoven panel of each of the closure members defines a fastener tab having a first end bonded to the elastic panel, and a second end defining a second end of the closure member such that the width of the closure member extends from the first end of the elastic panel to the second end of the fastener tab.

21. The article of claim 18, where the nonwoven panel of each of the closure members includes the respective elasticized portion.

22. The article of claim 21, where the nonwoven panel of each of the closure members includes a plurality of the fastener regions spaced along a portion of the width of the closure member.

23. The article of claim 22, where the fastener regions of each of the closure members are closer to the second end of the closure member than to the first end of the closure member.

24. The article of claim 18, where a landing portion of the outer surface on the front waist portion of the chassis is configured to be releasable engaged by the fastener portions of the closure members.

25. The article of claim 24, where the portion of the outer surface is defined by an anchoring member bonded to a backsheet of the chassis.

26. The article of claim 25, where the anchoring member comprises a loop fastener material.

27. The article of any of claims 18-26, where at least a portion of the fastener regions are spaced inward from a peripheral edge of the respective closure member.

28. The article of any of claims 18-27, where the hook fasteners of each of the nonwoven front-ear members are unitary with the nonwoven front-ear member.

29. The article of any of claims 18-15, where the front waist portion, rear waist portion, and crotch portion are defined by corresponding regions of a common chassis member.

30. The article of any of claims 18-15, where the chassis comprises a topsheet, a backsheet bonded to the topsheet, and an absorbent core disposed between the topsheet and the backsheet.

31. A method of making a disposable absorbent article, the method comprising: disposing a nonwoven polymer web between a sonotrode and a proximal surface of a tool such that a first side of the web contacts the proximal surface of the tool, the tool defining a plurality of cavities, each of the cavities extending from a base at the proximal surface to a distal end within the tool to define a negative mold of a hook fastener; delivering ultrasonic energy from the sonotrode to the web such that a temperature of the first side of the web increases above the polymer's glass transition temperature; compressing the web between the sonotrode and the tool such that polymer of the web flows into the cavities until the polymer substantially fills the cavities to form a plurality of hook fasteners on the first side of the web that are unitary with the web, the plurality of hook fasteners disposed in at least one fastener region; and cutting the web in at least one direction laterally across the or between the fastener region(s) to define a fastener member having a first end, a second end, and a fastener region between the first and second ends; and coupling the first end of the fastener member to a front or rear waist portion of a chassis of a disposable absorbent article; where the disposing, delivering, compressing, cutting, and coupling are performed on the same manufacturing floor.

32. The method of claim 31, where each fastener region comprises a plurality of distinct sub-regions of the hook fasteners.

33. The method of claim 31, where the disposing, delivering, compressing, cutting, and coupling are performed on the same manufacturing line.

34. The method of claim 31, where the fastener region of the fastener member is closer to the second end of the fastener member than to the first end of the fastener member.

35. The method of claim 31, where the web is not elasticized.

36. The method of claim 35, where coupling comprises bonding the first end of the fastener member to a second end of an elastic panel, and bonding a second end of the elastic panel to the front waist portion.

37. The method of claim 31, where the web has a width and a length that is at least five times longer than the width, the longitudinal axis of each of the fastener region(s) is parallel to the length.

38. The method of claim 37, where the fastener region(s) extends along a majority of the length of the web.

39. The method of any of claims 37-38, where first and second portions of the web are elasticized, the first elasticized portion is on a first lateral side of the fastener region(s), the second elasticized portion is on a second lateral side of the fastener region(s), and the cutting is performed such that a portion of the first elasticized portion is disposed between the first end of the fastener member and the fastener region.

40. The method of claim 39, where coupling comprises bonding a first end of the fastener portion to a rear waist portion of a chassis of a disposable absorbent article.

41. The method of any of claims 31, 38, and 39, where the fastener region(s) comprise: at least one medial fastener region; at least one first lateral fastener region on a first lateral side of the medial fastener region(s); and at least one second lateral fastener region on a second lateral side of the medial fastener region(s).

42. The method of claim 41, where: the at least one medial fastener region comprises a plurality of medial fastener regions; the at least one first lateral fastener region comprises a plurality of first lateral fastener regions; and the at least one second lateral fastener region comprises a plurality of second lateral fastener regions.

43. The method of claim 42, where each of the first lateral fastener regions is elongated, each of the second lateral fastener regions is elongated, and cutting the web comprises cutting sequentially: laterally inward from a first lateral edge of the web; laterally inward between a first one and second one of the first lateral fastener regions; around a first one of the medial fastener regions; and laterally outward between the second one and a third one of the first lateral fastener regions; and laterally outward to the first lateral edge of the web to separate the fastener member from the web.

44. The method of claim 43, where the fastener member is a first fastener member, and cutting the web comprises cutting sequentially: laterally inward from a second lateral edge of the web; laterally inward between a first one and second one of the second lateral fastener regions; around a second one of the medial fastener regions; and laterally outward between the second one and a third one of the second lateral fastener regions; and laterally outward to the second lateral edge of the web to separate a second fastener member from the web.

45. The method of claim 44, where the cutting is performed such that there is no wasted web between the first and second fastener members.

46. The method of any of claims 41-43, where coupling comprises bonding a first end of the fastener portion to a rear waist portion of a chassis of a disposable absorbent article.

47. A disposable absorbent pad or liner for a garment, the pad or liner comprising: a chassis having a front portion, a rear portion, and a crotch portion between the front and rear portions, the chassis including a liquid-permeable topsheet having a body-facing side configured to face a wearer when the article is in use, a liquid-impermeable backsheet having an outer side configured to face away from the wearer when the article is in use, and an absorbent core disposed between the topsheet and the backsheet; where the backsheet comprises an outermost layer with at least one fastener region on the outer side of the chassis, each fastener region comprising a plurality of hook fasteners that are unitary with the outermost layer.

48. The pad or liner of claim 47, where each fastener region comprises a plurality of distinct sub-regions of the hook fasteners.

49. The pad or liner of claim 47, where the fastener region(s) span a majority of a surface area of the outer side of the chassis.

50. The pad or liner of any of claims 47-49, where the fastener region(s) comprise a plurality of fastener regions.

51. The pad or liner of claim 47, where the chassis includes at least one pair of lateral wing panels each including an additional fastener region.

52. The pad or liner of claim 51, where the at least one pair of lateral wing panels includes a pair of lateral wing panels extending outward from opposing lateral sides of the crotch portion of the chassis.

53. The pad or liner of claim 52, where the fastener regions of each lateral wing panel is spaced inward from a peripheral edge of the respective lateral wing panel.

54. The pad or liner of any of claims 47-53, where the outermost layer of the backsheet comprises a nonwoven.

55. A method of making a disposable absorbent pad or liner for a garment, the method comprising: disposing a nonwoven polymer web between a sonotrode and a proximal surface of a tool such that a first side of the web contacts the proximal surface of the tool, the tool defining a plurality of cavities, each of the cavities extending from a base at the proximal surface to a distal end within the tool to define a negative mold of a hook fastener; delivering ultrasonic energy from the sonotrode to the web such that a temperature of the first side of the web increases above the polymer's glass transition temperature; compressing the web between the sonotrode and the tool such that polymer of the web flows into the cavities until the polymer substantially fills the cavities to form a plurality of hook fasteners on the first side of the web that are unitary with the web, the plurality of hook fasteners disposed in at least one fastener region; and cutting the web across the or between the fastener region(s) to separate a portion of the web that includes at least a portion of at least one of the fastener region(s); and bonding the web portion to a liquid-permeable topsheet, with an absorbent core disposed between the web portion and the liquid-permeable topsheet, to define the article such that the web portion forms a backsheet of the article.

56. The method of claim 55, where the disposing, delivering, compressing, cutting, and bonding are performed on the same manufacturing floor.

57. The method of claim 55, where the disposing, delivering, compressing, cutting, and bonding are performed on the same manufacturing line.

58. The method of claim 55, where the web portion includes a front portion, a rear portion, and a crotch portion between the front and rear portions.

59. The method of any of claims 55 and 58, where the fastener region(s) span a majority of a surface area of the outer side of the web portion.

60. The method of any of claims 55-59, where the fastener region(s) comprise a plurality of fastener regions.

61. The method of claim 60, where the article includes at least one pair of lateral wing panels each including an additional fastener region.

62. The method of claim 61, where the at least one pair of lateral wing panels includes a pair of lateral wing panels extending outward from opposing lateral sides of the crotch portion of the article.

63. The method of claim 62, where the fastener regions of each lateral wing panel is spaced inward from a peripheral edge of the respective lateral wing panel.

64. The method of claim 55, where each fastener region comprises a plurality of distinct sub-regions of the hook fasteners.

65. A disposable absorbent article comprising: a chassis having opposing front and rear waist portions, a crotch portion extending longitudinally between the front and rear waist portions, a body facing surface configured to face a wearer during use of the article, and an outer surface configured to face away from a wearer during use of the article; two rear closure members each having a first end, a second end, and a width extending between the first and second ends, and a height extending perpendicular to the width, each of the rear closure members comprising an elasticized portion and a nonwoven panel; two front closure members each having a first end, a second end, and a width extending between the first and second ends, and a height extending perpendicular to the width, each of the front closure members comprising an elasticized portion and a nonwoven panel; where the first end of each rear closure member is bonded to the rear waist portion of the chassis, the first end of each front closure member is bonded to the front waist portion of the chassis, and the second end of each rear closure member is configured to overlap and be releasably coupled to the second end of a corresponding one of the front closure members to define a closed configuration in which: the front and rear waist portions cooperate with front and rear the closure members to encircle and define a waist opening, a left side of the chassis defines a first leg opening, and a right side of the chassis defines a second leg opening; and where each of the front closure members and/or the rear closure members includes at least one fastener region on the respective nonwoven panel, each fastener region comprising a plurality of hook fasteners that are unitary with the nonwoven panel and configured to releasably couple the second end of each front closure member to the second end of the corresponding one of the front closure members.

66. The article of claim 65, where each of the fastener regions comprises a plurality of distinct sub-regions of the hook fasteners.

67. The article of claim 65, where the elasticized portion of each of the closure members is defined by an elastic panel having a first end defining the first end of the closure member, a second end, and a width extending between the first and second ends, and the nonwoven panel of each of the closure members has a first end bonded to the elastic panel, and a second end defining a second end of the closure member such that the width of the closure member extends from the first end of the elastic panel to the second end of the fastener tab.

68. The article of claim 65, where the nonwoven panel of each of the closure members includes the respective elasticized portion.

69. The article of claim 68, where the nonwoven panel of each of the closure members includes a plurality of the fastener regions spaced along a portion of the height of the closure member.

70. The article of claim 69, where the fastener regions of each of the respective closure members are closer to the second end of the closure member than to the first end of the closure member.

71. The article of any of claims 65-70, where at least a portion of the fastener regions are spaced inward from a peripheral edge of the respective closure member.

72. The article of any of claims 65-71, where the front waist portion, rear waist portion, and crotch portion are defined by corresponding regions of a common chassis member.

73. The article of any of claims 65-71, where the chassis comprises a topsheet, a backsheet bonded to the topsheet, and an absorbent core disposed between the topsheet and the backsheet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. Views in the figures are drawn to scale, unless otherwise noted, meaning the sizes of the depicted elements are accurate relative to each other for at least the embodiment in the view. Views described as conceptual are not necessarily drawn to scale.

[0040] FIG. 1 depicts a top plan view of a prior art disposable absorbent article, specifically a diaper, in an open configuration.

[0041] FIG. 2 depicts an exploded end view of the diaper of FIG. 1.

[0042] FIG. 3 depicts a plan view of an elasticized web of material illustrating a prior art method of manufacturing back ear closure members for the diaper of FIG. 1.

[0043] FIG. 4 depicts a plan view of a web of material illustrating a prior art method of manufacturing fastener members for the back ear closure members of FIG. 3.

[0044] FIGS. 5A-5C depict plan views of a back ear closure member manufactured by the methods of FIGS. 3 and 4 for the diaper of FIG. 1.

[0045] FIG. 6 depicts a conceptual side view of a prior art system for forming hook fasteners that are unitary with a web of material, such as a nonwoven.

[0046] FIG. 7 depicts a plan view of a web of material illustrating a first embodiment of a method of manufacturing fastener members that may be used in absorbent articles.

[0047] FIG. 8 depicts a top plan view of a first embodiment of the present disposable absorbent articles, specifically a diaper, in an open configuration.

[0048] FIG. 9 depicts an exploded end view of the diaper of FIG. 8.

[0049] FIG. 10 depicts a plan view of a web of material, half of which is shown in a stretched state in which the elasticized portion is stretched, illustrating a second embodiment of a method of manufacturing fastener members that may be used in absorbent articles.

[0050] FIG. 11 depicts a plan view of a web of material, both halves of which are shown in a non-stretched state, illustrating a third embodiment of a method of manufacturing fastener members that may be used in absorbent articles.

[0051] FIG. 12 depicts a plan view of a single fastener member made by the method of FIGS. 10 and 11.

[0052] FIGS. 13A-13B depicts plan views of the fastener member of FIG. 11 showing certain forces to which the fastener member may be subjected when included in an absorbent article.

[0053] FIG. 14 depicts a plan view of a first embodiment of the present front-ear members, with a region of unitary hook fasteners.

[0054] FIG. 15 depicts a plan view of a second embodiment of the present front-ear members, with two regions of unitary hook fasteners.

[0055] FIGS. 16A and 16B, respectively, depict open and closed configurations of the diaper of FIG. 8.

[0056] FIGS. 17A and 17B, respectively, depict side views of a prior art diaper and the diaper of FIG. 8 in closed configurations.

[0057] FIG. 18 depicts a top view of the diaper of FIG. 8 in a closed configuration.

[0058] FIG. 19 depicts a bottom view of a first embodiment of the present disposable absorbent sanitary pad or liner articles.

[0059] FIG. 20 depicts an exploded end view of the article of FIG. 19.

[0060] FIG. 21 depicts a bottom view of a second embodiment of the present disposable absorbent sanitary pad or liner articles.

[0061] FIG. 22 depicts an exploded end view of the article of FIG. 21.

[0062] FIG. 23 depicts an enlarged plan view of an additional embodiment of the present tape tabs for diapers and adult incontinence briefs.

[0063] FIG. 24 depicts an enlarged plan view of an additional embodiment of the present closure members for diapers and adult incontinence briefs.

[0064] FIG. 25 depicts a bottom plan view of a disposable absorbent article, specifically a training pant, in an open configuration.

[0065] FIG. 26 depicts a perspective view of the training pant of FIG. 25 in a closed configuration.

[0066] FIGS. 27A and 27B depict enlarged plan views of nonwoven connection portions for the training pant of FIGS. 25 and 26.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0067] In some embodiments of the present methods of making disposable absorbent articles, the method comprises: disposing a nonwoven polymer web between a sonotrode, for example sonotrode 158, and a proximal surface of a tool defining a plurality of negative molds of hook fasteners, for example proximal surface 162 of tool 166, such that a first side, for example 170, of the web contacts the proximal surface of the tool. Such methods further comprise delivering ultrasonic energy from the sonotrode to the web such that a temperature of the first side of the web increases above the polymer's glass transition temperature; and compressing the web between the sonotrode and the tool such that polymer of the web flows into the cavities until the polymer substantially fills the cavities to form a plurality of hook fasteners on the first side of the web that are unitary with the web.

[0068] By way of example, FIG. 7 depicts a plan view of a web of material illustrating one embodiment of a method of manufacturing fastener members, specifically tape tabs 62a, that may be used in absorbent articles. In this embodiment, rather than bonding a separate hook fastener material 110 to non-elasticized web 114, web 114 is disposed between a sonotrode and an appropriate tool, for example tool 166, and energy delivered and the web compressed as described above, to define a plurality of hook fasteners in two fastener regions 190 that extend the length of web 114 as shown. Tool 166, and specifically recesses 174 can be provided in a pattern corresponding to the desired pattern of fastener regions 190. For example, to form the embodiment shown in FIG. 7, tool 166 would include two substantially continuous rows of recesses 174 around the perimeter of tool 166.

[0069] Some embodiments of the present methods further comprise cutting the web in at least one direction laterally across the or between the fastener region(s) 110 to define one or more fastener members each having a first end 66, a second end 70, and a fastener region 74a that is closer to the second end than to the first end. For example, as shown in FIG. 7, once the hook fasteners are formed in fastener regions 110, web 114 can be cut in similar fashion to the prior art method described above; specifically, along lines 118laterally across fastener regions 110 and longitudinally between fastener regions 110to define a plurality of tape tabs 62a that can be used in place of tape tabs 62 described above. While fastener regions 190 are shown spanning the entire length of web 114, which length is typically much greater than the width of the web, other embodiments may include fastener regions 190 that span less than all but still a majority of the length of the web. For example, in some embodiments, distinct fastener regions 190 are applied to each longitudinal segment of web 114 that will form a separate tape tab 62a such that, after the web is cut, fastener region 74a of each tape tab 62a will be spaced apart from the respective edges of the tape tab.

[0070] Some embodiments of the present methods further comprise coupling the first end of the fastener member to a front or rear waist portion of a chassis of a disposable absorbent article. For example, in the embodiment shown in FIG. 7, once tape tabs 62a are separated from web 114, first end 66 of each tape tab 62a can be bonded to second end 58 of a corresponding elastic panel 50, the first end (54) of which elastic panel 50 can then be bonded to rear waist portion 18 of a chassis 14.

[0071] In some embodiments of the present methods, the foregoing disposing, delivering, compressing, cutting, and coupling steps are performed on the same manufacturing floor and/or on the same manufacturing line. In particular, the formation of hook fasteners by the present methods permit the formation of the hook fasteners on the same manufacturing floor or even in the same manufacturing line on which the rest of the absorbent article is assembled. In contrast to prior art methods in which hook fastener materials are obtained from a supplier, or at least from a separate manufacturing facility or line, and bonded to tape tabs, the present methods permit the more-efficient option of on-site formation of hooks that are unitary with a web of material that would be included in the absorbent article anyway, thereby eliminating the need for the additional hook fastener material.

[0072] Referring now to FIGS. 8 and 9; FIG. FIG. 8 depicts a top plan view of a first embodiment 10a of the present disposable absorbent articles, specifically a diaper, in an open configuration; and FIG. 9 depicts an exploded end view of rear waist portion 18 of diaper 10a. Diaper 10a is substantially similar in many respects to diaper 10, and the differences in diaper 10a relative to diaper 10 will therefore be described here. Specifically, diaper 10a includes back ear closure members 38a that differ relative to back ear closure members 38 of diaper 10, and includes front ears 82a that differ relative to front ears 82 of diaper 10. In other embodiments, however, diaper 10 may include only the modified closure members 38a or only the modified front ears 82a.

[0073] As shown in FIG. 8, each closure members 38a has an elasticized portion 194 and a nonwoven panel 198 with at least one fastener region 202 on a body facing side 34 of the nonwoven panel. As used in this disclosure, the terms elasticized, stretch, and stretchable are used interchangeably to define a material or composite that can be elongated by at least 25% of its relaxed length, i.e., elongated to at least 1 times its relaxed length (an elongation of 25%), and that will recover upon release of the applied force at least 10% of its elongation. According to this definition, upon release of the applied force at 25% elongation, the material or composite must recover to at least about a 15% or less elongation. For example, a material or composite is deemed to be stretchable if a sample length of 100 centimeters can be elongated to a length of at least 125 centimeters, and upon release of the applied force recovers to a length of not more than about 115 centimeters. Many elastic or stretchable materials or composites can be elongated by more than 25% of their relaxed length, and many of these will recover to, or close to, their original relaxed length upon release of the applied force. These materials can include not only webs of elastic or stretchable films, such as cast or blown films, but also nonwoven fibrous elastic webs such as meltblown elastomeric fibrous nonwoven webs. Elastic, elasticized and elasticity mean that property of a material by virtue of which it tends to recover its original size and shape after removal of a force causing a deformation.

[0074] In some embodiments, such as the one shown, the nonwoven panel of each closure member 38a includes a plurality of the fastener regions spaced along a portion of the width, measured in direction 206, of the closure member. For example, in the depicted embodiment, each closure member 38a includes a first fastener region 202a and a second fastener region 202b disposed between first fastener region 202b and elasticized portion 194. In some configurations, such as the one shown, second fastener region 202b can have a greater height, measured in direction 210, than that of first fastener region 202a. Each fastener region 202 comprises a plurality of hook fasteners 186 that are unitary with nonwoven panel 198. As with closure members 38, fastener regions 202a and 202b of each closure member 38a are closer to a second end 70a of the closure member than they are to a first end 54a of the closure member. In the depicted embodiment, nonwoven panel 198 includes elasticized portion 194; for example, nonwoven panel 198 spans and defines the entirety of closure member 38a; specifically, a portion of nonwoven panel 198 is elasticized, for example with elastic strands and/or elastic film, to define elasticized portion 194. In some such embodiments, at least a portion of the fastener regions 202 are spaced inward from a peripheral edge of the respective closure member. For example, in the embodiment shown in FIG. 8, the entire perimeters of fastener regions 202a and 202b are spaced inward from a peripheral edge of the corresponding closure member. This spacing can, for example, result in closure members that are perceived by users as softer and more compliant because, for example, the edges of the closure member do not include and/or are not directly bordered by relatively rigid hook fasteners that may tickle, scratch, or otherwise irritate a user's skin.

[0075] As shown in FIG. 9, the inclusion of elasticized portion 194 and unitary hook fasteners 186 on nonwoven panel 198 of closure member 38 simplifies the construction of diaper 10a relative to that of diaper 10. Specifically, rather than three separate pieceselastic panel 50, tape tab 62, and fastener patch 74and the corresponding manufacturing steps needed to join those three pieces together and to chassis 14, closure members 38a be formed with fewer steps at the point of manufacturing diaper 10, resulting in a single nonwoven panel that includes both the elasticized portion and the hook fasteners. Further, unlike the prior art construction with a separate fastener patch bonded to a tape tab, the unitary hook fasteners are not subject to separation from the nonwoven panel.

[0076] Referring now to FIGS. 10 and 11; FIG. 10 depicts a plan view of a first web 122a of material, one half 214 of which is shown in a stretched state in which elasticized portion 194 is stretched; and FIG. 11 depicts a plan view of a second web 122b with both halves 214 and 218 in a non-stretched state. Webs 122a and 122b can each have a width, measured in direction 222, and a length, measured in direction 224, that is significantly longer than the width of the web. These webs can be provided with longitudinal elasticized regions 226 on either side of a longitudinal centerline of the web, and one or more fastener regions 230 having a plurality of hook fasteners that are unitary with the web. Elasticized regions 226 can be elasticized, via elastic strands and/or elastic film, before or after formation of the fastener region(s).

[0077] In the embodiments shown in FIGS. 10 and 11, the fastener regions include at least one medial fastener region; at least one first lateral fastener region on a first lateral side of the medial fastener region(s); and at least one second lateral fastener region on a second lateral side of the medial fastener region(s). For web 122a of FIG. 10, the at least one medial fastener region comprises a plurality of medial fastener regions 230a-1; the at least one first lateral fastener region comprises a plurality of first lateral fastener regions 230b-1; and the at least one second lateral fastener region comprises a plurality of second lateral fastener regions 230c-1. In contrast, for web 122b of FIG. 11, the at least one medial fastener region comprises a single medial fastener region 230a-2 spanning the entire length of the web; the at least one first lateral fastener region comprises a single first lateral fastener region 230b-2 spanning the entire length of the web; and the at least one second lateral fastener region comprises a single second lateral fastener regions 230c-2 spanning the entire length of the web.

[0078] The fastener region(s) of webs 122a and 122b can be formed by an embodiment the present methods. For example, some embodiments of the present methods suitable for forming fastener regions 230 comprise: disposing a nonwoven polymer web between a sonotrode, for example sonotrode 158, and a proximal surface of a tool defining a plurality of negative molds of hook fasteners, for example proximal surface 162 of tool 166, such that a first side, for example 170, of the web contacts the proximal surface of the tool. Such methods further comprise delivering ultrasonic energy from the sonotrode to the web such that a temperature of the first side of the web increases above the polymer's glass transition temperature; and compressing the web between the sonotrode and the tool such that polymer of the web flows into the cavities until the polymer substantially fills the cavities to form a plurality of hook fasteners on the first side of the web that are unitary with the web.

[0079] In the embodiment shown in FIGS. 10 and 11, rather than bonding a separate hook fastener material to web 122a, web 122a is disposed between a sonotrode and an appropriate tool, for example tool 166, and energy delivered and the web compressed as described above, to define a plurality of hook fasteners in three fastener regions 230a, 230b, 230c that extend the length of web 122a as shown. Tool 166, and specifically recesses 174 can be provided in a pattern corresponding to the desired pattern of fastener regions 190. For example, to form the fastener regions of web 122a shown in FIG. 10, tool 166 would include three periodically-interrupted rows of recesses 174 around the perimeter of tool 166, with the interruptions in the first row corresponding to the spaces between adjacent ones of first lateral fastener regions 230b-1, interruptions in the medial row corresponding to the spaces between adjacent ones of medial fastener regions 230a-1, and interruptions in the second lateral row corresponding to the spaces between adjacent ones of second lateral fastener regions 230c-1. In contrast, to form the fastener regions of web 122b shown in FIG. 11, tool 166 would include three substantially continuous rows of recesses 174 around the perimeter of tool 166, with the medial row being wider than the two lateral rows.

[0080] Some embodiments of the present methods further comprise cutting the web in at least one direction laterally across the or between the fastener region(s) 230 to define one or more fastener members each having a first end 54, a second end 70, and a plurality of fastener regions 74a. For example, each of lateral fastener regions 230b-1 and 230c-1 is elongated, and cutting web 122a comprises cutting along line 234 in the following sequential segments: laterally inward from a first lateral edge 238 of web 122a; laterally inward between a first one and second one of first lateral fastener regions 230b-1; around a first one of the medial fastener regions 230a-1; and laterally outward between the second one and a third one of first lateral fastener regions 230b-1; and laterally outward to first lateral edge 238 of web 122a to separate a first fastener member 38a-1 from the web. In some embodiments, cutting 122a further comprises cutting web 122a along line 242 in the following sequential segments: laterally inward from a second lateral 246 edge of the web; laterally inward between a first one and second one of second lateral fastener regions 230c-1; around a second one of medial fastener regions 230a-1; and laterally outward between the second one and a third one of second lateral fastener regions 230c-1; and laterally outward to second lateral edge 246 of web 122a to separate a second fastener member 38a-2 from the web. In this embodiment, in which portions of lines 234 and 242 are coincident, the cutting is such that there is no wasted web between first and second fastener members 38a-1 and 38a-2. The cutting pattern of web 122b shown in FIG. 11 is substantially similar, with the only different relative to that of web 122a being that fastener regions 230a-2, 230b-2, and 230c-2 are continuous along the length of web 122b such that the cutting extends across respective ones of the fastener regions to define closure members 38b-1, 38b-2, and so on, with slightly different fastener portions 202a and 202b that extend to the upper and lower edges of the respective nonwoven panel 198.

[0081] Some embodiments of the present methods further comprise coupling the first end of the fastener member to a front or rear waist portion of a chassis of a disposable absorbent article. For example, in the embodiment shown in FIGS. 10 and 11, once closure members 38a or 38b are separated from web 122a or 122b, respectively, first end 54a of each closure member can be bonded to rear waist portion 18 of a chassis 14.

[0082] In some embodiments of the present methods, the foregoing disposing, delivering, compressing, cutting, and bonding steps are performed on the same manufacturing floor and/or on the same manufacturing line. In particular, the formation of hook fasteners by the present methods permit the formation of the hook fasteners on the same manufacturing floor or even in the same manufacturing line on which the rest of the absorbent article is assembled. In contrast to prior art methods in which hook fastener materials are obtained from a supplier, or at least from a separate manufacturing facility or line, and bonded to tape tabs, the present methods permit the more-efficient option of on-site formation of hooks that are unitary with a web of material that would be included in the absorbent article anyway, thereby eliminating the need for the additional hook fastener material.

[0083] FIG. 12 depicts a closure member 38b cut from web 122b shown in FIG. 11. The shape of the perimeter of nonwoven panel 194 and closure member 38b is substantially similar to that of closure member 38a. Closure member 38b has a width 250 between first end 54a and second end 70a, and a height 254. The width and height are described with reference to the orientation of the closure member when in use, specifically, when the width of the closure member horizontally extending circumferentially around a portion of a user's waist. As shown, a portion of closure member 38b adjacent second end 70a, with a width 258, has a height 262 that is smaller than height 254 of the majority of closure member 38b. In this configuration, the transition between the larger height (254) and the smaller height (262) is disposed between first fastener portion 202a and second fastener portion 202b, such that first fastener portion 202a has the relatively smaller height and second fastener portion 202b has the relatively larger height to reduce torque imparted to first fastener portion 202a.

[0084] For example, as indicated by arrows 138 in FIG. 13A, the primary force to which closure member 38b is subjected during use is tension between first end 54a, at which the closure member is bonded to the rear waist portion, and second end 70a, at which the closure member is coupled to the front waist portion. However, as indicated by arrow 142 in FIG. 13B, closure member 38b may also be subject to torque around first fastener portion 202a. However, in contrast to the prior art design discussed above with reference to FIGS. 5A-5C, second fastener portion 202b also engages the front waist portion of the chassis to resists torque around first fastener portion 202a, and this purpose of resisting torque is furthered to an even greater degree by the larger height of second fastener portion 202b which allows second fastener portion to resist forces applied from any of a larger range of angles around first fastener portion. In this way, second fastener portion 202b results in more-even distribution of forces, relative to prior art closure member 38, at first end 54a, permitting the use of relatively smaller number of elastic strands 130, or elastic strands of smaller size or decitex, than may be required in the elastic panel (50) of the prior art closure member 38.

[0085] Referring now to FIGS. 14 and 15; FIG. 14 depicts a first embodiment 82a-1 of the present front-ear members with a region of unitary hook fasteners; and FIG. 15 depicts a second embodiment 82a-2 of the present front-ear members with two regions of unitary hook fasteners. Front-ear member 82a-1 includes a nonwoven panel 266 having a first end 86, a second end 90, and a fastener region 270 with a plurality of hook fasteners that are unitary with the nonwoven panel 266. Front-ear member 82a-1, and specifically fastener region 270, can be formed by methods similar to those described above for tape tabs 62a and closure members 38a and 38b. However, for front-ear member 82-1 the unitary hook fasteners are configured to engage the body facing side of the corresponding closure member 38, 38a, or 38b of the diaper, such that fastener region 270 is disposed on an outer side 30 of nonwoven panel 266. Front-ear member 82a-2 is substantially similar to front-ear member 82a-1, with two primary exceptions. First, the front-ear member 82a-2 includes a first fastener regions 270a and a second fastener region 270b disposed between first fastener region 270a and second end 90. Second, fastener regions 270a and 270b are spaced inwardly of the edges of nonwoven panel 266

[0086] Referring now to FIGS. 16A, 16B, 17A, 17B, and 18, various views of diaper 10a are shown to illustrate its closure for use and certain benefits relative to prior art diapers. Specifically, FIGS. 16A and 16B, respectively, depict open and closed configurations of diaper 10a. As indicated by arrow 274 in FIG. 16A, chassis 14 is folded to bring front waist portion 22 closer to the level of rear waist portion 18 and closure members 38a overlap and fastener portions 202a and 202b are releasably coupled to the front waist portion to define a closed configuration in which: the front and rear waist portions cooperate with the closure members to encircle and define a waist opening 278, a left side of the chassis defines a first leg opening 282, and a right side of the chassis defines a second leg opening 286. Additionally, FIGS. 17A and 17B, respectively, depict side views of a prior art diaper 10 and a variation of diaper 10a in closed configurations. As indicated by the relative positions of arrows 142 in the respective figures, the inclusion of front-ear member 82a-2, even in the absence of a second fastener region on closure member 38, resists torque on fastener region 202. Finally, FIG. 18 depicts a top view of diaper 10a in the closed configuration illustrating fastener regions 202 of closure members 38a releasably engaging the outer surface of the front waist portion, and fastener regions 270 of front-ear members 82a-1 releasably engaging the body facing surface of closure members 38a.

[0087] Some embodiments of the present disposable absorbent articles include disposable absorbent pads or liners for a garment with a backsheet having unitary hook fasteners on an outer surface of the backsheet. For example, FIGS. 19 and 20 depict one embodiment 300 of such a pad or liner. In this embodiment, pad 300 comprises: a chassis 304 having a front portion 308, a rear portion 312, and a crotch portion 316 between the front and rear portions. As shown in FIG. 20, chassis 304 including a liquid-permeable topsheet 320 having a body-facing side 324 configured to face a wearer when the article is in use, a liquid-impermeable backsheet 328 having an outer side 332 configured to face away from the wearer when the article is in use, and an absorbent core 336 disposed between the topsheet and the backsheet. Backsheet 328 comprises an outermost layer with at least one fastener region 340 on the outer side of the chassis, with each fastener region 340 comprising a plurality of hook fasteners 344 that are unitary with the outermost layer. Backsheet 328 can comprise one or more laminated layers. For example, when backsheet 328 comprises an inner film layer and an outer nonwoven layer, the unitary hook fasteners may be formed from both layers or only from the outer nonwoven layer, for example before the outer nonwoven layer is bonded to the inner film layer. In some embodiments, such as the one shown, pad 300 also includes an acquisition-distribution layer or ADL 348. As shown in FIG. 19, fastener region 340 spans a majority of a surface area of the outer side of the chassis, specifically the entire length of backsheet 328 between lateral boundaries 352. In this embodiment, pad 300 includes a plurality of fastener regions. Specifically, chassis 304 includes two pairs of optional lateral wing panels 356 with each lateral wing panel including an additional fastener region 340a with a plurality of unitary hook fasteners 344.

[0088] FIGS. 21 and 22 depict a second embodiment 300a of the present pads or liners. Pad 300 is substantially similar in many respects to diaper 10, and the differences in pad 300a relative to pad 300 will therefore be described here. Specifically, chassis 304a of pad 300a is simpler than that of pad 300 in that chassis 304a does not include lateral wing panels 356. Pad 300a also differs in that it includes a plurality of fastener regions 340, for example spaced along a length of the pad as shown.

[0089] In some embodiments of the present methods of making a pad or liner, the method comprises: disposing a nonwoven polymer web between a sonotrode, for example sonotrode 158, and a proximal surface of a tool defining a plurality of negative molds of hook fasteners, for example proximal surface 162 of tool 166, such that a first side, for example 170, of the web contacts the proximal surface of the tool. Such methods further comprise delivering ultrasonic energy from the sonotrode to the web such that a temperature of the first side of the web increases above the polymer's glass transition temperature; and compressing the web between the sonotrode and the tool such that polymer of the web flows into the cavities until the polymer substantially fills the cavities to form a plurality of hook fasteners on the first side of the web that are unitary with the web.

[0090] Some embodiments of the present methods further comprise cutting the web in at least one direction laterally across the or between the fastener region(s) to separate a portion of the web that includes at least a portion of at least one of the fastener region(s). For example, the web can be cut to form a backsheet having the shape shown in FIG. 19 or the shape shown in FIG. 21.

[0091] Some embodiments of the present methods further comprise bonding the separated web portion to a liquid-permeable topsheet 328, with an absorbent core 336 disposed between the separated web portion and the liquid-permeable topsheet, to define a pad, for example 300 or 300a, such that the web portion forms a backsheet of the article, for example backsheet 320.

[0092] In some embodiments of the present methods of forming a pad or liner, the foregoing disposing, delivering, compressing, cutting, and coupling steps are performed on the same manufacturing floor and/or on the same manufacturing line. In particular, the formation of hook fasteners by the present methods permit the formation of the hook fasteners on the same manufacturing floor or even in the same manufacturing line on which the rest of the absorbent article is assembled. In contrast to prior art methods in which hook fastener materials are obtained from a supplier, or at least from a separate manufacturing facility or line, and bonded to tape tabs, the present methods permit the more-efficient option of on-site formation of hooks that are unitary with a web of material that would be included in the absorbent article anyway, thereby eliminating the need for the additional hook fastener material. Additionally, for pads of the type shown in FIGS. 19 and 21, the fastener portions 340 would typically include adhesive and need to be covered by a release strip to prevent the adhesive from sticking to surfaces or collecting lint prior to use. Thus, the inclusion of unitary hook fasteners can simplify the construction of the pad or liner by eliminating the manufacturing steps or processes, and materials, associated with conventional adhesives and release strips.

[0093] FIG. 23 depicts an enlarged plan view of an additional embodiment 62b of the present tape tabs for diapers and adult incontinence briefs. Tape tab 62b is substantially similar to tape tab 62a, with the primary exception that the fastener region 190a includes a plurality of distinct sub-regions 190b. Specifically, in the embodiment shown, sub-regions 190b include elongated areas of unitary hook fasteners that extend at an angle relative to the width (horizontal in the depicted configuration) of the tape tab. In other embodiments, these elongated areas may be parallel or perpendicular to the width of the tape tab. In those of the present embodiments in which a fastener region includes a plurality of distinct sub-regions, the edge or boundaries of the sub-regions have an overall length that is greater than fastener region with a single perimeter, which increase in edge or boundary length can increase the tensile strength of the fastener region in use, and thereby the ability of the fastener region to reliably engage a material such a loop fasteners and/or to resist unintended separation.

[0094] FIG. 24 depicts an enlarged plan view of an additional embodiment 38c of the present closure members for diapers and adult incontinence briefs. Closure member 38c is substantially similar to closure members 38a and 38b, with the primary exception that closure member 38b includes a fastener region 202c that includes a plurality of distinct sub-regions 202d. Specifically, in the embodiment shown, sub-regions 202d include elongated, curved or corrugated areas of unitary hook fasteners that extend generally perpendicular to the width (horizontal in the depicted configuration) of the tape tab. In other embodiments, sub-regions 202d may be angled or parallel to the width of the closure member. Further, sub-regions 202d may in other configurations be shaped similarly to sub-regions 190b of tape tab 62b.

[0095] Referring now to FIGS. 25 and 26, shown is one example of an additional type of disposable absorbent article into which unitary hook fasteners can be incorporated. By way of reference, U.S. Pat. No. 9,398,986 discloses certain prior art examples of training pants, and U.S. Pat. Nos. 6,976,978 and 4,940,464 disclose certain prior art examples of disposable incontinence garments or training pants. In the present embodiment depicted in FIGS. 25 and 26, training pant 400 includes a chassis 404 having a front waist portion 408, an opposing rear waist portion 412, and a crotch portion 416 extending longitudinally between front and rear waist portions 408, 412. Chassis 404 further includes an outer surface 420 configured to face away from a wearer during use of the diaper, and an opposing body facing surface 424 configured to face a wearer during use of the diaper.

[0096] As shown in FIGS. 25-26, training pant 400 further includes a pair of front elastic side panels 428 and a pair of rear elastic side panels 432 configured to couple rear waist portion 412 to front waist portion 408 in a well-known configuration in which a left side 436 of the chassis defines a first leg opening 440 for a wearer's left leg, and in which a right side 444 of the chassis defines a second leg opening 448 for the wearer's right leg. In the depicted configuration, each of side panels 428, 432 includes a connection portion 452 configured to be coupled to a connection portion 452 of another of side panels 428, 432. Specifically, connection portion 452 of the left one of front side panels 428 is configure to be coupled to connection portion 452 of the left one of rear side panels 432, and connection portion 452 of the right one of front side panels 428 is configure to be coupled to connection portion 452 of the right one of rear side panels 432, such that the waist portions 408, 412 and side panels, 428, 432 cooperate to define a waist opening 456 as shown in FIG. 26. Connection portions 452 of the respective side panels are configured to be removably coupled together via the present unitary hook fasteners to define a refastenable or adjustable side seam.

[0097] FIGS. 27A and 27B depict enlarged plan views of nonwoven side panels 428, 432 with unitary connection portions 452 for training pants such as training pant 10 of FIGS. 25 and 26. In each of these embodiments, a portion of the nonwoven side panel is elasticized, such as with a film or elastic strands, and a portion of the nonwoven panel is subject to the present methods to define unitary hook fasteners. For example, in the embodiment shown in FIG. 27A, the connection portion comprises a fastener region 456a that extends a majority of a height of the panel, whereas in the embodiment of FIG. 27B, the connection portion comprises a fastener region 456b that includes a plurality of distinct sub-regions 456c of the unitary hook fasteners. Specifically, in the embodiment of FIG. 27B, sub-regions 456c include elongated areas of unitary hook fasteners that extend at an angle relative to the width (horizontal in the depicted configuration) of the tape tab. In other embodiments, these elongated areas may be parallel or perpendicular to the width of the tape tab, or may be curved or corrugated as with sub-regions 202c described above. Front side panels 428 and/or rear side panels 428for example only front side panels 428, only rear side panels 432, or both front and rear side panels 428, 432can include fastener regions 456a or 456b/456c. In those of the present embodiments in which a fastener region includes a plurality of distinct sub-regions, the edge or boundaries of the sub-regions have an overall length that is greater than fastener region with a single perimeter, which increase in edge or boundary length can increase the tensile strength of the fastener region in use, and thereby the ability of the fastener region to reliably engage a material such a loop fasteners and/or to resist unintended separation.

[0098] The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

[0099] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) means for or step for, respectively.