MULTI-PURPOSE DISPOSABLE UNDERWEAR

Abstract

Disposable articles, and, more particularly, a disposable undergarment including a product chassis configured to serve as a basis of a variety of disposable articles, including disposable underwear without an absorbent core, disposable underwear with an absorbent core designed for menstrual use, and disposable underwear or training pant with an absorbent core designed for incontinence use (adult and child). The product chassis is comprised of multiple sections including an elastomeric composite, containing stretch film, coupled to one another, each section is designed to provide stretch in a desired direction, thereby resulting in improved securement of the undergarment to a wearer for optimizing fit and comfort for the wearer, while reducing the risk of leakage as well as reducing the amount overall material required for producing the undergarment. Furthermore, the inclusion of an elastomeric composite can provide a smooth contoured fit to a wearer, thereby improving appearance and self-confidence for the wearer.

Claims

1. A method for making a disposable absorbent product, comprising steps of: providing a front section material in a machine direction (MD), said front section material comprising a front section elastomeric composite including an elastomeric material and configured to stretch in the machine direction upon application of a force thereto; providing a rear section material in the machine direction (MD), said rear section material comprising a rear section elastomeric composite including an elastomeric material and configured to stretch in the machine direction upon application of a force thereto; providing a crotch section material in the machine direction (MD), between the front section material and the rear section material, said crotch section material comprising a crotch section elastomeric composite including an elastomeric material and configured to stretch in a cross direction (CD) substantially transverse to the machine direction upon application of a force thereto; coupling the front and rear section materials to the crotch section material to form a product chassis; cutting leg openings extending at least in the crotch section material; providing an insert assembly having an absorbent core and attaching said insert assembly to at least a portion of the crotch section material, wherein the insert assembly is positioned such that longitudinal sides of the insert assembly are disposed inwardly from the leg openings; folding a portion of the front section material and folding a portion of the rear section material to obtain folded outer edges that form folded waist edges of the product chassis, wherein the insert assembly is positioned such that transversal sides of the insert assembly are disposed inwardly from the folded outer edges; folding the product chassis to align side edges of the front section with longitudinal side edges of the rear section; ultrasonically bonding the aligned front and rear sections to form a pair of side seams; and cutting the product chassis to obtain a plurality of individual disposable absorbent products having a waist opening defined by the folded waist edges.

2. The method of claim 1, further comprising providing waist elastic strands, wherein the step of folding the portion of the front section material and folding the portion of the rear section material, comprises folding said portions over the waist elastic strands, such that the waist elastic strands are disposed within the folded waist edges.

3. The method of claim 2, wherein the waist elastic strands extend continuously along the folded waist edges and through the side seams, and wherein said elastic strands are applied by unwinding the elastic strands, stretching the elastic strands and adhering the stretched elastic strands to the front and rear section materials.

4. The method of claim 1, wherein the step of cutting the leg openings is performed before the step of providing the insert assembly.

5. The method of claim 1, wherein the step of coupling the front and rear section materials to the crotch section material to form the product chassis is performed by ultrasonic bonding.

6. The method of claim 1, wherein the crotch section elastomeric composite is provided as a prefabricated composite designed to stretch in the cross direction (CD) and not stretch in the machine direction (MD).

7. The method of claim 1, wherein the front section elastomeric composite and the rear section elastomeric composite each have a central elastic film layer arranged between a first and second nonwoven substrate layers, which layers are ultrasonically bonded together to form the respective composite material.

8. The method of claim 7, wherein the first and/or the second nonwoven layer comprise spunbond polypropylene (SBPP) or spunbond meltblown spunbond (SMS).

9. The method of claim 7, wherein at least one of the first and second nonwoven substrate layers comprises a spunbond nonwoven material and the other of the first and second substrate layers comprises a through-air bonded carded nonwoven material.

10. The method of claim 1, wherein the insert assembly further comprises stand-up leg gathers, wherein said stand-up leg gathers comprise hydrophobic spunbond meltblown spunbond material.

11. A disposable absorbent garment, comprising a product chassis comprising: a front section comprising a front section elastomeric composite including an elastomeric material and configured to stretch in a first direction, the front section configured to be fitted against a front portion of a wearer's body; a rear section comprising a rear section elastomeric composite including an elastomeric material and configured to stretch in the first direction, the rear section configured to be fitted against a rear portion of the wearer's body; and a crotch section coupled between the front and rear sections, the crotch section comprising an elastomeric composite including an elastomeric material and configured to stretch in a second direction substantially transverse to the first direction; and an insert assembly comprising at least an absorbent core, the insert assembly positioned within at least a portion of the crotch section; wherein the front section and the rear section are coupled together along opposing side edges to form a pair of ultrasonically bonded side seams and a waist opening; wherein the product chassis defines a pair of leg openings extending at least through the crotch section; wherein outer edges of the front section and the rear section are folded forming folded waist edges; wherein longitudinal sides of the insert assembly are disposed inwardly from the leg openings; and wherein transversal sides of the insert assembly are disposed inwardly from the folded waist edges.

12. A disposable absorbent garment comprising a product chassis comprising: a front section comprising a front section elastomeric composite including an elastomeric material and configured to stretch in a first direction, the front section configured to be fitted against a front portion of a wearer's body; a rear section comprising a rear section elastomeric composite including an elastomeric material and configured to stretch in the first direction, the rear section configured to be fitted against a rear portion of the wearer's body; and a crotch section coupled between the front and rear sections, the crotch section comprising an elastomeric composite including an elastomeric material and configured to stretch in a second direction substantially transverse to the first direction; and an insert assembly comprising at least an absorbent core, the insert assembly positioned within at least a portion of the crotch section; the front section and the rear section are coupled together along opposing side edges to form a pair of ultrasonically bonded side seams and a waist opening; the product chassis defines a pair of leg openings extending at least through the crotch section; wherein outer edges of the front section and the rear section are folded forming folded waist edges, and wherein the folded waist edges include waist elastic strands disposed therein.

13. The disposable garment of claim 12, wherein the waist elastic strands extend continuously within the folded waist edges and through the ultrasonically bonded side seams.

14. The disposable garment of claim 11, wherein the first direction is a machine direction and the second direction is a cross direction.

15. The disposable garment of claim 11, wherein the leg openings are free of separately attached elastic strands, and wherein elastic tension around the leg openings is provided by the elastomeric composites of the front section, the rear section, and the crotch section.

16. The disposable garment of claim 14, wherein the elastomeric composite of the crotch section is a prefabricated composite, and wherein said prefabricated composite stretches in the cross direction only.

17. The disposable garment of claim 11, wherein each elastomeric composite comprises a first substrate layer and a second substrate layer, each comprising a nonwoven material, and a third layer comprising an elastomeric film positioned between the first and second substrate layers.

18. The disposable garment of claim 17, wherein the first and second substrate layers of at least one of the elastomeric composites are sealed to one another via an ultrasonically bonded seal.

19. The disposable garment of claim 17, wherein at least one of the first and second substrate layers comprises a spunbond nonwoven material and the other of the first and second substrate layers comprises a through-air bonded carded nonwoven material.

20. The disposable garment of claim 11, wherein the insert assembly further comprises an acquisition layer disposed between the absorbent core and a first substrate layer, and a pair of stand-up leg gathers, wherein said stand-up leg gathers comprise hydrophobic spunbond meltblown spunbond material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Features and advantages of the claimed subject matter will be apparent from the following detailed description of embodiments consistent therewith, which description should be considered with reference to the accompanying drawings.

[0014] FIG. 1 is a top plan view of one embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear in an unfolded and unsealed state.

[0015] FIG. 2 is a top plan view of the disposable underwear of FIG. 1, illustrating what would constitute typical or normal material waste along leg cut-out sections (via conventional underwear design construction).

[0016] FIG. 3 is a top plan view of the disposable underwear of FIG. 1, illustrating reduced material waste along leg cut-out sections.

[0017] FIG. 4 is a top plan view of another embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear including an absorbent core and insert provided within at least the crotch section, as well as a stand-up leg gather. The disposable underwear may be useful as a disposable incontinence product.

[0018] FIG. 5 is a front view of another embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear in a folded and sealed state and having an anatomically-shaped design.

[0019] FIG. 6 is a top plan view of the disposable underwear of FIG. 5 in an unfolded and unsealed state, illustrating reduced material waste along leg cut-out sections.

[0020] FIG. 7 is a top plan view of the disposable underwear of FIG. 5 in an unfolded and unsealed state, illustrating what would constitute typical or normal material waste along leg cut-out sections (via conventional underwear design construction).

[0021] FIG. 8 is a top plan view of another embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear in an unfolded and unsealed state and having a boxer short shape.

[0022] FIGS. 9 and 10 are schematic representations of a method for manufacturing a disposable underwear in accordance with the present disclosure.

[0023] For a thorough understanding of the present disclosure, reference should be made to the following detailed description, including the appended claims, in connection with the above-described drawings. Although the present disclosure is described in connection with exemplary embodiments, the disclosure is not intended to be limited to the specific forms set forth herein. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient.

DETAILED DESCRIPTION

[0024] The present disclosure relates generally to disposable articles, and, more particularly, to a disposable undergarment including a stretchable product chassis configured to serve as a basis for a variety of disposable articles, including, but not limited to, disposable underwear without an absorbent core, disposable underwear with an absorbent core designed for menstrual use, and disposable underwear or training pant with an absorbent core designed for incontinence use (adult and child). The product chassis is comprised of multiple sections coupled to one another. For example, in one embodiment, a product chassis may generally include three main sections, which includes a front section, a rear section, and a crotch section. Each section of the product chassis generally includes at least two substrate layers containing an elastomeric material disposed there between. In some embodiments, an absorbent core may be disposed between the two substrate layers. However, in other embodiments, an absorbent core can be applied on top of the two substrate layers.

[0025] The elastomeric material and the two substrate layers form elastomeric composites for each given section of the product chassis (i.e., the front, rear, and crotch sections). Each of the sections May be strategically constructed so as to stretch in a specific direction to help maximize the fit on the wearer from a minimum to a maximum range, thereby accommodating the varying shapes and sizes from wearer to wearer. For example, in one embodiment, the front section, which is generally designed to be fitted against the front, or anterior portion, of a wearer, and the rear section, which is generally designed to be fitted against the rear, or posterior portion, of the wearer, may both be constructed so as to stretch in a machine direction (MD), while the crotch section, which is designed to be fitted against the crotch region of the wearer, may be constructed so as to stretch in a cross direction (CD).

[0026] By providing different stretching characteristics for each given section, the product chassis provides a superior fitting undergarment with improved comfort, as well as reducing the risk of leakage and, in some cases, provides a much more economical disposable underwear design. For example, because the undergarment lies flat against a wearer's body in at least the three main areas (front section, rear section, and crotch section), the undergarment is about to provide a smooth contoured fit to the body, such that any gaps caused by overlapping materials are reduced or eliminated. By reducing or eliminating gaps between the garment and the body, the undergarment of the present disclosure provides improved leak resistance over prior art constructions.

[0027] Additionally, the elastomeric composite provides consistent pressure and smooth contact against the leg and waist during wear when it is stretched, such that improved performance against leakage is obtained.

[0028] The smooth interface of the undergarment with the body provides improved comfort for the wearer and reduces the risk of skin irritation, particularly around the crotch and waist areas of the consumer, which are some of the most sensitive areas of the body. More specifically, the elastomeric composite design of the present disclosure eliminates the need for individual elastic strands (under high tension) and stiff materials (nonwoven & adhesive) along the leg openings, which are commonly found in current disposable underwear designs. In addition, the elastomeric composite design of the present disclosure allows for a wearer to participate in physical activities that may otherwise cause irritation, such as active motion of the wearer during walking or running exercises, which generally increases the rubbing action of material against the skin. The softer material and lower tension elastic provided by the undergarment of the present disclosure reduces the risk of skin irritation long the leg and crotch area of the consumer.

[0029] The use of at least three separately constructed sections (i.e., the front, rear, and crotch section, which are then coupled to one another to form the final undergarment product (via ultrasonic bonding or the like) minimizes waste of what could otherwise be an expensive elastomeric material. In particular, less material is necessarily required to be removed during the manufacturing process, as compared to the amount of material required to be removed if the undergarment was made entirely from single sheets of elastomeric composites.

[0030] FIG. 1 is a top plan view of one embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear in an unfolded and unsealed state. As shown, the disposable underwear generally includes a stretchable product chassis configured to serve as a basis for a variety of disposable articles, including, but not limited to, disposable underwear without an absorbent core, disposable underwear with an absorbent core designed for menstrual use, and disposable underwear or training pant with an absorbent core designed for incontinence use (adult and child).

[0031] The product chassis is comprised of multiple sections coupled to one another. For example, as shown, the product chassis generally includes three main sections: a front section (section 1): a rear section (section 3); and a crotch section (section 2). The front section is generally designed to be fitted against the front, or anterior portion, of a wearer and the rear section is generally designed to be fitted against the rear, or posterior portion, of the wearer, such that front and rear sections generally oppose one another once fitted to the wearer. The crotch section is positioned between the front and rear sections and coupled to each. In some embodiments, the crotch section may include an insert, such as an absorbent core including a liquid-absorbing material (see FIG. 4). However, in other embodiments, including the embodiment currently shown, the product chassis may be devoid of any absorbent core. Rather, an absorbent core can be added after initial construction of the product chassis. For example, commercially available incontinence pads and pantyliners can be attached along the top sheet.

[0032] Each of the front section, rear section, and crotch section are stretchable for providing improved securement of the underwear to a wearer for reducing the risk of leakage and further improving comfort for the wearer, as well as a more smooth contoured fit to a wearer, thereby improving appearance and self-confidence for the wearer.

[0033] For example, each section of the product chassis generally includes at least two substrate layers containing an elastomeric material disposed there between. In some embodiments, an absorbent core may be disposed between the two substrate layers. However, in other embodiments, an absorbent core can be applied on top of the two substrate layers.

[0034] The first substrate may be referred to as a top sheet and is generally configured to contact the wearer's skin and allow fluid from the wearer to flow through it, at least in a direction away from the wearer's skin. In some embodiments, the top sheet may include at least one of a nonwoven material, a hydrophilic or partially hydrophilic material, a nonwoven material with a zone-coated surfactant, and a nonwoven and apertured film. One material that can be used for the top sheet is an SBPP (Spunbond Polypropylene) hydrophilic nonwoven, commercially available from Berry Global, located in Charlotte, NC. The second substrate may be referred to as a back sheet and may generally serve as the outermost layer of the product chassis of the underwear. The back sheet is generally formed from a nonwoven material, to provide a more undergarment-like appearance and feel, and as well as a more cost-effective and comfortable alternative to conventional disposable undergarment designs. The fibers in the nonwoven may include, for example, polypropylene, polyethylene, polyester, bi-component (polypropylene & polyethylene or polyester & polyethylene), cotton, cotton blend, viscose, rayon, etc. or a combination of different fibers. The nonwoven web may include, but is not limited to, Spunbond Polypropylene (SBPP), Spunbond-Meltblown-Spunbond (SMS), Thermal-bonded Carded Web, Spunlace, Laminate, or combinations thereof.

[0035] The inclusion of an elastomeric material, which comprises a stretch film bonded between two layers of hydrophobic nonwoven materials, in the construction of the sections of the product chassis results in improved securement of the article to a wearer for reducing the risk of leakage and further improving comfort for the wearer. In particular, each section may be designed to stretch in a desired direction, thereby resulting in improved securement of the undergarment to a wearer for optimizing fit and comfort for the wearer, while reducing the risk of leakage as well as reducing the amount overall material required for producing the undergarment. Furthermore, the inclusion of an elastomeric material can provide a smooth contoured fit to a wearer, thereby improving appearance and self-confidence for the wearer.

[0036] In one embodiment, the elastomeric material is a stretch film that is unwound in the machine direction (MD) along an absorbent article assembly line. Machine direction (MD), longitudinal and the like as used herein are used interchangeably and refer to a direction running parallel to the maximum linear dimension of the structure and includes directions within 45 of the longitudinal direction.

[0037] The stretchable film can impart a stretchable characteristic to an assembly, for example, after the film is stretched and bonded between two layers of hydrophobic nonwoven materials (under tension), allowing the nonwoven layers to retract after the product is relaxed (no tension). In an example, a stretchable film can be used in place of elastic strands and can be applied to augment an extension or contraction characteristic of another stretchable material such as clastic strands or stretchable adhesive. Generally, the elastomeric composite is configured to stretch in the direction in which the stretchable film was applied to form the elastomeric composite. Thus, if the stretchable was applied in a machine direction, then the elastomeric composite will stretch in the machine direction. More specifically, in this embodiment, the elastomeric composite (used for the front and rear sections of the product chassis) will be assembled on the manufacturing machine and stretch in the machine direction. The elastomeric composite used for the crotch (central) sections of the product chassis will be prefabricated, prior to placing on the manufacturing machine. The elastic composite, that will be assembled on the machine, will comprise of three materials. Two of the materials will be a hydrophobic nonwoven, preferably SBPP (Spundbond Polypropylene) or SMS (Spunbond-Meltblown-Spunbond). However, the hydrophobic nonwoven can also be a Through-Air Carded Web or Spunlace. Note that these two nonwoven materials may or may not be similar in basis weights. In addition, they can be different nonwoven types. For example, one may be SBPP and the other SMS. Or one may be SMS and the other Through-Air Carded Web. However, it is desired that the majority of the fibers in the nonwoven material can fuse together during ultrasonic bonding. These nonwoven materials are commercially available from Berry Global located in Charlotte, NC. The last material will be an elastic film, which is commercially available from 3M Corporation located in Minneapolis, MN.

[0038] The elastomeric material and the two substrate layers form elastomeric composites for each given section of the product chassis (i.e., the front, rear, and crotch sections). Each of the sections may be strategically constructed so as to stretch in a specific direction to help maximize the fit on the wearer from a minimum to a maximum range, thereby accommodating the varying shapes and sizes from wearer to wearer.

[0039] For example, in one embodiment, the front section and the rear section are both constructed so as to stretch in a machine direction (MD), while the crotch section is constructed so as to stretch in a cross direction (CD). Cross direction (CD), lateral or transverse and the like as used herein are used interchangeably and refer to a direction which is orthogonal to the longitudinal direction and includes directions within 45 of the transversal direction. The product can be folded (e.g., in half) and ultrasonically bonded at the side edges to provide a disposable pull-up undergarment. By providing different stretching characteristics for each given section, the product chassis provides a superior fitting undergarment with improved comfort, as well as reducing the risk of leakage and, in some cases, provides a much more economical disposable underwear design. For example, because the undergarment lies flat against a wearer's body in at least the three main areas (front section, rear section, and crotch section), the undergarment is about to provide a smooth contoured fit to the body, such that any gaps caused by overlapping materials are reduced or eliminated. By reducing or eliminating gaps between the garment and the body, the undergarment of the present disclosure provides improved leak resistance over prior art constructions.

[0040] Additionally, the elastomeric composite provides consistent pressure and smooth contact against the leg and waist during wear when it is stretched, such that improved performance against leakage is obtained.

[0041] The smooth interface of the undergarment with the body provides improved comfort for the wearer and reduces the risk of skin irritation, particularly around the crotch and waist areas of the consumer, which are some of the most sensitive areas of the body. More specifically, the elastomeric composite design of the present disclosure eliminates the need for individual elastic strands (under high tension) and stiff materials (nonwoven & adhesive) along the leg openings, which are commonly found in current disposable underwear designs. In addition, the elastomeric composite design of the present disclosure allows for a wearer to participate in physical activities that may otherwise cause irritation, such as active motion of the wearer during walking or running exercises, which generally increases the rubbing action of material against the skin. The softer material and lower tension elastic provided by the undergarment of the present disclosure reduces the risk of skin irritation long the leg and crotch area of the consumer.

[0042] Furthermore, by providing different stretching characteristics for each given section, material elasticity and gasketing is increased, especially around the circumference of the leg openings, where leakage is more likely. Improvement in elasticity is due to both the type of elastomeric materials used and the way they are strategically positioned within the product. The front and back chassis of the product are designed to stretch in the machine direction (MD), which elongate in the cross-section (horizontally) along the waist, hip and thighs. The crotch section of the product is designed to stretch in the cross direction (CD), which elongate in the longitudinal direction (vertically) along the legs and crotch area. The combination of these three separate elastomeric composite sections and the manner in which they are orientated in the product, maximizes the amount of total elastic elongation. This theory has been verified in product stretch testing, as illustrated in Table 1 below:

TABLE-US-00001 TABLE 1 Product Stretch Testing Maximum Leg Product Size Circumference Difference Prototype 1 L/XL 1038 millimeters Prototype 2 L/XL 1092 millimeters +54 millimeters Prototype 1 S/M 964 millimeters Prototype 2 S/M 1038 millimeters +74 millimeters

[0043] Testing of two prototypes was performed. Prototype 1 is an elastic composite F (with MD stretch) used in the front, back and crotch sections, while Prototype 2 is an elastic composite F (with MD stretch) in the front and rear sections and elastic composite H (with CD stretch) in the crotch section, which is consistent with the disposable underwear product chassis of the present disclosure.

[0044] For testing of both prototypes, the minimum leg circumference was the same for similar product sizes. As shown in the table above, the elastic elongation (expansion) increased by simply replacing the elastic composite F (with MD stretch) with an elastic composite H (with CD stretch) for the crotch section. The increase was over two inches for L/XL size and nearly three inches for S/M size, using the same product dimensions.

[0045] Thus, the construction of the disposable underwear product chassis of the present disclosure allows for a decrease of the minimum dimension of leg circumference, while still being able to meet the original maximum dimension of leg circumference. By decreasing the minimum dimension of leg circumference, the overall elastic tension is increased and the possibility of open gaps is reduced. This improvement in gasketing, along the leg openings, will help reduce the possibility of leakage and provide increased sense of security to the consumer. Consumer use testing has revealed that tighter leg openings in the product, with no gaps, will make most consumers feel more confident that the product will provide superior absorbency performance and will not leak.

[0046] If the elastic tension will increase along the leg openings, one may think that it will increase red marking and irritation to the skin. However, in this new product concept, that will not be the case. The elastomeric composite materials (with both MD and CD Stretch), used along the leg openings, are constructed of soft elastic film and nonwovens. The flat elastic film spreads out the force (elastic tension) along a larger surface area, which is much different than elastic strands, which direct the force (elastic tension) to a single point that is much smaller in surface area. This can cause red marking and irritation to the skin, if the elastic tension is too tight. If the elastic tension is too loose, the product will leak. Thus, the right balance of elastic tension and spreading out the forces along a larger surface area is required to achieve both a comfortable and anti-leak gasket at the leg area.

[0047] The use of at least three separately constructed sections (i.e., the front, rear, and crotch section, which are then coupled to one another to form the final undergarment product (via ultrasonic bonding or the like) minimizes the amount of waste of what could otherwise be an expensive elastomeric material. In particular, less material is necessarily required to be removed during the manufacturing process, as compared to the amount of material required to be removed if the undergarment was made entirely from single sheets of elastomeric composites. FIG. 2 is a top plan view of the disposable underwear of FIG. 1, illustrating what would constitute typical or normal material waste along leg cut-out sections (via conventional underwear design construction). FIG. 3 is a top plan view of the disposable underwear of FIG. 1, illustrating reduced material waste along leg cut-out sections. FIG. 5 is a front view of another embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear in a folded and sealed state and having an anatomically-shaped design. FIG. 6 is a top plan view of the disposable underwear of FIG. 5 in an unfolded and unsealed state, illustrating reduced material waste along leg cut-out sections. FIG. 7 is a top plan view of the disposable underwear of FIG. 5 in an unfolded and unsealed state, illustrating what would constitute typical or normal material waste along leg cut-out sections (via conventional underwear design construction). FIG. 8 is a top plan view of another embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear in an unfolded and unsealed state and having a boxer short shape.

[0048] As previously described, the disposable underwear consistent with the present disclosure may also contain an absorbent core for collecting bodily fluids or even excrement. For example, the disposable underwear may be used for menstrual and/or incontinence use. This would be more convenient for the consumer overall.

[0049] FIG. 4 is a top plan view of another embodiment of disposable underwear consistent with the present disclosure, illustrating the underwear including an absorbent core and insert provided within at least the crotch section, as well as a stand-up leg gather (SULP). The disposable underwear may be useful as a disposable incontinence product.

[0050] The absorbent core may generally include an absorbent material, a nonabsorbent material, and a combination thereof. For example, the absorbent core may include one or more of: pulp only. core: pulp & SAP core: pulp & SAP & tissue core: pulp & SAP nonwoven core, airlaid composite core: airlaid composite core with cotton fibers: rayon viscose core: rayon viscose & pulp core: rayon viscose & SAP core: rayon viscose & pulp & SAP core: rayon viscose & pulp & SAP & tissue core: tissue core: tissue & SAP core: creped tissue or paper towel core: creped tissue with SAP core: pulp & curly fiber core: pulp & curly fiber & SAP core; SAP and nonwoven composite core (Pulpless); and pulp & curly fiber & SAP & tissue core.

[0051] The absorbent core may be comprised of multiple layers or structures. For example, as shown, the absorbent core may include at least three absorbent core structures. Optionally, more than three core structures can be used. Optionally, one or more core structures can be used, and the one or more core structures can have a variable thickness, or can have non-homogeneously-distributed constituent parts. For example, a unitary but non-homogenous core structure can have a portion that comprises fluff without SAP and another portion that comprises fluff with SAP, and optionally another portion that comprises fluff with a different proportion of SAP relative to fluff. The multicore design of the absorbent core is discussed in co-pending international application titled Multi-Core Absorbent Article, having application no. PCT/US2016/012710, and filed Jan. 8, 2016, the content of which is incorporated by reference herein in its entirety.

[0052] In the case of an absorbent core for menstruation, it would mainly comprise of Pulp fibers to absorb blood and other high viscosity fluids & solids. One absorbent material that would be suitable is Golden Isles fluff pulp (Grades 4865 or 4875), which have exceptional absorbency rate, anti-bacterial properties and are capable of capturing & neutralizing malodors. They are available from Georgia Pacific located in Atlanta, GA. The pulp board would be ground into fluff fibers, formed in vacuum pockets and enwrapped between a soft Top Sheet made of SBPP (Spunbond Polypropylene) Nonwoven (hydrophilic) and a soft Back Sheet made of Poly Film (fluid-impervious/hydrophobic). The Poly Film may also be microporous and breathable, if so desired. One Top Sheet Nonwoven material that would be suitable is 12 gsm SBPP from Berry Global located in Charlotte, NC. One Poly Film material that would be suitable is 0.55 mil PE/PP (Polyethylene/Polypropylene) Blend Film available from Berry Global located in Chippewa Falls, WI. Construction Adhesive will be used to hold the absorbent core system together. One Construction Adhesive that would be suitable is F-5603 olefin available from H.B. Fuller Company located in Vadnais Heights, MN.

[0053] In addition to being comprised of Pulp, the absorbent cores may also contain a small amount of SAP (Super Absorbent Polymer). This has a dual purpose. It will provide extra absorbent capacity and allow the product to be used as a combo Menstrual & Incontinence Pad. One SAP material that would be suitable is Favor Max 2010 available from Evonik Industries located in Greensboro, NC.

[0054] The absorbent core may also comprise of an Airlaid material, instead of Pulp fibers & SAP particles blended & formed in a vacuum pocket, as described earlier. Airlaids contain Pulp & Binder fibers, which gives it improved integrity when wet & under stress. One Airlaid material that would be suitable is Airlaid VH-145.101 (145 gsm) or VH-160.116 (160 gsm), which do not contain Superabsorbent Polymer (SAP). However, Airlaid materials may contain some SAP, in addition to Pulp & Binder fibers for dual use products (menstrual & incontinence care). Another Airlaid material that would be suitable would be VH-180.135 (180 gsm), which contains SAP. They are all available from Glatfelter Falkenhagen GmbH located in Pritzwalk, Germany.

[0055] The shape of the absorbent core may be symmetrical or asymmetrical, rectangular, hourglass, dog bone, etc. Usually, hourglass shaped cores are desired, since they are more anatomically correct. However, wrapped absorbent cores (Pulp/SAP) or Airlaids are usually rectangular in shape, to reduce material waste. Although they may be shaped as well for improved fit.

[0056] The absorbent core may be single layer, dual layer or even multiple layers depending on the use. Products used for overnight or require higher absorbent capacities, may use a dual core system, while products used for day or require lower absorbent capacities, may use a single core system. The single core system is usually thinner and lighter in weight.

[0057] SULG (Stand-Up Leg Gathers) or Cuffs may also be added to the product, if additional leakage performance is needed. They are mostly used in Incontinence care products, however they can be used for Feminine care products as well. The height of the SULG or Cuffs is usually higher in Incontinence care products vs. Feminine care products.

[0058] In the case of an absorbent core for incontinence, it would mainly comprise of a mixture of Pulp fibers and SAP (Super Absorbent Polymer) particles (blended together) to absorb high quantities of urine. Usually, the percentage of SAP vs. pulp is higher for incontinence care products versus menstrual care products due to the fact that SAP absorbs approximately four to five times the amount of pulp, in a gram (absorbent weight) per gram (fluid absorbed) basis.

[0059] As mentioned before, the absorbent core may be a single layer or have multiple layers depending on the absorbent capacity needed. For instance, overnight incontinence products may comprise of two or more layers, while daytime incontinence products may comprise of a single layer. If more than one absorbent layer is used, the core shape and size may be different as well. The Top Core may be mostly rectangular shaped (with round ends), while the Bottom Core may be hourglass shaped.

[0060] Also mentioned before, is the fact that the absorbent core may also comprise of an Airlaid material. In addition, the material may be a combination of Airlaid and ADL (Acquisition Distribution Layer) made of high-loft Nonwoven. One material combination that would be suitable is a Hybrid Airlaid VH-270.203 (270 gsm) available from Glatfelter Falkenhagen GmbH located in Pritzwalk, Germany. When using this material combination, it eliminates the need for an additional cut & place unit on the machine. Most machines already have a cut & place unit, along with an unwind station, to apply ADL (Acquisition Distribution Layer) on top of the absorbent core.

[0061] One preferred embodiment of the absorbent core would comprise of a combined Airlaid and ADL material that is cut & placed on top of Pulp/SAP single core. This would provide a dual absorbent core system with ADL. The combined Airlaid and ADL material would be cut shorter in length and be narrower in width vs. Pulp/SAP single core. It would also be less likely to rope, bunch & crack, thus providing improved integrity when wet and under stress.

[0062] As mentioned before, SULG or Cuffs can be added to the new product to improve leakage performance. The SULG or Cuff will comprise of hydrophobic SMS (Spunbond/Meltblown/Spunbond) Nonwoven available from Berry Global located in Charlotte, NC. The basis weight would be around 13.5 gsm.

[0063] FIGS. 9 and 10 are schematic representations of a method for manufacturing a disposable underwear in accordance with the present disclosure. It should be noted that FIGS. 9 and 10 do not illustrate the manner in which the front and rear sections the Front and Rear sections of the product chassis are constructed and bonded on the machine. It is explained below, along with the rest of the manufacturing process. The steps for manufacturing a disposable underwear product chassis consistent with the present disclosure are as follows:

[0064] 1. A soft nonwoven is unwound and slit in half on the machine. One nonwoven material that would be suitable is SMS (Spunbond/Meltblown/Spunbond) with Super CD Rod embossing pattern available from Fitesa located in Simpsonville, SC. One half of the material would be used on the outside of the Front Chassis and the other half on the outside of the Back Chassis.

[0065] 2. Another nonwoven is unwound and slit in half on the machine. One nonwoven material that would be suitable is SMS (Spunbond/Meltblown/Spunbond) available from Berry Global located in Charlotte, NC. One half of the material would be used on the inside of the Front Chassis and the other half on the inside of the Back Chassis.

[0066] 3. An elastic film would be unwound and slit in half on the machine. One elastic film that would be suitable is from 3M Corporation located in Minneapolis, MN. One half of the elastic material would be stretched, placed and aligned in between the nonwoven of #1 and #2 above and used in the Front Chassis. The other half of the elastic material would be stretched, placed and aligned in between the nonwoven of #1 and #2 above and used in the Back Chassis. The elongation of stretch would be around 200%-450% in the MD (Machine Direction).

[0067] 4. The three plies of material (mentioned in #1, #2 and #3 above) would be ultrasonically bonded to each other and separated at specific dimension, creating an open gap.

[0068] 5. An elastic composite would be unwound and positioned within the open gap mentioned in #4 above, with a slight overlap on the Front and Rear sections of the product chassis. This material is unwound in the MD (Machine Direction) on the machine and stretches in the CD (Cross Direction). One elastic composite that would be suitable would be Hexaflex 15 available from Golden Phoenix Fiberwebs, Inc. located in Taipei, Taiwan.

[0069] 6. The elastic composite (mentioned in #5 above) would be ultrasonically bonded to the Front and Rear sections of the product chassis.

[0070] 7. The leg openings of the product chassis would be cutout with a rotary die cutter and the scrap removed & discarded.

[0071] 8. Elastic strands would be unwound, stretched and adhered to the Front and Back edges of the product chassis. Then a portion of the Front and Back edges of the product chassis would be folded over the elastic strands. The folded material can be permanently bonded to the product chassis using a heat seal. One suitable elastic strand material would be 800 Decitex from Hyosung Corporation located in Seoul, South Korea.

[0072] 9. The open product would be folded in half (creating the Front and Back portions) and ultrasonically sealed at the Left & Right sides of the chassis, to create an enclosed pull-up product.

[0073] 10. The product would be cut as the final stage to create individual disposable underwear pieces ready to be folded, stacked and enwrapped in a package.

[0074] By providing different stretching characteristics for each given section, the product chassis provides a superior fitting undergarment with improved comfort, as well as reducing the risk of leakage and, in some cases, provides a much more economical disposable underwear design. For example, because the undergarment lies flat against a wearer's body in at least the three main areas (front section, rear section, and crotch section), the undergarment is about to provide a smooth contoured fit to the body, such that any gaps caused by overlapping materials are reduced or eliminated. By reducing or eliminating gaps between the garment and the body, the undergarment of the present disclosure provides improved leak resistance over prior art constructions. Additionally, the elastomeric composite provides consistent pressure and smooth contact against the leg and waist during wear when it is stretched, such that improved performance against leakage is obtained.

[0075] The smooth interface of the undergarment with the body provides improved comfort for the wearer and reduces the risk of skin irritation, particularly around the crotch and waist areas of the consumer, which are some of the most sensitive areas of the body. More specifically, the elastomeric composite design of the present disclosure eliminates the need for individual elastic strands (under high tension) and stiff materials (nonwoven & adhesive) along the leg openings, which are commonly found in current disposable underwear designs. In addition, the elastomeric composite design of the present disclosure allows for a wearer to participate in physical activities that may otherwise cause irritation, such as active motion of the wearer during walking or running exercises, which generally increases the rubbing action of material against the skin. The softer material and lower tension elastic provided by the undergarment of the present disclosure reduces the risk of skin irritation long the leg and crotch area of the consumer.

[0076] The use of at least three separately constructed sections (i.e., the front, rear, and crotch section, which are then coupled to one another to form the final undergarment product (via ultrasonic bonding or the like) minimizes waste of what could otherwise be an expensive elastomeric material. In particular, less material is necessarily required to be removed during the manufacturing process, as compared to the amount of material required to be removed if the undergarment was made entirely from single sheets of elastomeric composites.

[0077] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0078] The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described (or portions thereof), and it is recognized that various modifications are possible within the scope of the claims. Accordingly, the claims are intended to cover all such equivalents.

INCORPORATION BY REFERENCE

[0079] References and citations to other documents, such as patents, patent applications, patent publications, journals, books, papers, web contents, have been made throughout this disclosure. All such documents are hereby incorporated herein by reference in their entirety for all purposes.

EQUIVALENTS

[0080] Various modifications of the invention and many further embodiments thereof, in addition to those shown and described herein, will become apparent to those skilled in the art from the full contents of this document, including references to the scientific and patent literature cited herein. The subject matter herein contains important information, exemplification and guidance that can be adapted to the practice of this invention in its various embodiments and equivalents thereof