EP-4736825-A2 - MULTI-PURPOSE DISPOSABLE UNDERWEAR

EP4736825A2EP 4736825 A2EP4736825 A2EP 4736825A2EP-4736825-A2

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.

Inventors

GLAUG, FRANK
BORRERO, Ricardo
ANDERSEN, KARL

Assignees

Drylock Technologies NV

Dates

Publication Date: 20260506
Application Date: 20190508

Claims (15)

A method for making a disposable absorbent product comprising the 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; and 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; cutting leg openings extending at least in the crotch section material; providing the crotch section material with an insert assembly such that it is positioned within at least a portion of the crotch section, the insert assembly comprising at least an absorbent core including a liquid-absorbing material; unwinding elastic strands, stretching and adhering said elastic strands to front and back edges of the product chassis, folding a portion of the front and back edges of the product chassis over the elastic strands; folding the rear section material on the front section material or folding the front section material on the rear section material, wherein the folding is performed downstream of the coupling, and upstream or downstream of the cutting, as seen in the machine direction; coupling side edges of the front section of each obtained product chassis to side edges of the rear section thereof, in order to form a garment; cutting the front and rear section materials in order to obtain a plurality of product chassis, each comprising a front section of front section material, a rear section of rear section material and a crotch section of crotch section material.
The method of claim 1, wherein the folding is performed downstream of the coupling of the front and rear section materials to the crotch section material, and upstream or downstream of the cutting, as seen in the machine direction.
The method of claim 1 or 2, wherein the coupling is done by ultrasonic bonding.
The method of any one of the previous claims, wherein the cutting of leg openings is done before the step of cutting of the front and rear section materials.
The method of any one of the previous claims, wherein the front section and/or rear section and/or crotch section elastomeric composite comprises at least a first substrate layer and a second substrate layer, each of which comprises a nonwoven material, and a third layer comprising an elastomeric material positioned between the first and second substrate layers.
The method of claim 5, wherein the third layer is comprising an elastomeric film positioned between the first and second substrate layers; wherein each of the first and second substrate layers comprises more than one material; 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.
A disposable garment comprising: a product chassis comprising: a front section comprising an elastomeric composite including an elastomeric material and configured to stretch in a first direction upon application of a force thereto, the front section configured to be fitted against a front, or anterior, portion of a wearer's body; a rear section comprising an elastomeric composite including an elastomeric material and configured to stretch in the first direction upon application of a force thereto, the rear section configured to be fitted against a rear, or superior, 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 upon application of a force thereto, the crotch section configured to be fitted against a crotch region of the wearer's body; further comprising an insert assembly positioned within at least a portion of the crotch section, the insert comprising at least an absorbent core including a liquid-absorbing material; wherein unwound, stretched elastic strands are adhered to front and back edges of the product chassis, wherein a portion of the front and back edges of the product chassis are folded over the elastic strands.
The disposable garment of claim 7, wherein the first direction is a machine direction and the second direction is a cross direction.
The disposable garment of claim 7 or 8, wherein the elastic strands extend continuously within the folded waist edges and through the ultrasonically bonded side seams.
The disposable garment of any one of the previous claims 7 - 9, wherein the elastomeric composite is prefabricated.
The disposable garment of any one of the previous claims 7 - 10, the garment having leg openings, wherein no individual elastic strands are disposed along the leg openings.
The disposable garment of any one of the previous claims 7 - 11, wherein the elastomeric composite comprises at least a first substrate layer and a second substrate layer, each of which comprises a nonwoven material; wherein the elastomeric composite comprises a third layer comprising an elastomeric film positioned between the first and second substrate layers.
The disposable garment claim 12, wherein each of the first and second substrate layers comprises more than one material, 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
The disposable garment claim of any one of the previous claims 7 - 13; wherein the insert assembly further comprises an acquisition layer disposed between the absorbent core and a first substrate layer; and wherein the insert assembly further comprises of a polymer film barrier disposed between the absorbent core and a second substrate layer.
The disposable garment of any one of the previous claims 7 - 14; wherein the garment is ultrasonically bonded at side edges.

Description

Cross-Reference to Related Applications This application is a provisional application, priority to which may be claimed in a later-filed U.S. Non-Provisional application and/or a foreign application. Field 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. Background There are several types of commercially available products for the absorption of bodily fluids. Such absorbent products are available in different types, designs, and dimensions, each one having one or more unique features. For example, training pants, baby diapers, adult diapers, and incontinence guards are products designed for the containment of urine and excrement. There are other types of disposable absorbent articles, such as feminine hygiene products (e.g., heavy and light incontinence pads, pantyliners, etc.) that are designed to contain and absorb urine and/or menses by female wearers. Another type of absorbent article includes underpads configured to absorb and collect body fluid discharge from a person who may be generally confined to a bed or chair, or may otherwise be immobilized. Current absorbent products in the form of underwear, training pants, or diapers, generally suffer from poor design. For example, in order to hold the product close to the wearer's body so that it does not fall down, elastic strands or other features are usually provided around leg openings and/or waist openings of the absorbent product. However, this type of construction often leads to discomfort to the wearer from the rubbing of the overlapping components and/or seams holding the components together. Additionally, the elastic elements around the leg and waist openings used to hold the garment against the wearer often contribute to leakage. The leakage is due to the gapping between the article and the wearer's body caused by the elastic gatherings, the gapping providing an inconsistent seal. Furthermore, many current absorbent underwear products contribute to a bulky appearance when worn. Accordingly, improperly-fit absorbent garments can lead to a number of different issues for the wearer of the garment. For example, an improperly-fit garment can be uncomfortable, can adversely affect the wearer's mobility (actual or perceived), and there can be an increased chance of leakage. This in undesirable to a wearer and can be cause for embarrassment and shame. Thus, there exists a need to minimize leakage at the openings and providing a smooth contoured fit to the body of the wearer. Summary The present disclosure relates generally to disposable article. More specifically, the present disclosures relates to a disposable undergarment that 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). 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 one or two substrate layers. However, in other embodiments, an absorbent core can be applied on top of the two substrate layers. The inclusion of an elastomeric material, such as a stretch adhesive, 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. In one embodiment, the elastomeric material is a stretch film that can be unwound in the machine direction (MD) along an absorbent article assembly line. 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 i