EP0274753A2 — Disposable absorbent garment

Claim 1

Independent Claim 166 words

An anatomically form-fitting, generally self-adjusting disposable absorbent garment (10) comprising: a breathable elastomeric nonwoven outer cover (12), including a pair of leg openings (18), front (13) and rear (14) waist sections together defining a waist opening, a crotch section (16) situated between said leg openings (18) and opposed front (28) and rear (30) panels separated by said crotch section (16); an absorbent insert structure (32) having opposed longitudinal ends and substantially superposable on said front (28) and rear (30) panels and said crotch section (16), including a liquid impermeable barrier (36) and a liquid permeable bodyside liner (34) with an absorbent composite (38) disposed therebetween; attachment means (74, 76, 62) for attaching and integrating said longitudinal ends (64, 66) of said insert (32) to said outer cover (12), at selected front (68) and rear (70) waist attachment zones, defining one or more free-span zones (72) underlying said insert (32) wherein the functional stretchability of said outer cover (12) in said free-span zone (72) is substantially unrestricted.

Claim 2

Dependent Claim 166 words

An anatomically form-fitting, generally self-adjusting disposable absorbent garment (10) comprising: a breathable elastomeric nonwoven outer cover (12), including a pair of leg openings (18), front (13) and rear (14) waist sections together defining a waist opening, a crotch section (16) situated between said leg openings (18) and opposed front (28) and rear (30) panels separated by said crotch section (16); an absorbent insert structure (32) having opposed longitudinal ends and substantially superposable on said front (28) and rear (30) panels and said crotch section (16), including a liquid impermeable barrier (36) and a liquid permeable bodyside liner (34) with an absorbent composite (38) disposed therebetween; attachment means (74, 76, 62) for attaching and integrating said longitudinal ends (64, 66) of said insert (32) to said outer cover (12), at selected front (68) and rear (70) waist attachment zones, defining one or more free-span zones (72) underlying said insert (32) wherein the functional stretchability of said outer cover (12) in said free-span zone (72) is substantially unrestricted.

Claim 3

Dependent Claim 21 words

The garment of claim 1, wherein said free-span zone (72) is in either of said front (28) and rear (30) panels.

Claim 4

Dependent Claim 20 words

The garment of claim 1 or 2 wherein said outer cover (12) is resiliently stretchable in an essentially cross-body direction.

Claim 5

Dependent Claim 22 words

The garment of claim 3 wherein said outer cover is stretchable more than about 20%, preferably from about 20% to about 200%.

Claim 6

Dependent Claim 51 words

The garment of one of the preceding claims further comprising a waist attachment flap (74, 76) extending from at least one of said opposed longitudinal ends (64, 66) of said insert (32) and attached to an associated one of said waist sections (13, 14) at said waist attachment zone (68, 70).

Claim 7

Dependent Claim 42 words

The garment of claim 5 wherein said front (13) and rear (14) waist sections have hems (78) and further comprising front (74) and rear (76) waist attachment flaps entrapped and attached within said hems (78) at said waist attachment zones (68, 70).

Claim 8

Dependent Claim 23 words

The garment of claim 6 wherein said waist hems (78) comprise inwardly folded-over edges of outermost portions of said waist sections (13, 14).

Claim 9

Dependent Claim 82 words

The garment of one of the preceding claims further comprising one or more pairs of side attachment flaps (86) extending laterally from opposed marginal sides of said absorbent composite (32) and attached to either of said front and rear panels (28, 30), said side attachment flaps (86) deflecting laterally when said outer cover (12) is stretched in said essentially cross-body direction, thereby functionally maintaining said free-span zone (72 ) while supporting said insert (32) in registration with the body of a wearer.

Claim 10

Dependent Claim 21 words

The garment of claim 8 wherein a pair of said side attachment flaps (86) are attached to said rear panel (30).

Claim 11

Dependent Claim 23 words

The garment of claims 8 or 9 wherein a pair of said side attachment flaps (86) are attached to said front panel (28).

Claim 12

Dependent Claim 38 words

The garment of one of the preceding claims wherein said liner (34) and barrier (36) are attached to one another (80) substantially about their entire peripheries with said absorbent composite (38) disposed therebetween, preventing leakage of fluid therefrom.

Claim 13

Dependent Claim 30 words

The garment of claim 5 or 8 wherein either of said waist (79, 76) and side attachment flaps (86) comprise extensions of either of said barrier (36) and liner (34).

Claim 14

Dependent Claim 49 words

The garment of claim 5 wherein at least one of said waist attachment flaps (74, 76) includes expansion means in said waist attachment zone (68, 70) for allowing cross-body expansion of said waist flap (74, 76) when said outer cover (12) is stretched in said essentially cross-body direction (59).

Claim 15

Dependent Claim 17 words

The garment of claim 13 wherein said expansion means comprises one or more longitudinally extending expansible pleats.

Claim 16

Dependent Claim 22 words

The garment of claim 13 wherein said expansion means comprises a plurality of longitudinally extending slits (88) expansible in said cross-body direction.

Claim 17

Dependent Claim 15 words

The garment of claim 13 wherein said expansion means comprises a plurality of notches (90).

Claim 18

Dependent Claim 43 words

The garment of claim 15 or 16 wherein said expansion means are retracted inwardly together and bonded to said outer cover in said inwardly retracted position, allowing further expansion thereof when said outer cover is stretched in said cross-body direction. (Fig. 14, 15).

Claim 19

Dependent Claim 38 words

The garment of one of the preceding claims further comprising a pair of crotch flaps (92) extending laterally from opposed marginal sides of an intermediate portion of said absorbent composite (32) and attached to said crotch section (16).

Claim 20

Dependent Claim 23 words

The garment of claim 18 wherein said crotch flaps (92) are attached along said leg openings (18) in selected crotch attachment zones (94).

Claim 21

Dependent Claim 19 words

The invention of claim 19 wherein said crotch flaps (92) have longitudinally extending crotch elastic members (96) situated thereon.

Claim 22

Dependent Claim 38 words

The invention of claim 20 wherein said crotch elastic members (96) are spaced outwardly from said intermediate portion of said composite (32) a distance of at least 1.91 cm (0.75 inches), defining an elasticized contractible crotch flap (92).

Claim 23

Dependent Claim 24 words

The garment of one of claims 18 to 21 wherein said crotch flaps (92) comprise outward extensions of either of said liner and barrier.

Claim 24

Dependent Claim 17 words

The garment of one of the preceding claims wherein said leg openings (18) have leg hems (98).

Claim 25

Dependent Claim 25 words

The garment of claim 23 wherein said crotch flaps (92) are entrapped within said leg hems (98) and bonded at said crotch attachment zones (94).

Claim 26

Dependent Claim 35 words

The garment of one of the preceding claims further comprising leg elastic members (102) extending along outermost portions of said leg openings (18) for gathering said leg openings (18) about the body of a wearer.

Claim 27

Dependent Claim 18 words

The garment of claim 25 wherein said leg elastic members (102) are contained within said leg hems (98).

Claim 28

Dependent Claim 37 words

The garment of one of the preceding claims further comprising waist elastic members (104) extending along either of said front (13) and rear (14) waist sections for gathering said waist opening about the body of a wearer.

Claim 29

Dependent Claim 41 words

The garment of one of the preceding claims wherein said barrier (36) surrounds the bottom and sides of said absorbent composite (32) with said liner 834) extending across and contacting a top surface thereof, defining a generally rectangular, boat-shaped insert configuration.

Claim 30

Dependent Claim 40 words

The garment of one of the preceding claims wherein said barrier (36) closely conforms to the sides of said absorbent composite (32) and has one or more relaxed localized areas therein adjacent said bottom to accommodate swelling thereof during use.

Claim 31

Dependent Claim 35 words

The garment of one of the preceding claims wherein said liner (34) and barrier (36) are secured together in an undulatory pattern extending substantially about at least said intermediate portion of said absorbent composite (32).

Claim 32

Dependent Claim 20 words

The garment of claim 30 wherein said undulatory pattern extends essentially continuously about the periphery of said absorbent composite (32).

Claim 33

Dependent Claim 22 words

The garment of one of claims 18 to 31 wherein said crotch attachment zone (94) comprises at least one bond point (100).

Claim 34

Dependent Claim 23 words

The garment of one of claims 5 to 32 wherein said waist attachment zone (68, 70) comprises at least one bond point (62).

Claim 35

Dependent Claim 40 words

The garment of one of claims 25 to 33 wherein said leg elastic members (102) are applied to said outer lo cover (12) in a relatively tensioned condition to gather said leg openings (18) about the legs of a wearer.

Claim 36

Dependent Claim 35 words

The garment of one of claims 26 to 33 wherein said leg elastic members (102) are tensioned relative to said outer cover (12) to gather said leg openings (18) about the legs of a wearer.

Claim 37

Dependent Claim 41 words

The garment of one of the preceding claims wherein said absorbent insert structure (32) is attached at either of said waist (68, 70) and crotch (94) attachment zones while said outer cover (12) is stretched in an essentially cross-body direction (59).

Claim 38

Dependent Claim 26 words

The garment of one of the preceding claims wherein the longitudinal length of said free-span zone (72) is at least about 6.35 cm (about 2.5 inches).

Claim 39

Dependent Claim 28 words

The garment of one of claims 18 to 37 wherein said crotch attachment zone (94) comprises a linear distance of less than about 10.16 cm (about 4 inches).

Claim 40

Dependent Claim 35 words

The garment of claim 38 wherein said crotch attachment zone (94) comprises at least three discrete bonds (100) at spaced apart locations within a total linear distance less than about 8.89 cm (about 3.5 inches).

Claim 41

Dependent Claim 37 words

The garment of claim 33 wherein said waist attachment zone (68, 70) comprises at least three discrete bonds (62) at spaced apart locations within a total linear distance of less than about 2.54 cm (about 1.0 inch).

Claim 42

Dependent Claim 41 words

The garment of claims 27 to 40 wherein a waist elastic member (104) is disposed within each of said waist hems (78) in an operatively tensioned condition relative to said outer cover (12) to gather said waist opening about a wearer.

Claim 43

Dependent Claim 36 words

The garment of claim 27 to 41 wherein the distance between the outermost edges of said waist elastic member (104) and said absorbent composite (32) is at least 1.91 cm (0.75 inches) at any given point.

Claim 44

Dependent Claim 41 words

The garment of one of the preceding claims wherein said absorbent structure (32) includes a pair of tensioned longitudinally extending crotch elastic members (96) for causing said absorbent structure (32) to conform to the area between the thighs of a wearer.

Claim 45

Dependent Claim 22 words

The garment of claim 43 wherein said crotch elastic members (96) are attached to said liner (34) or to said barrier (36).

Claim 46

Dependent Claim 37 words

The garment of claim 44 wherein said crotch elastic members (96) are spaced at least 1.91 cm (0.75 inches) from opposed marginal sides of said intermediate portion of said absorbent composite (32) overlying said crotch section (16).

Claim 47

Dependent Claim 34 words

The garment of one of the preceding claims wherein said attachment means (74, 76, 62) comprise autogenous bonds generated thermally or ultrasonically or by adhesive bonds or manually fastenable closures which preferably are refastenable.

Claim 48

Dependent Claim 26 words

The garment of one of the preceding claims wherein the outer cover (12) comprises an elastic nonwoven web joined to one or more gatherable nonwoven webs.

Claim 49

Dependent Claim 151 words

In a disposable absorbent garment, a method of integrating an absorbent insert structure into an outer cover, said method comprising the steps of: (a) providing a resiliently stretchable outer cover having opposed waist sections, a central crotch section and front and rear panels between said crotch and said waist sections, respectively; (b) providing an absorbent insert substantially superposable upon said outer cover and having a liquid permeable bodyside liner, a liquid impermeable barrier, an absorbent composite disposed between said liner and barrier absorbing and containing bodily exudates and opposed longitudinal ends; (c) stretching said outer cover more than about 20% in an essentially cross-body direction; (d) superposing said absorbent insert structure upon an inner surface of said outer cover; and (e) simultaneously attaching said opposed ends of said insert at selected waist attachment zones, defining free-span zones underlying said insert wherein the functional stretchability of said outer cover is substantially unrestricted.

Claim 50

Dependent Claim 151 words

In a disposable absorbent garment, a method of integrating an absorbent insert structure into an outer cover, said method comprising the steps of: (a) providing a resiliently stretchable outer cover having opposed waist sections, a central crotch section and front and rear panels between said crotch and said waist sections, respectively; (b) providing an absorbent insert substantially superposable upon said outer cover and having a liquid permeable bodyside liner, a liquid impermeable barrier, an absorbent composite disposed between said liner and barrier absorbing and containing bodily exudates and opposed longitudinal ends; (c) stretching said outer cover more than about 20% in an essentially cross-body direction; (d) superposing said absorbent insert structure upon an inner surface of said outer cover; and (e) simultaneously attaching said opposed ends of said insert at selected waist attachment zones, defining free-span zones underlying said insert wherein the functional stretchability of said outer cover is substantially unrestricted.

Claim 51

Independent Claim 129 words

A method of using a disposable absorbent garment comprising steps of: (a) providing a stretchable outer cover having opposed fastenable waist sections, a central crotch section and front and rear panels between said crotch and waist sections, respectively; (b) providing a substantially superposable absorbent insert structure capable of absorbing and containing bodily exudates; (c) stretching said outer cover more than about 20% in an essentially cross-body direction while superposing said absorbent structure upon an inner surface of said outer cover; (d) attaching longitudinally opposed ends of said insert at selected waist attachment zones, defining free-span zones underlying said insert and having substantially unrestricted functional stretchability therein; (e) positioning said garment underneath the torso of a wearer; and (f) fastening said waist sections together about the body of the wearer.

Claim 52

Independent Claim 129 words

A method of using a disposable absorbent garment comprising steps of: (a) providing a stretchable outer cover having opposed fastenable waist sections, a central crotch section and front and rear panels between said crotch and waist sections, respectively; (b) providing a substantially superposable absorbent insert structure capable of absorbing and containing bodily exudates; (c) stretching said outer cover more than about 20% in an essentially cross-body direction while superposing said absorbent structure upon an inner surface of said outer cover; (d) attaching longitudinally opposed ends of said insert at selected waist attachment zones, defining free-span zones underlying said insert and having substantially unrestricted functional stretchability therein; (e) positioning said garment underneath the torso of a wearer; and (f) fastening said waist sections together about the body of the wearer.

Claim 53

Dependent Claim 20 words

The method of claim 49 further comprising the step of removably attaching said insert at said attachment zones using snaps.

Claim 54

Dependent Claim 35 words

The method of claim 49 or 50 further comprising the step of inwardly folding over the outermost edges of said waist sections, forming waist hems entrapping said longitudinally opposed ends of said absorbent structure therein.

Disposable absorbent garment

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