Elastic form-fitting closure constructions for disposable garments

Claim 2

In a disposable garment (10) of the type including an outer marginal portion of material and an interior marginal portion of material along a part of the garment intended to fit along a wearer's body and an elastic element joined thereto to provide an elasticized opening for the garment, the improvement wherein: (1) the elastic element (25) includes an exterior surface (26) joined to the outer marginal portion of material (21) along the opening and an inner surface (24) joined to the interior marginal portion of materiallalong the opening; (2) the outer edges of the elastic element, the outer marginal portion of material and the interior marginal (A-A) portion of material are substantially coincident; (3) the outer marginal portion of material (21) is selected from the class consisting of (a) composite webs having an outer layerlof nonwoven fibrous material and an inner layer (24) of plastic material, the inner layer (24) being in contact with the exterior surfacelof the elastic element, (b) nonwoven webs of synthetic or natural fibers, or (c) plastic films, (i) the outer marginal portion having a thickness in the range of 0.0075 to 0.045 inches when a composite web, in the range of 0.005 to 0.03 inches when a non- woven web, and in the range of 0.0003 to 0.006 inches when a plastic film, (ii) the outer marginal portion having a flexural rigidity in the range of 0.01 to 0.1 cm-g when a composite web or nonwoven web and in the range of 0.002 to 0.008 cm-g when a plastic film; (4) the exterior surfacelof the elastic element (25) and the outer marginal portion (21) are in contact along an interface and joined together along a plurality of bond points (50) disposed along the entire interface, the bond points being spaced in the direction of elongation of the elastic element and transversely thereof, and (a) when the material of the outer marginal portion (21) is a composite web, the area of each bond point (50) is 0.05 to 3 mm2, the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion is 0.5 to 4 mm, and the total area of the bond points is 5 to 40% of the area of said interface, (b) when the material of the outer marginal portion l is (50) a nonwoven web, the area of each bond pointlis 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion is 0.25 to 4 mm, and the total area of the bond points is 5 to 50% of the area of said interface, (c) when the material of the outer marginal portion (21) is (50) a plastic film, the area of each bond pointlis 0.05 to 1.5 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion is 0.05 to 2 mm, and the total area of the bond points is 20 to 80% of the area of said interface; (5) wherein the elastic element (25) is joined along the bond (50) pointslwhen in an elongated condition and remains joined only to the bond points when in a retracted condition to provide an elasticized opening characterized by micro-ribbing (51) of the outer marginal portion of material between the bond points.

Claim 3

A disposable garment according to claim 1, wherein: the outer edges of the elastic element (25), the outer marginal portion of material (21) and the inner marginal portion of mater- iallare coincident (A-A).

Claim 4

A disposable garment according to claim 1 or 2, wherein: the elastic elementlincludes a flat exterior surface (26) and a flat inner surface (24).

Claim 5

A disposable garment according to claim 1 or 2 wherein: the elastic elementlhas a circular cross-section and the exterior surface thereof comprises one-half of the longitudinal circumferential surface of the element and the inner surface thereof comprises the remaining one-half of the longitudinal circumferential surface of the element.

Claim 6

In a disposable garmentlof the type including an outer marginal portion of material (21) and an interior marginal portion of materiallalong a part of the garment intended to fit along a wearer's body and an elastic element (25) joined thereto to provide an elasticized opening for the garment, the improvement wherein: (1) the elastic elementtincludes an exterior surface (26) joined to the outer marginal portion of material (21) along the opening and an inner surfaceljoined to the interior marginal portion of material (20) along the opening; (2) the outer edges of the elastic element (25), the outer marginal portion of materialland the interior marginal portion of material (20) are substantially coincident (A-A); (3) the outer marginal portion of material (21) is selected from the class consisting of (a) composite webs having an outer layer (23) of nonwoven fibrous material and an inner layer (24) of plastic material, the inner layer (24) being in contact with the exterior surface (26) of the elastic element (25), (b) nonwoven webs of synthetic or natural fibers, or (c) plastic films, (i) the outer marginal portion (23) having a thickness in the range of 0.0075 to 0.045 inches when a composite web, in the range of 0.005 to 0.03 inches when a non- woven web, and in the range of 0.0003 to 0.006 inches when a plastic film, (ii) the outer marginal portion (21) having a flexural rigidity in the range of 0.01 to 0.1 cm-g when a composite web or nonwoven web and in the range of 0.002 to 0.008 cm-g when a plastic film; (4) the outer marginal portion of material (21) includes a plurality of closely-spaced bond points (50) extending along the entire exterior surface of the elastic element/joined there- to, the bond points (50) being spaced in the direction of elongation of the elastic element and transversely thereof, and (a) when the material of the outer marginal portion (21) is a composite web, the area of each bond point (50) is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25) prior to joinder of the elastic element to the outer marginal portion is 0.5 to 4 mm, and the total area of the bond points is 5 to 40% of the area of the exterior surface of the elastic element, (b) when the material of the outer marginal portion (21) is (50) a nonwoven web, the area of each bond point is 0.05 to 3 mm2, the distance between neighboring bond points in the direction of elongation of the elastic element (25) prior to joinder of the elastic element to the outer marginal portion is 0.25 to 4 mm, and the total area of the bond points is 5 to 50% of the area of the exterior surface of the elastic element, (c) when the material of the outer marginal portion (21) is a plastic film, the area of each bond point (50) is 0.05 to 1.5 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25) prior to joinder of the elastic element to the outer marginal portion is 0.05 to 2 mm, and the total area of the bond points is 20 to 80% of the area of the exterior surface of the elastic element; (5) wherein the elastic element (25) is joined to the bond points when in an elongated condition and remains joined only to the bond points when in a retracted condition to provide an elasticized opening characterized by micro-ribbing (51) of the outer marginal portion of material between the bond points.

Claim 7

In a disposable garmentlof the type including an outer marginal portion of material (21) and an interior marginal portion of materiallalong a part of the garment intended to fit along a wearer's body and an elastic element (25) joined thereto to provide an elasticized opening for the garment, the improvement wherein: (1) the elastic elementtincludes an exterior surface (26) joined to the outer marginal portion of material (21) along the opening and an inner surfaceljoined to the interior marginal portion of material (20) along the opening; (2) the outer edges of the elastic element (25), the outer marginal portion of materialland the interior marginal portion of material (20) are substantially coincident (A-A); (3) the outer marginal portion of material (21) is selected from the class consisting of (a) composite webs having an outer layer (23) of nonwoven fibrous material and an inner layer (24) of plastic material, the inner layer (24) being in contact with the exterior surface (26) of the elastic element (25), (b) nonwoven webs of synthetic or natural fibers, or (c) plastic films, (i) the outer marginal portion (23) having a thickness in the range of 0.0075 to 0.045 inches when a composite web, in the range of 0.005 to 0.03 inches when a non- woven web, and in the range of 0.0003 to 0.006 inches when a plastic film, (ii) the outer marginal portion (21) having a flexural rigidity in the range of 0.01 to 0.1 cm-g when a composite web or nonwoven web and in the range of 0.002 to 0.008 cm-g when a plastic film; (4) the outer marginal portion of material (21) includes a plurality of closely-spaced bond points (50) extending along the entire exterior surface of the elastic element/joined there- to, the bond points (50) being spaced in the direction of elongation of the elastic element and transversely thereof, and (a) when the material of the outer marginal portion (21) is a composite web, the area of each bond point (50) is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25) prior to joinder of the elastic element to the outer marginal portion is 0.5 to 4 mm, and the total area of the bond points is 5 to 40% of the area of the exterior surface of the elastic element, (b) when the material of the outer marginal portion (21) is (50) a nonwoven web, the area of each bond point is 0.05 to 3 mm2, the distance between neighboring bond points in the direction of elongation of the elastic element (25) prior to joinder of the elastic element to the outer marginal portion is 0.25 to 4 mm, and the total area of the bond points is 5 to 50% of the area of the exterior surface of the elastic element, (c) when the material of the outer marginal portion (21) is a plastic film, the area of each bond point (50) is 0.05 to 1.5 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25) prior to joinder of the elastic element to the outer marginal portion is 0.05 to 2 mm, and the total area of the bond points is 20 to 80% of the area of the exterior surface of the elastic element; (5) wherein the elastic element (25) is joined to the bond points when in an elongated condition and remains joined only to the bond points when in a retracted condition to provide an elasticized opening characterized by micro-ribbing (51) of the outer marginal portion of material between the bond points.

Claim 8

A disposable garment according to claim 5, wherein: the elastic element (25) includes a flat exterior surface'and a flat inner surface (24).

Claim 9

A disposable garment according to claim 5, wherein: the elastic element (40) has a circular cross-section and the exterior surface thereof comprises one-half of the longitudinal circumferential surface of the element and the inner surface thereof comprises the remaining one-half of the longitudinal circumferential surface of the element.

Claim 10

A disposable garment according to claim 5, 6 or 7, wherein: the garment (10) comprises an exterior panellincluding the outer marginal portion and an interior panel (20) including the inner marginal portion.

Claim 11

An integral disposable panty (10) comprising the combination of (1) an outer covert (2) a bodyside liner (20); (3) an absorbent batt (22) between the outer cover (21) and the . bodyside liner (20); (4) a pair of opposed side seams (16) joining together portions of the outer cover and bodyside liner to form a panty having a waist opening defined by an outer marginal portion of the outer cover and an interior marginal portion of the bodyside liner, and a pair of leg openings each defined by an outer marginal portion of the outer cover and an interior marginal portion of the bodyside liner; (5) an elastic element (25) along the waist opening and an elastic element (30) along each leg opening, each elastic element (25,30) including an exterior surface (25,31) joined to an outer marginal portion of the outer cover and an inner surface (24,32) joined to an interior marginal portion of the bodyside liner (20) along its respective waist or leg opening; (6) the outer edges of the.elastic element (25,30), the outer marginal portion of the outer cover (21) and the interior marginal portion of the bodyside liner (20) along the waist opening and each leg opening being substantially coincident (A-A); (7) the outer marginal portion of the outer cover'along the waist opening and each leg opening being a material selected from the class consisting of (a) composite webs having an outer layer (23) of nonwoven fibrous material and an inner layer (24) of plastic material, the inner layer (24) being in contact with the exterior surface (26,31) of the elastic element (25,30); (b) nonwoven webs of synthetic or natural fibers, or (c) plastic films, (i) the outer marginal portion having a thickness in the range of 0.0075 to 0.045 inches when a composite web, in the range of 0.005 to 0.03 inches when a non- woven web, and in the range of 0.0003 to 0.006 inches when a plastic film, (ii) the outer marginal portion having a flexural rigidity in the range of 0.01 to 0.1 cm-g when a composite web or nonwoven web and in the range of 0.002 to 0.008 cm-g when a plastic film; (8) the outer marginal portion of the outer cover (21) along the waist opening and each leg opening including a plurality of closely-spaced bond points (50) extending along the entire exter- ior surface. of the elastic element ! joined thereto, neighboring bond points being spaced in the direction of elongation of the elastic element and transversely thereof, and (a) when the material of the outer marginal portion (21) is . a composite web; the area of each bond point (50) is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25,30) prior to joinder of the elastic element to the outer marginal portion is 0.5 to 4 mm, and the total area of the bond points is 5 to 40% of the area of the exterior surface of the elastic element, (b) when the material of the outer marginal portion (21) is a nonwoven web, the area of each bond point (50) is 0.05 to 3 mm 2 the distance between neighboring bond points in the direction of elongation of the elastic element (25,30) prior to joinder of the elastic element to the outer marginal portion is 0.25 to 4 mm, and the total area of the bond points is 5 to 50% of the area of the exterior surface of the elastic element, (c) when the material of the outer marginal portion (21) is a plastic film, the area of each bond pointlis 0.05 to 1.5 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25,30) prior to joinder of the elastic element to the outer marginal portion is 0.05 to 2 mm, and the total area of the bond points is 20 to 80% of the area of the exterior surface of the elastic element; (9) wherein the elastic element (25,30) is joined to the bond points (50) when in an elongated condition and remains joined only to the bond points when in a retracted condition to provide an elasticized waist opening (11) and elasticized leg openings/characterized by micro-ribbing (51) of the material of the outer marginal portion of the outer coverlbetween the bond points (50).

Claim 12

An integral disposable panty (10) comprising the combination of (1) an outer covert (2) a bodyside liner (20); (3) an absorbent batt (22) between the outer cover (21) and the . bodyside liner (20); (4) a pair of opposed side seams (16) joining together portions of the outer cover and bodyside liner to form a panty having a waist opening defined by an outer marginal portion of the outer cover and an interior marginal portion of the bodyside liner, and a pair of leg openings each defined by an outer marginal portion of the outer cover and an interior marginal portion of the bodyside liner; (5) an elastic element (25) along the waist opening and an elastic element (30) along each leg opening, each elastic element (25,30) including an exterior surface (25,31) joined to an outer marginal portion of the outer cover and an inner surface (24,32) joined to an interior marginal portion of the bodyside liner (20) along its respective waist or leg opening; (6) the outer edges of the.elastic element (25,30), the outer marginal portion of the outer cover (21) and the interior marginal portion of the bodyside liner (20) along the waist opening and each leg opening being substantially coincident (A-A); (7) the outer marginal portion of the outer cover'along the waist opening and each leg opening being a material selected from the class consisting of (a) composite webs having an outer layer (23) of nonwoven fibrous material and an inner layer (24) of plastic material, the inner layer (24) being in contact with the exterior surface (26,31) of the elastic element (25,30); (b) nonwoven webs of synthetic or natural fibers, or (c) plastic films, (i) the outer marginal portion having a thickness in the range of 0.0075 to 0.045 inches when a composite web, in the range of 0.005 to 0.03 inches when a non- woven web, and in the range of 0.0003 to 0.006 inches when a plastic film, (ii) the outer marginal portion having a flexural rigidity in the range of 0.01 to 0.1 cm-g when a composite web or nonwoven web and in the range of 0.002 to 0.008 cm-g when a plastic film; (8) the outer marginal portion of the outer cover (21) along the waist opening and each leg opening including a plurality of closely-spaced bond points (50) extending along the entire exter- ior surface. of the elastic element ! joined thereto, neighboring bond points being spaced in the direction of elongation of the elastic element and transversely thereof, and (a) when the material of the outer marginal portion (21) is . a composite web; the area of each bond point (50) is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25,30) prior to joinder of the elastic element to the outer marginal portion is 0.5 to 4 mm, and the total area of the bond points is 5 to 40% of the area of the exterior surface of the elastic element, (b) when the material of the outer marginal portion (21) is a nonwoven web, the area of each bond point (50) is 0.05 to 3 mm 2 the distance between neighboring bond points in the direction of elongation of the elastic element (25,30) prior to joinder of the elastic element to the outer marginal portion is 0.25 to 4 mm, and the total area of the bond points is 5 to 50% of the area of the exterior surface of the elastic element, (c) when the material of the outer marginal portion (21) is a plastic film, the area of each bond pointlis 0.05 to 1.5 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element (25,30) prior to joinder of the elastic element to the outer marginal portion is 0.05 to 2 mm, and the total area of the bond points is 20 to 80% of the area of the exterior surface of the elastic element; (9) wherein the elastic element (25,30) is joined to the bond points (50) when in an elongated condition and remains joined only to the bond points when in a retracted condition to provide an elasticized waist opening (11) and elasticized leg openings/characterized by micro-ribbing (51) of the material of the outer marginal portion of the outer coverlbetween the bond points (50).

Claim 13

In a disposable garment (10) of the type including an outer marginal portion of material (21) and an interior marginal portion of material (21) along a part of the garment intended to fit along a wearer's body and a plurality of spaced elastic elements (40) joined thereto to provide an elasticized portion (40) of the garment, the improvment wherein: (1) each elastic element'includes an exterior surface joined to the outer marginal portion of material (40) and an inner surface joined to the interior marginal portion of material (41); (2) the elastic elements (40) are spaced from each other in a direction transverse to their direction of elongation with one of said elastic elements arranged about the boundary of said marginal portions, and the outer edges of said one elastic element (40), the outer marginal portion of material (41) and the interior marginal portion of material (42) are substantially coincident; (3) the outer marginal portion of material (41) is selected from the class consisting of (a) composite webs having an outer layer of nonwoven fibrous material and an inner layer of plastic material, the inner layer being in contact with the exterior surface of the elastic element, (b) nonwoven webs of synthetic or natural fibers, or (c) plastic films, (i) the outer marginal portion having a thickness in the range of 0.0075 to 0.045 inches when a composite web, in the range of 0.005 to 0.03 inches when a non- woven web, and in the range of 0.0003 to 0.006 inches when a plastic film, (ii) the outer marginal portion having a flexural rigidity in the range of 0.01 to 0.1 cm-g when a composite web or nonwoven web and in the range of 0.002 to 0.008 cm-g when a plastic film; (4) the outer marginal portion of material includes a plurality of closely-spaced bond points extending along the entire exterior surface of each elastic element joined thereto, neighboring bond points being spaced in the direction of elongation of the elastic elements and transversely thereof, and (40) (a) when the material of the outer marginal portion / is a composite web, the area of each bond point is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion is 0.5 to 4 mm, and the total area of the bond points is 5 to 40% of the area of the exterior surface of the elastic element, (b) when the material of the outer marginal portion (40) s a nonwoven web, the area of each bond point is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion.is 0.25 to 4 mm, and the total area of the bond points is 5 to 50% of the area of the exterior surface of the elastic element, (c) when the material of the outer marginal portion (40) is a plastic film, the area of each bond point is 0.05 to 1.5 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion is 0.05 to 2 mm, and the total area of the bond points is 20 to 80% of the area of the exterior surface of the elastic element; (5) wherein the elastic elements (40) are joined to the bond points (50) when in an elongated condition and remain joined only to the bond points when in a retracted condition to provide an elasticized body-encircling opening characterized by micro-ribbing/of the outer marginal portion of material between the bond points.

Claim 14

In a disposable garment (10) of the type including an outer marginal portion of material (21) and an interior marginal portion of material (21) along a part of the garment intended to fit along a wearer's body and a plurality of spaced elastic elements (40) joined thereto to provide an elasticized portion (40) of the garment, the improvment wherein: (1) each elastic element'includes an exterior surface joined to the outer marginal portion of material (40) and an inner surface joined to the interior marginal portion of material (41); (2) the elastic elements (40) are spaced from each other in a direction transverse to their direction of elongation with one of said elastic elements arranged about the boundary of said marginal portions, and the outer edges of said one elastic element (40), the outer marginal portion of material (41) and the interior marginal portion of material (42) are substantially coincident; (3) the outer marginal portion of material (41) is selected from the class consisting of (a) composite webs having an outer layer of nonwoven fibrous material and an inner layer of plastic material, the inner layer being in contact with the exterior surface of the elastic element, (b) nonwoven webs of synthetic or natural fibers, or (c) plastic films, (i) the outer marginal portion having a thickness in the range of 0.0075 to 0.045 inches when a composite web, in the range of 0.005 to 0.03 inches when a non- woven web, and in the range of 0.0003 to 0.006 inches when a plastic film, (ii) the outer marginal portion having a flexural rigidity in the range of 0.01 to 0.1 cm-g when a composite web or nonwoven web and in the range of 0.002 to 0.008 cm-g when a plastic film; (4) the outer marginal portion of material includes a plurality of closely-spaced bond points extending along the entire exterior surface of each elastic element joined thereto, neighboring bond points being spaced in the direction of elongation of the elastic elements and transversely thereof, and (40) (a) when the material of the outer marginal portion / is a composite web, the area of each bond point is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion is 0.5 to 4 mm, and the total area of the bond points is 5 to 40% of the area of the exterior surface of the elastic element, (b) when the material of the outer marginal portion (40) s a nonwoven web, the area of each bond point is 0.05 to 3 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion.is 0.25 to 4 mm, and the total area of the bond points is 5 to 50% of the area of the exterior surface of the elastic element, (c) when the material of the outer marginal portion (40) is a plastic film, the area of each bond point is 0.05 to 1.5 mm 2 , the distance between neighboring bond points in the direction of elongation of the elastic element prior to joinder of the elastic element to the outer marginal portion is 0.05 to 2 mm, and the total area of the bond points is 20 to 80% of the area of the exterior surface of the elastic element; (5) wherein the elastic elements (40) are joined to the bond points (50) when in an elongated condition and remain joined only to the bond points when in a retracted condition to provide an elasticized body-encircling opening characterized by micro-ribbing/of the outer marginal portion of material between the bond points.

Claim 17

A method according to claim 11 including the step of: providing an exterior panel (21) for the garment including the outer marginal portion having bond points (50) formed therein.

Claim 18

A method according to claim 11 or 12 including the step of: controlling micro-buckling (51) of the outer marginal portion by controlling the area and spacing of the bond points (50).