Pants type diaper and method for producing same

Abstract

A pants-type diaper, is provided which is equipped with leg-hole elastics which effectively encircle the leg-holes without traversing the crotch region. Also provided are methods for producing such diapers. Typical products of this type are provided with an outer laminate, formed of an inner liner material and an outer backsheet material between which the leg-hole elastics are disposed. The invention provides for the removal of a strip of inner liner material carrying undesirable crotch-region elastic strands prior to lamination or combining of the remaining inner liner with a complementary outer layer backsheet.

We claim:  
     
         1 . A protective underwear arranged to be worn by a person having legs to trap and collect loose or liquid waste products of the person, said underwear comprising a pants-shaped chassis having a front waist portion, a belly portion, a rear waist portion, a rear back portion, a crotch portion, and a pair of leg openings disposed on opposite sides of said chassis, with said crotch portion being located between said leg openings and having a front section and a rear section, said front waist portion and said rear waist portion being joined together at the sides of said chassis, said belly portion and said rear back portion being joined together at the sides of said chassis, said underwear additionally comprising an insert having an insert sheet and a liquid absorbent core disposed between said insert sheet and said chassis, each of said leg openings having a first arcuate section, a second arcuate section, and an intermediate section, said first arcuate section having an inner end located adjacent said core, said second arcuate section having an inner end located adjacent said core, said intermediate section being located adjacent said core between said inner ends of said first and second arcuate sections, said front waist portion of said chassis including plural transversely oriented elastic threads extending parallel to one another, said plural transversely oriented elastic threads encompassing a substantial portion of said chassis from said waist portion into said belly portion to a point adjacent said crotch portion, said underwear additionally comprising at least two generally linear longitudinally oriented elastic threads, with respective ones of said longitudinally oriented elastic threads extending on opposite sides of said core outside margins of said core and between said leg openings, said longitudinally oriented elastic threads intersecting at least one of said transversely oriented elastic threads of said belly portion and intersecting at least one of said transversely oriented elastic threads of said rear back portion to form an enclosed, rectangular gasketed compartment for said liquid absorbent core closely conforming to the perimeter of said core to prevent the egress of liquid therefrom, said first arcuate section of each of said leg openings being elasticized by at least one arcuate elastic thread, said second arcuate section of each of said leg openings being elasticized by at least one arcuate elastic thread, said at least one elastic thread of said first arcuate section terminating at an inner end, said at least one elastic thread of said second arcuate section terminating at an inner end, said inner ends being spaced from each other by a gap, said gap being located at said intermediate section, and wherein a portion of one of said longitudinally oriented elastic threads is located very close to said gap in said intermediate section of one of said leg openings, and a portion of the other of said longitudinally oriented elastic threads is located very close to said gap in said intermediate section of the other of said leg openings, whereupon said longitudinally oriented elastic threads cooperate with said arcuate elastic threads to elasticized said leg openings to enable said leg openings to closely conform about the legs of the person.  
     
     
         2 . The protective underwear of  claim 1  wherein said compartment has an area, wherein said insert sheet and said chassis are liquid permeable, and wherein said underwear additionally comprises a liquid impermeable layer disposed between said core and said chassis and encompassing said area of said compartment.  
     
     
         3 . The protective underwear of  claim 1  wherein said underwear additionally comprises a fluid acquisition layer located between said insert sheet and said liquid absorbent core within said compartment.  
     
     
         4 . The protective underwear of  claim 1  wherein said transversely oriented elastic threads comprise two first groups and two second groups, a first one of said two first groups being located in said front waist portion and a second one of said first two groups being located in said rear waist portion, a first one of said two second groups being located in said belly portion and a second one of said two second groups being located in said rear back portion, and wherein said transversely oriented threads of said first groups are spaced closer to one another than said transversely oriented threads of said second groups.  
     
     
         5 . The protective underwear of  claim 1  wherein said underwear includes a front section comprising said front waist portion and said belly portion and a rear section comprising said rear waist portion and said rear back portion and wherein portions of said transversely extending threads that are located in either said front section or said rear section of a distinctive color are compared to said chassis to be readily visible by the person.  
     
     
         6 . The protective underwear of  claim 1  wherein said compartment has a periphery and said insert sheet and said chassis are bonded about said periphery of said compartment.  
     
     
         7 . The protective underwear of  claim 1  wherein said core is of a generally rectangular shape.  
     
     
         8 . The protective underwear of  claim 1  wherein said chassis comprises a backsheet and two inner sheets adhesively secured to said backsheet, said inner sheets being of non-woven material.  
     
     
         9 . The protective underwear of  claim 1  wherein said transversely oriented elastic threads and said longitudinally oriented linear elastic threads sre of the same material.  
     
     
         10 . The protective underwear of  claim 9  wherein said arcuate elastic threads are of a different material than said transversely oriented elastic threads.  
     
     
         11 . The protective underwear of  claim 1  wherein said chassis material is a polylaminate.  
     
     
         12 . The protective underwear of  claim 11  wherein said polylaminate is polyfilm laminated to a non-woven material.  
     
     
         13 . The protective underwear of  claim 1  wherein said insert sheet comprises a non-woven material.  
     
     
         14 . The protective underwear of  claim 13  wherein said non-woven material is spunbond polypropylene.  
     
     
         15 . The protective underwear of  claim 13  where said non-woven material is zone-coated spunbond polypropylene, having a longitudinal central area that is hydrophilic and two longitudinal side areas that are hydrophobic.  
     
     
         16 . The protective underwear of  claim 1  wherein said core is formed of a highly moisture absorbent material.  
     
     
         17 . The protective underwear of  claim 16  wherein said core is formed of pulp and a superabsorbent particulate.  
     
     
         18 . The protective underwear of  claim 16  wherein said core is formed of an airlaid composite, containing pulp, superabsorbent particulates and/or fibers, and at least one binder.  
     
     
         19 . The protective underwear of  claim 18  wherein said at least one binder is selected from the group consisting of chemical and thermal binders.  
     
     
         20 . The protective underwear of  claim 1  wherein said chassis comprises a non-woven material.  
     
     
         21 . The protective underwear of  claim 20  wherein said non-woven material is a spunbond polypropylene material.  
     
     
         22 . The protective underwear of  claim 20  wherein said non-woven material is spunbond/meltblown/spunbond polypropylene.  
     
     
         23 . The protective underwear of  claim 22  wherein said insert sheet is an apertured three dimensional film or a combination of such film and a non-woven material.  
     
     
         24 . The protective underwear of  claim 23  wherein said compartment has an area, and wherein said underwear additionally comprises a liquid impermeable layer disposed between said core and said chassis and encompassing said area of said compartment.  
     
     
         25 . The protective underwear of  claim 24  wherein said liquid impermeable layer is microporous polyfilm, which is vapor permeable.  
     
     
         26 . The protective underwear of  claim 24  wherein said liquid impermeable layer is polyethylene film.  
     
     
         27 . The protective underwear of  claim 26  wherein said underwear additionally comprises a fluid acquisition layer located between said insert sheet and said core.  
     
     
         28 . The protective underwear of  claim 27  wherein said fluid acquisition layer comprises a thru-air-bonded, bicomponent fiber with a fast finish surfactant.  
     
     
         29 . The protective underwear of  claim 26  wherein said fluid acquisition layer comprises an apertured three dimensional film or a combination of such film and a non-woven material.