Pant-type absorbent article and a method for producing pant-type absorbent articles

Abstract

A method for producing pant-type absorbent articles each article including a chassis structure having at least one elastic panel and an integrated absorbent core component, the method including a continuous pant-forming process including forming the chassis structure and incorporating the absorbent core component into the chassis structure. The at least one elastic panel is formed by a) separately producing a two-layer laminate including a first non-elastic fibrous nonwoven web and an elastic film, b) activating the two-layer laminate by incremental stretching in at least one direction to render the two-layer laminate elastically stretchable, c) stretching the activated two-layer laminate by 35-200% in at least one direction, d) introducing the two-layer laminate in the pant-forming process, and e) laminating the elastic film of the stretched two-layer laminate to an elastic or nonwoven chassis component. Also, an absorbent pant-type article produced in accordance with the method.

1 . (canceled) 
     
     
         2 . A method for producing pant-type absorbent articles each article including a chassis structure having at least one elastic panel and an integrated absorbent core component, the method including a continuous pant-forming process comprising forming the chassis structure and incorporating the absorbent core component into the chassis structure, wherein the at least one elastic panel is produced by:
 stretching an activated two-layer laminate by 35-200% in the activation direction and introducing the activated two-layer laminate in the pant-forming process, wherein the activated two-layer laminate is formed by:
 separately producing a two-layer laminate comprising a first non-elastic fibrous nonwoven web and an elastic film; and 
 activating the two-layer laminate by incremental stretching in at least one activation direction to render the two-layer laminate elastically stretchable; and 
   laminating the elastic film of the stretched, activated two-layer laminate to a continuous nonwoven chassis web to form a three layer laminate,   wherein a portion of the continuous nonwoven chassis web extends beyond the stretched, activated two-layer laminate in a direction perpendicular to the activation direction to form an extension part.   
     
     
         3 . The method of  claim 2 , wherein the method further comprises forming a second three layer laminate by:
 stretching a second activated two-layer laminate by 35-200% in the activation direction and introducing the second activated two-layer laminate in the pant-forming process, wherein the second activated two-layer laminate is formed by:
 separately producing a two-layer laminate comprising a first non-elastic fibrous nonwoven web and an elastic film; and 
 activating the two-layer laminate by incremental stretching in at least one activation direction to render the two-layer laminate elastically stretchable; and 
   laminating the elastic film of the second stretched, activated two-layer laminate to a continuous nonwoven chassis web to form a three layer laminate,   wherein a portion of the continuous nonwoven chassis web extends beyond the second stretched, activated two-layer laminate in a direction perpendicular to the activation direction to form a second extension part.   
     
     
         4 . The method of  claim 3 , wherein the extension parts are each used to form part of a crotch portion. 
     
     
         5 . The method of  claim 4 , wherein the activated two-layer laminate and the second activated two-layer laminate are formed by splitting an initial activated two-layer laminate into two laminates. 
     
     
         6 . The method of  claim 3 , wherein the extension parts are each used to form part of a waist portion. 
     
     
         7 . The method of  claim 6 , wherein the activated two-layer laminate and the second activated two-layer laminate are formed by splitting an initial activated two-layer laminate into two laminates. 
     
     
         8 . The method of  claim 3 , wherein the continuous nonwoven chassis web extends beyond both sides of the stretched, activated two-layer laminate to form two extension parts and wherein the continuous nonwoven chassis web extends beyond both sides of the second stretched, activated two-layer laminate to form two extension parts. 
     
     
         9 . The method of  claim 8 , wherein the activated two-layer laminate and the second activated two-layer laminate are formed by splitting an initial activated two-layer laminate into two laminates. 
     
     
         10 . The method of  claim 2 , wherein the continuous nonwoven chassis web extends beyond both sides of the stretched, activated two-layer laminate to form two extension parts. 
     
     
         11 . The method of  claim 10 , wherein the method further comprises splitting the three layer laminate into two components, each component having an extension part. 
     
     
         12 . The method of  claim 11 , wherein the extension parts are each used to form part of a crotch portion. 
     
     
         13 . The method of  claim 11 , wherein the extension parts are each used to form part of a waist portion. 
     
     
         14 . The method according to  claim 2 , wherein the nonwoven chassis component is a non-elastic component. 
     
     
         15 . The method according to  claim 2 , wherein the core component is formed separately from the pant-forming process and introduced in the pant-forming process before or after lamination the elastic film to the nonwoven chassis component. 
     
     
         16 . A method for producing pant-type absorbent articles each article including a chassis structure having at least two elastic panels and an integrated absorbent core component, the method including a continuous pant-forming process comprising forming the chassis structure and incorporating the absorbent core component into the chassis structure, wherein the at least two elastic panels are produced by:
 stretching a first activated two-layer laminate by 35-200% in the activation direction and introducing the first activated two-layer laminate in the pant-forming process, wherein the first activated two-layer laminate is formed by:
 separately producing a two-layer laminate comprising a first non-elastic fibrous nonwoven web and an elastic film; and 
 activating the two-layer laminate by incremental stretching in at least one activation direction to render the two-layer laminate elastically stretchable; and 
   laminating the elastic film of the first stretched, activated two-layer laminate to a continuous nonwoven chassis web to form a three layer laminate,   wherein a portion of the continuous nonwoven chassis web extends beyond the first stretched, activated two-layer laminate in a direction perpendicular to the activation direction to form a first extension part at an outside edge of the first stretched, activated two-layer laminate, and   stretching a second activated two-layer laminate by 35-200% in the activation direction and introducing the second activated two-layer laminate in the pant-forming process, wherein the second activated two-layer laminate is formed by:
 separately producing a two-layer laminate comprising a first non-elastic fibrous nonwoven web and an elastic film; and 
 activating the two-layer laminate by incremental stretching in at least one activation direction to render the two-layer laminate elastically stretchable; and 
   laminating the elastic film of the second stretched, activated two-layer laminate to the continuous nonwoven chassis web to form a three layer laminate,   wherein a portion of the continuous nonwoven chassis web extends beyond the second stretched, activated two-layer laminate in a direction perpendicular to the activation direction to form a second extension part at an outside edge of the second stretched, activated two-layer laminate.   
     
     
         17 . The method of  claim 16 , wherein the first activated two-layer laminate and the second activated two-layer laminate are formed by splitting an initial activated two-layer laminate into two laminates. 
     
     
         18 . The method of  claim 16 , wherein there is a gap between the first and second stretched, activated two-layer laminates on the continuous nonwoven chassis web. 
     
     
         19 . The method of  claim 18 , wherein the first activated two-layer laminate and the second activated two-layer laminate are formed by splitting an initial activated two-layer laminate into two laminates. 
     
     
         20 . A method for producing pant-type absorbent articles each article including a chassis structure having at least two elastic panels and an integrated absorbent core component, the method including a continuous pant-forming process comprising forming the chassis structure and incorporating the absorbent core component into the chassis structure, wherein the at least two elastic panel are produced by:
 stretching a first activated two-layer laminate by 35-200% in the activation direction and introducing the first activated two-layer laminate in the pant-forming process, wherein the first activated two-layer laminate is formed by:
 separately producing a two-layer laminate comprising a first non-elastic fibrous nonwoven web and an elastic film; and 
 activating the two-layer laminate by incremental stretching in at least one activation direction to render the two-layer laminate elastically stretchable; 
   laminating the elastic film of the first stretched, activated two-layer laminate to a continuous nonwoven chassis web to form a three layer laminate,   stretching a second activated two-layer laminate by 35-200% in the activation direction and introducing the second activated two-layer laminate in the pant-forming process, wherein the second activated two-layer laminate is formed by:
 separately producing a two-layer laminate comprising a first non-elastic fibrous nonwoven web and an elastic film; and 
 activating the two-layer laminate by incremental stretching in at least one activation direction to render the two-layer laminate elastically stretchable; and 
   laminating the elastic film of the second stretched, activated two-layer laminate to the continuous nonwoven chassis web to form a three layer laminate,   wherein there is a gap between the first and second stretched, activated two-layer laminates on the continuous nonwoven chassis web.   
     
     
         21 . The method of  claim 20 , wherein the first activated two-layer laminate and the second activated two-layer laminate are formed by splitting an initial activated two-layer laminate into two laminates.