CA1207104A - Form fit diaper with inside seal and thickened crotch and method of making the same - Google Patents
Form fit diaper with inside seal and thickened crotch and method of making the sameInfo
- Publication number
- CA1207104A CA1207104A CA000437183A CA437183A CA1207104A CA 1207104 A CA1207104 A CA 1207104A CA 000437183 A CA000437183 A CA 000437183A CA 437183 A CA437183 A CA 437183A CA 1207104 A CA1207104 A CA 1207104A
- Authority
- CA
- Canada
- Prior art keywords
- diaper
- pad
- sheet
- backing
- strips
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Abstract
Abstract of the Disclosure A form fit disposable diaper has an absorbent pad folded intermediate the ends to provide increased absorbent material in the crotch and has water impervi-ous side seal strips folded over the pad in the crotch to minimize leakage along the edges of the diaper and to prevent the absorbent pad from shifting. A quantity of water absorbent polymer is employed to enhance moisture absorbing capabilities. The side seal strips are desirably perforated to permit moisture strike through into the pad but prevent transfer of the poly-mer to the facing sheet and the skin of the diaper wearer.
Description
~;~0710D~
FORM FIT DIAPER WITH INSID~
SEAL AND THIcKFN~n CROTCH
AND METHOD.OF M~KI~G THF. SAME
Back~round of the Invention The pre~erred disposable diaper construction provides good ~luid re~ention without leakag~, the pad does not shift or`disîntegrate i.n use and the diape.
does not feel uncomfortable on the skin. In addi~ion, ~he pre~erred diap~r does not cause excess we~ contact wi~h the s'~in which tends to macerate the skin, reduc-ing its ability to resist diaper rash or irritation~
Diapexs employi.ng elastic bands to hold the diaper tightly against the ba~y~s legs helps stop side leak;lge.
The elastic bands, however, greatly increase the cost o the diapers. U. S. patents 3,86~,003 and 4,050,462 are illustrative of diaper constructions with elastic bands.
My U.S. p~tent 4,227,952 illustrates a method and appar-atus for makin~ diapers with elastic bands.
Various d;aper constructions have also beendeveloped which employ hydrocolloidal matexial to in-crease moisture absorbency. One of the draw~acks of this construction has been t:he slippery) unc~mfox~a~le feeli.ng of this material to the wearer of the diapers.
71~)4 Diaper constructions have also been developed with water impervious side seals to prevent leakage from the absorbent pad along the side margins of the diaper. Sabee United States patent 3,386,442 discloses the use of separate plastic strips along the side margins of the diaper to serve as a side seal. The plastic strips of this type of construction, however, contact the skin and cause chafing of the skin of the wearer of the diaper.
Summary of the Invention The present invention provides a disposable diaper having a generally rectangular outline and having an intermediate portion of less width than the end portions to provide a form fitting diaper crotch portion, said diaper comprising a moisture impervious backing sheet, an absorbent pad on the backing, with the pad being folded over upon itself in the crotch area to be of a thickness greater than the thickness in the waistband portions to provide increased absorbency in the crotch area, moisture impermeable strips between said pad and said backing, said strips being folded over the absorbent pad in the crotch area to lock the pad against shifting, and a moisture permeable facing sheet having a shape generally complementary to the backing sheet and sealed along its edges to the backing sheet, and including spaced elastic bands secured to one o said acing and backing sheets.
Various of the drawbacks and disadvantages of prior art diapers are overcome. Leakage is mi nimi zed by providing an auxiliary seal along the side edges of the pad, with the sealing sheet located beneath a comfortable, porous facing sheet and spaced inwardly from the side margins of the diaper. Positioning the seal on the side edges of the pad under the facing sheet pre-~2~7~04 vents it from coming in contact with the wearer's skin, thusavoiding chafing and irritation caused by contact of the plastic film typically used for the water impervious parts of a diaper.
The side margins of the absorbent pads are free to open or expand as they absorb the body fluids. Various absorbent materials having different absorbent properties can be employed with this seal con-struction. Examples are wood cellulose fibers and hydrocolloidal absorbent materials. The side seals also hold the pad in place so that it does not shift or disintegrate during use. This insures that the pad is positively positioned as intended, to maximize pro-tection.
~ , ..
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The absorbent pad assembly may have thicker margins spac~d apart by a thinner central area which will result in differential expansion of the margins to a greater degxee than the central area when becoming wet, which ~h~nces the seal against the baby's legs.
The thinner central area being more flexible will allow the diaper to conform better to various body shapes.
This combined with the thicker side margins under an expandable seal reduces to a m; n;m~lm the spill-over which occurs during flooding conditions.
The side seal stxips are desirably per~orated if they are wide to enable strike ~hrough o~ moisture through the water impervious sealing strip portions whi~h face ~he inan~ or user of the diaper. The per-forated water impervious strips will preven~ Gon~actof the hydrocolloidal material with the user's skin ~nd hence avoid the unpleasant feeling associated with con-tact or such materials. An intermedia~e saaling sheet may also be used whieh has per~oration~ at least in the crotch area. This sheet will allow fast strike thxough in the crotch area and allow wicking to the remainde~x of the absorbent pad under the sealing sheet where it cannot contact the skln of the wearer and become an irritant. Moisture trapped against the skin can cause irrita~ion.
The diaper and me~hQd of the in~antion can employ ~70 spaced water impervious ribbons upon which th~ absorbent pad is suppor~ed prior ~o assemb~y nf the facing o~ the backing sheets~ The pad and ribbons are sirnultaneously cu~ wit~ transverse cuts to fol~m the ,~
~z~ o~
foldable pad flaps. The ribbon and pad flaps are then folded with the ribbon forming the edge side seals. The ribbon is provided with adhesive prior to the cutting and folding operation. The folded~ adhesively secured ribbon also main~ains the folds of the absorbent pad.
Further objects and advantages of the inven-~ion will be apparent from the disclosure.
Description of the Drawin~s Fig. 1 is a plan view showing the method of 10 ~ki ng the diaper of the invention.
Fig. 2 is a side elevational view of the pro~
.edure in m~k;ng the diaper.
Fig. 3 is a sectional view along line 3--3 o~
~;1 ig r 1 ~
lS Fig. 4 is a view along line ~--4 of Fig. 1.
Fig. S is a view along line 5--5 o$ Fig. 1.
Fig. 6 is an enlarged perspective view with parts broken away o the diaper of the in~ention.
Fig. 7 is a perspective ~iew o a modified embodiment o the diaper.
Fig. 8 is a perspective view o~ a dîaper con-s~ruction in which the side seal ribbons are pesorated and ha~e incxeas~d absorbency zones under the si~e seal ribbons.
Fig. 9 is ~ sec~ional view of a diaper simi-lar ~ ~he diape~ shown in Fi~. 8 except the side seals are made of orla piece cons~ru~tion with an auxiliary pad in the cro~ch area.
Fig. 10 is a sectional view of a diaper con-struc~ion with a perforated sealing sheet which is ,., sealingly connected to the top and bottom sheets at the same general point along the margins.
Fig. 11 is a perspective view of the dia~er shown in Fig. 10.
Fig. 12 is a diaper construction of a diaper similar to that shown in Fig. 10 with the sealing sheet sealed to the backing sheet at a different poin~ o~
contact for a form ~it diaper.
Fig. 13 is a perspective view with portions removed of the diaper shown in Fig. 12.
Fig. 14 is a sectional view of a diaper con-struc~lon in which the sealing sheet is tuc~ed around beneath tne absorbent pad and side Inargins conta;ning at~Eiliary absorbent strips.
Fig. lS is a perspective view of the diaper cons~rucLion shown in Fig. 14.
Fig. 16 is a sectional view of a diaper con-struction in -~hich the backing sheet i5 olded over the facillg and sealing sheet~
Fig. 17 is a perspective view o~ the diaper cons~ruction shown in Fig, 16.
Fig. 18 is a sectional view of a d~aper con-~tru~tion having a one piece sealing sheet havin~ sides folded aro~md and over the top of the absorbent pad.
~S Fig. 19 is ~ diape~ construction simi l~r to Fig. 18 in which the folded over sides of thP sealing sheet are~perforated.
Fig. Z0 is a sectional Vi8W of a diaper con-s~ruction in which increas~d absorbent material is located under the side mar~ins of the sealin~ sheet.
12~7~04 Fig. 21 is a perspective view with parts re-moved of the diaper construction shown in Fig. 20.
Fig. 22 is a diaper construction of a diaper similar ~o Fig. 20, but o~ a foxm fit diaper.
Fig. 23 is a perspective view of the diaper construction shown in Fig. 22.
Fig. 24 is a diaper construction similar to the diaper shown in Figs. lO and 11 with increased thick~ess of absorbent material along the side margins in ~e crotch àrea.
Fig. 25 is a perspectiva view with parts removed of the diaper shown in Fig. 24, Fig. 26 shows a diaper cons~ructîon similar to the diaper in Fig. 12 with increased absorbent mater~al in the margins under the sealing sheat.
Fig. 27 is a perspective view with parts xe-moved of the dîaper construction shown in Fig. 2Ç.
Fig. 28 is an e~larged ~ragmen~ary sectional view of a diaper having ~he pad contAinin~ hydro~
colloidal material folded over under the side seal.
Fig. %9 is a view similar to Fig. 2~ with the pad expanded upon absorption of moisture.
Fig. 30 is a diagrammatic perspective view o~
a modified embodimen~ of the method of ~qk7n~ diapers wi~h ribbons which fonm ed~e seals.
Fig. 31 is a perspective view of a diapar made in accordance with the meth~d o~ Fig. 30~
Fig. 32 is a fragmen~ary perspec~ive view of a modified pad construction with a thin cen~ral we~
portion.
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Description of the Pra~erred EmbodimPnt Although ~he disclosure hereof is de~ailed and exaet to enable those skilled in ~he art to practice the invention9 the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
The diaper of the invention is best described by the me~hod of ~ki n~ one embodiment thereof.
Referring to Fig. 1, the initial step of forming the diaper involves providi~g absorbent pad material 10 and suppor~ing the pad 10 on continuous spa~ed water impervious plas~ic ribbons 12 and 14 supplied from parent rolls 15. As illustrated in Fig.
FORM FIT DIAPER WITH INSID~
SEAL AND THIcKFN~n CROTCH
AND METHOD.OF M~KI~G THF. SAME
Back~round of the Invention The pre~erred disposable diaper construction provides good ~luid re~ention without leakag~, the pad does not shift or`disîntegrate i.n use and the diape.
does not feel uncomfortable on the skin. In addi~ion, ~he pre~erred diap~r does not cause excess we~ contact wi~h the s'~in which tends to macerate the skin, reduc-ing its ability to resist diaper rash or irritation~
Diapexs employi.ng elastic bands to hold the diaper tightly against the ba~y~s legs helps stop side leak;lge.
The elastic bands, however, greatly increase the cost o the diapers. U. S. patents 3,86~,003 and 4,050,462 are illustrative of diaper constructions with elastic bands.
My U.S. p~tent 4,227,952 illustrates a method and appar-atus for makin~ diapers with elastic bands.
Various d;aper constructions have also beendeveloped which employ hydrocolloidal matexial to in-crease moisture absorbency. One of the draw~acks of this construction has been t:he slippery) unc~mfox~a~le feeli.ng of this material to the wearer of the diapers.
71~)4 Diaper constructions have also been developed with water impervious side seals to prevent leakage from the absorbent pad along the side margins of the diaper. Sabee United States patent 3,386,442 discloses the use of separate plastic strips along the side margins of the diaper to serve as a side seal. The plastic strips of this type of construction, however, contact the skin and cause chafing of the skin of the wearer of the diaper.
Summary of the Invention The present invention provides a disposable diaper having a generally rectangular outline and having an intermediate portion of less width than the end portions to provide a form fitting diaper crotch portion, said diaper comprising a moisture impervious backing sheet, an absorbent pad on the backing, with the pad being folded over upon itself in the crotch area to be of a thickness greater than the thickness in the waistband portions to provide increased absorbency in the crotch area, moisture impermeable strips between said pad and said backing, said strips being folded over the absorbent pad in the crotch area to lock the pad against shifting, and a moisture permeable facing sheet having a shape generally complementary to the backing sheet and sealed along its edges to the backing sheet, and including spaced elastic bands secured to one o said acing and backing sheets.
Various of the drawbacks and disadvantages of prior art diapers are overcome. Leakage is mi nimi zed by providing an auxiliary seal along the side edges of the pad, with the sealing sheet located beneath a comfortable, porous facing sheet and spaced inwardly from the side margins of the diaper. Positioning the seal on the side edges of the pad under the facing sheet pre-~2~7~04 vents it from coming in contact with the wearer's skin, thusavoiding chafing and irritation caused by contact of the plastic film typically used for the water impervious parts of a diaper.
The side margins of the absorbent pads are free to open or expand as they absorb the body fluids. Various absorbent materials having different absorbent properties can be employed with this seal con-struction. Examples are wood cellulose fibers and hydrocolloidal absorbent materials. The side seals also hold the pad in place so that it does not shift or disintegrate during use. This insures that the pad is positively positioned as intended, to maximize pro-tection.
~ , ..
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The absorbent pad assembly may have thicker margins spac~d apart by a thinner central area which will result in differential expansion of the margins to a greater degxee than the central area when becoming wet, which ~h~nces the seal against the baby's legs.
The thinner central area being more flexible will allow the diaper to conform better to various body shapes.
This combined with the thicker side margins under an expandable seal reduces to a m; n;m~lm the spill-over which occurs during flooding conditions.
The side seal stxips are desirably per~orated if they are wide to enable strike ~hrough o~ moisture through the water impervious sealing strip portions whi~h face ~he inan~ or user of the diaper. The per-forated water impervious strips will preven~ Gon~actof the hydrocolloidal material with the user's skin ~nd hence avoid the unpleasant feeling associated with con-tact or such materials. An intermedia~e saaling sheet may also be used whieh has per~oration~ at least in the crotch area. This sheet will allow fast strike thxough in the crotch area and allow wicking to the remainde~x of the absorbent pad under the sealing sheet where it cannot contact the skln of the wearer and become an irritant. Moisture trapped against the skin can cause irrita~ion.
The diaper and me~hQd of the in~antion can employ ~70 spaced water impervious ribbons upon which th~ absorbent pad is suppor~ed prior ~o assemb~y nf the facing o~ the backing sheets~ The pad and ribbons are sirnultaneously cu~ wit~ transverse cuts to fol~m the ,~
~z~ o~
foldable pad flaps. The ribbon and pad flaps are then folded with the ribbon forming the edge side seals. The ribbon is provided with adhesive prior to the cutting and folding operation. The folded~ adhesively secured ribbon also main~ains the folds of the absorbent pad.
Further objects and advantages of the inven-~ion will be apparent from the disclosure.
Description of the Drawin~s Fig. 1 is a plan view showing the method of 10 ~ki ng the diaper of the invention.
Fig. 2 is a side elevational view of the pro~
.edure in m~k;ng the diaper.
Fig. 3 is a sectional view along line 3--3 o~
~;1 ig r 1 ~
lS Fig. 4 is a view along line ~--4 of Fig. 1.
Fig. S is a view along line 5--5 o$ Fig. 1.
Fig. 6 is an enlarged perspective view with parts broken away o the diaper of the in~ention.
Fig. 7 is a perspective ~iew o a modified embodiment o the diaper.
Fig. 8 is a perspective view o~ a dîaper con-s~ruction in which the side seal ribbons are pesorated and ha~e incxeas~d absorbency zones under the si~e seal ribbons.
Fig. 9 is ~ sec~ional view of a diaper simi-lar ~ ~he diape~ shown in Fi~. 8 except the side seals are made of orla piece cons~ru~tion with an auxiliary pad in the cro~ch area.
Fig. 10 is a sectional view of a diaper con-struc~ion with a perforated sealing sheet which is ,., sealingly connected to the top and bottom sheets at the same general point along the margins.
Fig. 11 is a perspective view of the dia~er shown in Fig. 10.
Fig. 12 is a diaper construction of a diaper similar to that shown in Fig. 10 with the sealing sheet sealed to the backing sheet at a different poin~ o~
contact for a form ~it diaper.
Fig. 13 is a perspective view with portions removed of the diaper shown in Fig. 12.
Fig. 14 is a sectional view of a diaper con-struc~lon in which the sealing sheet is tuc~ed around beneath tne absorbent pad and side Inargins conta;ning at~Eiliary absorbent strips.
Fig. lS is a perspective view of the diaper cons~rucLion shown in Fig. 14.
Fig. 16 is a sectional view of a diaper con-struction in -~hich the backing sheet i5 olded over the facillg and sealing sheet~
Fig. 17 is a perspective view o~ the diaper cons~ruction shown in Fig, 16.
Fig. 18 is a sectional view of a d~aper con-~tru~tion having a one piece sealing sheet havin~ sides folded aro~md and over the top of the absorbent pad.
~S Fig. 19 is ~ diape~ construction simi l~r to Fig. 18 in which the folded over sides of thP sealing sheet are~perforated.
Fig. Z0 is a sectional Vi8W of a diaper con-s~ruction in which increas~d absorbent material is located under the side mar~ins of the sealin~ sheet.
12~7~04 Fig. 21 is a perspective view with parts re-moved of the diaper construction shown in Fig. 20.
Fig. 22 is a diaper construction of a diaper similar ~o Fig. 20, but o~ a foxm fit diaper.
Fig. 23 is a perspective view of the diaper construction shown in Fig. 22.
Fig. 24 is a diaper construction similar to the diaper shown in Figs. lO and 11 with increased thick~ess of absorbent material along the side margins in ~e crotch àrea.
Fig. 25 is a perspectiva view with parts removed of the diaper shown in Fig. 24, Fig. 26 shows a diaper cons~ructîon similar to the diaper in Fig. 12 with increased absorbent mater~al in the margins under the sealing sheat.
Fig. 27 is a perspective view with parts xe-moved of the dîaper construction shown in Fig. 2Ç.
Fig. 28 is an e~larged ~ragmen~ary sectional view of a diaper having ~he pad contAinin~ hydro~
colloidal material folded over under the side seal.
Fig. %9 is a view similar to Fig. 2~ with the pad expanded upon absorption of moisture.
Fig. 30 is a diagrammatic perspective view o~
a modified embodimen~ of the method of ~qk7n~ diapers wi~h ribbons which fonm ed~e seals.
Fig. 31 is a perspective view of a diapar made in accordance with the meth~d o~ Fig. 30~
Fig. 32 is a fragmen~ary perspec~ive view of a modified pad construction with a thin cen~ral we~
portion.
. .
12C~ 0~
Description of the Pra~erred EmbodimPnt Although ~he disclosure hereof is de~ailed and exaet to enable those skilled in ~he art to practice the invention9 the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
The diaper of the invention is best described by the me~hod of ~ki n~ one embodiment thereof.
Referring to Fig. 1, the initial step of forming the diaper involves providi~g absorbent pad material 10 and suppor~ing the pad 10 on continuous spa~ed water impervious plas~ic ribbons 12 and 14 supplied from parent rolls 15. As illustrated in Fig.
2, ~n adhesive is applied to the ribbons 12, 14 by ~he glu~ assembly 17 prior to application of the ribbons ~o the Fad. SubsequeIltly and s~nultaneously, t~e pad an~ part o~ the ribbons are cut by ~uts 20, 22~ 24 and 26 formed by a Ic~ife assembly 2~ which may conver~e or be at 90 to the machine dire~tion.
The cut por~ions of the pad and cut portions o the ribbons are olded over by conventional folding apparatus (no~ sho~) to for~n side seals for the diaper.
As illustrated ~n Fig. ~, the edges ~8 and 30 of the absorbent pad can be f~lded over upon the mid portion 32 o~ the pad to provide increased absorbency. ThP
olded over rlbbons 1~ and 14 are preferably ad~esively secured to the pad and backing to mainLain the folds and lock the pad in place to preven~ .he pad from shifting between the top and bottom sheets and pr~vent 12~7~04 - the pad from coming apart. Films having a high degree o~ cling characteristics will secure itself to a com-patible backing without ~he need of adhesives, some of these films being high cling polyethylene or poly-propylene, vinyldene chloride and various blends of ethylene vinyl acetate (EVA) resins, but not limited to these.
The folded over ribbons 12 and 14 may be ad-hesively secured to the pad, facing or b~ck;ng to ln further insure that the ~olds are maintained and the pad locked in place to prevent the pad from shi~ing between tha top and bottom shee~s and to preven~ the pad from disentegrating.
Sllbsequent to the folding over of the pad lS and ribbons, ~he pulp is CU~ o~f by a cut-of~ knife 39 and the top shPet 40 and the bot~om sheet 42 are applied to the folded pad ~Fig. ~). Adh~sive is applied to either the top or bottom sheet, or both~ by a glue ap-plicator, suc~ as applicator 443 to seal the ed~es of the ~op and bot~om shae~s and encapsula~e the pad. The top and bo~.tom sheets are then llotchad by a cutting assembly 45 so that ~hese shee~s are complementary in sh3pe ~o the pad. The term~ "plastic ribbons", "water impervious ribbons", "sealing strips'7 and "~ealing sheet" arP used interchangeabl~ in this application.
The ~op or bo~om she~t can be provided with spaced elastic ribbons 60, ~1 ~Fig~ ~) in the crotch area by a method described in my pa~ent, or any other technique. The elastic ribbons are adhesively applied prior to assembly of both the ~op and botrom sheets.
lZ07~0~
g After th~ top and bottom sheets are secured together, tabs ~re applied to complete the diaper.
Fig. 8 is illustrative of a diaper construc-tion in which the ribbons 112 and 114 have inturned sealing portions 116 and 118 which seal the side edges of the pad 111 in the crotch area to prevent leakage.
The ribbons 112, 114 have perforated ~ones 117 in the crotch area. Beneath the perforated zones 116 and 118 are incr~ased absorbency zon~s provided by either folded over sides 120 of the pad 111~ auxilia~y pads or a quantity of hydrocolloid material.
As used herein3 the term hydrocolloid material means any water insoluble hydrocolloid in any of its forms, whether i~ be a fiber, tape or powder or any substance tha~ yields gels with water. This would in-cl~lde but i~ not limited to the ~ollowing substances.
~a~ hydrolyzcd starch polyacrylonitrile eopdlymer H-span, Produrt 35-A~100, Grain Processing Corp., Muscatine, Iowa, disclosed in U.S. pata~t No. 3~6~1,815;
(b) Product No. XD-8587.0IL, whi~h is cross-linked, Dow Corning Chemical Co.~ Midland, Michigan; (c) Produrt No.
SGP 502S, General Mills Chemical, Inc. ~ Minneapolis, Minn~sota; ~d) Product No. 7~-3710~ ~ational Starch and Chemical Corp., New York, N.Y.; (e~ a hydrogel base product, Carbowaxs a Trademark o~ Union Carbide Coxp~, Charleston, West Virginia; ~f) ~ase-saponified starch-polyacrylonitrile and graft copolymers, Unite~ States D~partm2n~ of Agricul~ur2, Peoria, Illinois~ disclosed in U S. paten~ ~o. 3,4~5,971; ~g~ Aqualon C and Aqualon R wa~er insoluble sodium (arboxymethyl ceLlulose fibers . ~.
12(~7~0~
from Hexcules; (h~ absnrben~ starch ba~ed copolymer Sstarcn-acrylonitrile)9 No. 35-A-100 polymer from Grain Processing Co.rp.; and (i) polyacrylamide polymers, such as XD-7~43.01 from Dow Chemical are all suitable S and any of the wa~er insoluble absorbent polymers known as "super slurpers" in ~he trade.
These produc~s are satis~a~tory ~or high fluid retention in ~h~ crotch area while being sub-jected to the nor~al flexing and pressures resulting frorn movements of a wearer. Absorbent polymers are also available in a ~i~m form and printed on or be-tween two layers o~ abs~rbent tissue which can then be cut to shape and placed in ~he most ef~c~ive area~
such a~ inside the seals at ~he sides of the absorbent pad in the cro~ch area, othe- areas of the crotch area, or tha t~tal crotch area. Elastic ba~ds may be attached to the sides of the diaper in the ~ro~ch areaS at an increase in cost, to furthe~ in~ure con~inement o flooding to the absoxbents loca~ed in ~he crotch area.
Fluff-pulp, which is used in diapers~ has almost in-stantaneous uptakP rate o~ liquids~ because only a small percent o~ ~he. liquid is absorbed in the fiber, with the remai.nter being heLd in ~he intPrstic~s o~ ~he fiber in the pad. It îs extremely sensitive to pressure in that applied pressures squeeze ~luids from ~he pad and into body ~ontact whare it becomes an irritant~ Therefore, increasing the bulk. in the sides or the absorbent pad will h~lp instant.aneous a~sorption bu~ also subjects these sides ~o greater pres.sures and a greater squeezing action, causi.ng a grea~er amount of body f~uids to 12~0~L
escape from inside the edge seals. The use o an ab-sorbent polymer in the edge seal zones overcomes this problem. Sueh hydrocolloid materials have the capa-bility of absorbing many times their weigh~ in liquids and swell to form a gelatinous mass when wetted, and will ~ot releas~ this l quid when subjected to pressures from body movements~
Referring to Fig. 8, the sealing strips 112, 114 are preferably sealed to the backing sheet so that the inturned portions 116, 118 of ~he sealing s~rips lock the pad 111 against shifting be~waen the bottom or backing sheet 109 and the ~acing sheet 127 (Fig. 9).
The perforated zones 117 permit moisture penetration through the perforations or openings in these zones and allow tha hydrocolloid material to absorb the moisture. Tha perforated zones 117, how-ever, will prevent co~ nication of the hydrocolloid through the facing sheet which would provide a slip-pery and gelatinous feeLing which is uncom~ortable and undesirable. This undesirable feeling has been a drawback in the past in tha u~se of hydrocolloids ~n diapers.
Fig. 9 is a diaper construc~ion similar to Fig. 8. However, the inturned edge seal portions 116 and 118 are the side margins of the one piece sealing sheet 115 and are folded over an auxîliary pad 123.
Figs. 10 through 27 show various modified embodiments using ~nterme~ia~e sealing sheets in between the facing and backing shaets to assist in locking the pad in place and to provide edge seals to prevent leak-~z~
- age fro~ the sides of the absorbent pad and to provide an intermediate sealing sheet having perforations, slits or valvular openings~ or being foraminous, to prevent transfer of the hydrocolloid back through the facing sheet. Figs. lO and 11 show a rectangular diaper con-struction in which an intermediate water impervious sealing sheet 140 has a perforated zone 142 in at least the crotch area, as shown in Fig. ll, and the inter-mediate sheet is sealed either by heat sealing or glue along the margins 144 and 146 to both the ~acking sheet 150 and facing sheet 152. The sheet portions lSl pro-vlde the seals for the absorbent pad 154.
Figs. 12 and 13 show an intermediate water impervious sheet 1~0 with perfora~ions 152 in the ~5 crot~h area which is sealed alvng its la~eral edges a~ 158, 160 at a point inwardly f~om the side edges of the backing alld acing shPets, which are also sealed aL 144 and 146. This type o~ seal is appropriate for ~he form fitting diaper.
Figs. 14 and 15 show a diaper construction wi.th an intermedia~e sealing sheet 140 in which thP
lateral edges are folded around and tucked under the absorbent pa~ by folds 162 and 164 and sealed to the backing sheet intermediate the edges of the diaper at 166 and 168. Auxiliary pad strips 167 are provided.
In Figs. 16 arld 17j the intermediate sealing sheet 140 is sealed to both the facing and backing sh~ets. The backing sheet 150 has edges 171 and 173 whi~h are folded over the margins 175 of the facing sheet 152.
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Fig. 18 shows an intermediate sealing sheet 140 having folds 176, 178 folded around and over on the top of the pad 154. Fig. 19 is similar to Fig. 18, but the inturned ends 180 and 182 are perforated at 184 in the crotch area to permit strike through of fluid from the top sheet.
Figs. 20 ~hrough 29 show diaper constructions with increased pad thickness fonmed by either an extra pad or hydrocolloidal material at the margins of the diaper. When a hydrocolloid is used, swelling of this material when e~posed to moisture tightens the diaper against the body to enh~nçe the seal between the diaper and the body to prevent spiLl-over or loss of body ~I.uids.
In Figs. 20 and 21, an intermediate sealing sheet 14Q is wrapped around the absorbent pad 154.
Hydrocolloidal material 179 is located under thP flaps 176 and 178~ The diaper shown in Figs. 2~ and 23 is similar to that shown in Fig. 20, but is a form ~it~ing diaper. The flaps 176, 178 can be perforated in the crotch.
T~e ~iaper construction illustra~ed in Figs~
24 and 25 in~ludes a sealing ~heet 140 with a perforated zone 142 similar in construction to the dlaper show~
2S in ~igs. 10 and ll. Xowever, this diaper has increased thit~kness o~ absorbent material along the side margin~
177, 17$ at least in ~he crotch area.
The diaper o~ Figs, 26 and 27 has an aux-iliary pad in t;ne croteh area as well as the pad 111.
The cut por~ions of the pad and cut portions o the ribbons are olded over by conventional folding apparatus (no~ sho~) to for~n side seals for the diaper.
As illustrated ~n Fig. ~, the edges ~8 and 30 of the absorbent pad can be f~lded over upon the mid portion 32 o~ the pad to provide increased absorbency. ThP
olded over rlbbons 1~ and 14 are preferably ad~esively secured to the pad and backing to mainLain the folds and lock the pad in place to preven~ .he pad from shifting between the top and bottom sheets and pr~vent 12~7~04 - the pad from coming apart. Films having a high degree o~ cling characteristics will secure itself to a com-patible backing without ~he need of adhesives, some of these films being high cling polyethylene or poly-propylene, vinyldene chloride and various blends of ethylene vinyl acetate (EVA) resins, but not limited to these.
The folded over ribbons 12 and 14 may be ad-hesively secured to the pad, facing or b~ck;ng to ln further insure that the ~olds are maintained and the pad locked in place to prevent the pad from shi~ing between tha top and bottom shee~s and to preven~ the pad from disentegrating.
Sllbsequent to the folding over of the pad lS and ribbons, ~he pulp is CU~ o~f by a cut-of~ knife 39 and the top shPet 40 and the bot~om sheet 42 are applied to the folded pad ~Fig. ~). Adh~sive is applied to either the top or bottom sheet, or both~ by a glue ap-plicator, suc~ as applicator 443 to seal the ed~es of the ~op and bot~om shae~s and encapsula~e the pad. The top and bo~.tom sheets are then llotchad by a cutting assembly 45 so that ~hese shee~s are complementary in sh3pe ~o the pad. The term~ "plastic ribbons", "water impervious ribbons", "sealing strips'7 and "~ealing sheet" arP used interchangeabl~ in this application.
The ~op or bo~om she~t can be provided with spaced elastic ribbons 60, ~1 ~Fig~ ~) in the crotch area by a method described in my pa~ent, or any other technique. The elastic ribbons are adhesively applied prior to assembly of both the ~op and botrom sheets.
lZ07~0~
g After th~ top and bottom sheets are secured together, tabs ~re applied to complete the diaper.
Fig. 8 is illustrative of a diaper construc-tion in which the ribbons 112 and 114 have inturned sealing portions 116 and 118 which seal the side edges of the pad 111 in the crotch area to prevent leakage.
The ribbons 112, 114 have perforated ~ones 117 in the crotch area. Beneath the perforated zones 116 and 118 are incr~ased absorbency zon~s provided by either folded over sides 120 of the pad 111~ auxilia~y pads or a quantity of hydrocolloid material.
As used herein3 the term hydrocolloid material means any water insoluble hydrocolloid in any of its forms, whether i~ be a fiber, tape or powder or any substance tha~ yields gels with water. This would in-cl~lde but i~ not limited to the ~ollowing substances.
~a~ hydrolyzcd starch polyacrylonitrile eopdlymer H-span, Produrt 35-A~100, Grain Processing Corp., Muscatine, Iowa, disclosed in U.S. pata~t No. 3~6~1,815;
(b) Product No. XD-8587.0IL, whi~h is cross-linked, Dow Corning Chemical Co.~ Midland, Michigan; (c) Produrt No.
SGP 502S, General Mills Chemical, Inc. ~ Minneapolis, Minn~sota; ~d) Product No. 7~-3710~ ~ational Starch and Chemical Corp., New York, N.Y.; (e~ a hydrogel base product, Carbowaxs a Trademark o~ Union Carbide Coxp~, Charleston, West Virginia; ~f) ~ase-saponified starch-polyacrylonitrile and graft copolymers, Unite~ States D~partm2n~ of Agricul~ur2, Peoria, Illinois~ disclosed in U S. paten~ ~o. 3,4~5,971; ~g~ Aqualon C and Aqualon R wa~er insoluble sodium (arboxymethyl ceLlulose fibers . ~.
12(~7~0~
from Hexcules; (h~ absnrben~ starch ba~ed copolymer Sstarcn-acrylonitrile)9 No. 35-A-100 polymer from Grain Processing Co.rp.; and (i) polyacrylamide polymers, such as XD-7~43.01 from Dow Chemical are all suitable S and any of the wa~er insoluble absorbent polymers known as "super slurpers" in ~he trade.
These produc~s are satis~a~tory ~or high fluid retention in ~h~ crotch area while being sub-jected to the nor~al flexing and pressures resulting frorn movements of a wearer. Absorbent polymers are also available in a ~i~m form and printed on or be-tween two layers o~ abs~rbent tissue which can then be cut to shape and placed in ~he most ef~c~ive area~
such a~ inside the seals at ~he sides of the absorbent pad in the cro~ch area, othe- areas of the crotch area, or tha t~tal crotch area. Elastic ba~ds may be attached to the sides of the diaper in the ~ro~ch areaS at an increase in cost, to furthe~ in~ure con~inement o flooding to the absoxbents loca~ed in ~he crotch area.
Fluff-pulp, which is used in diapers~ has almost in-stantaneous uptakP rate o~ liquids~ because only a small percent o~ ~he. liquid is absorbed in the fiber, with the remai.nter being heLd in ~he intPrstic~s o~ ~he fiber in the pad. It îs extremely sensitive to pressure in that applied pressures squeeze ~luids from ~he pad and into body ~ontact whare it becomes an irritant~ Therefore, increasing the bulk. in the sides or the absorbent pad will h~lp instant.aneous a~sorption bu~ also subjects these sides ~o greater pres.sures and a greater squeezing action, causi.ng a grea~er amount of body f~uids to 12~0~L
escape from inside the edge seals. The use o an ab-sorbent polymer in the edge seal zones overcomes this problem. Sueh hydrocolloid materials have the capa-bility of absorbing many times their weigh~ in liquids and swell to form a gelatinous mass when wetted, and will ~ot releas~ this l quid when subjected to pressures from body movements~
Referring to Fig. 8, the sealing strips 112, 114 are preferably sealed to the backing sheet so that the inturned portions 116, 118 of ~he sealing s~rips lock the pad 111 against shifting be~waen the bottom or backing sheet 109 and the ~acing sheet 127 (Fig. 9).
The perforated zones 117 permit moisture penetration through the perforations or openings in these zones and allow tha hydrocolloid material to absorb the moisture. Tha perforated zones 117, how-ever, will prevent co~ nication of the hydrocolloid through the facing sheet which would provide a slip-pery and gelatinous feeLing which is uncom~ortable and undesirable. This undesirable feeling has been a drawback in the past in tha u~se of hydrocolloids ~n diapers.
Fig. 9 is a diaper construc~ion similar to Fig. 8. However, the inturned edge seal portions 116 and 118 are the side margins of the one piece sealing sheet 115 and are folded over an auxîliary pad 123.
Figs. 10 through 27 show various modified embodiments using ~nterme~ia~e sealing sheets in between the facing and backing shaets to assist in locking the pad in place and to provide edge seals to prevent leak-~z~
- age fro~ the sides of the absorbent pad and to provide an intermediate sealing sheet having perforations, slits or valvular openings~ or being foraminous, to prevent transfer of the hydrocolloid back through the facing sheet. Figs. lO and 11 show a rectangular diaper con-struction in which an intermediate water impervious sealing sheet 140 has a perforated zone 142 in at least the crotch area, as shown in Fig. ll, and the inter-mediate sheet is sealed either by heat sealing or glue along the margins 144 and 146 to both the ~acking sheet 150 and facing sheet 152. The sheet portions lSl pro-vlde the seals for the absorbent pad 154.
Figs. 12 and 13 show an intermediate water impervious sheet 1~0 with perfora~ions 152 in the ~5 crot~h area which is sealed alvng its la~eral edges a~ 158, 160 at a point inwardly f~om the side edges of the backing alld acing shPets, which are also sealed aL 144 and 146. This type o~ seal is appropriate for ~he form fitting diaper.
Figs. 14 and 15 show a diaper construction wi.th an intermedia~e sealing sheet 140 in which thP
lateral edges are folded around and tucked under the absorbent pa~ by folds 162 and 164 and sealed to the backing sheet intermediate the edges of the diaper at 166 and 168. Auxiliary pad strips 167 are provided.
In Figs. 16 arld 17j the intermediate sealing sheet 140 is sealed to both the facing and backing sh~ets. The backing sheet 150 has edges 171 and 173 whi~h are folded over the margins 175 of the facing sheet 152.
~207~0~
Fig. 18 shows an intermediate sealing sheet 140 having folds 176, 178 folded around and over on the top of the pad 154. Fig. 19 is similar to Fig. 18, but the inturned ends 180 and 182 are perforated at 184 in the crotch area to permit strike through of fluid from the top sheet.
Figs. 20 ~hrough 29 show diaper constructions with increased pad thickness fonmed by either an extra pad or hydrocolloidal material at the margins of the diaper. When a hydrocolloid is used, swelling of this material when e~posed to moisture tightens the diaper against the body to enh~nçe the seal between the diaper and the body to prevent spiLl-over or loss of body ~I.uids.
In Figs. 20 and 21, an intermediate sealing sheet 14Q is wrapped around the absorbent pad 154.
Hydrocolloidal material 179 is located under thP flaps 176 and 178~ The diaper shown in Figs. 2~ and 23 is similar to that shown in Fig. 20, but is a form ~it~ing diaper. The flaps 176, 178 can be perforated in the crotch.
T~e ~iaper construction illustra~ed in Figs~
24 and 25 in~ludes a sealing ~heet 140 with a perforated zone 142 similar in construction to the dlaper show~
2S in ~igs. 10 and ll. Xowever, this diaper has increased thit~kness o~ absorbent material along the side margin~
177, 17$ at least in ~he crotch area.
The diaper o~ Figs, 26 and 27 has an aux-iliary pad in t;ne croteh area as well as the pad 111.
3~ It also includes a perfarated sPaling shnet 140.
~207~04 Fig. 2~ shows the differential expansion of the pad 1~4 in comparison with Fig. 28 along the edges after being exposed to mois~ure as a resul~ or a larger quanti~y of hydrocolloid at the longitudinal m~rgins of the diaper rather than in the center of the diaper.
Fig. 30 bul~ pad material 200 is delivered to a cut-off knire assembly 202 by conveyor 204. Dis-creet lengths 206 of pad material are cut off by the cut-off assembly 202 and deli~ered to a pair of spaced ribbons 208 supplied from par~nt rolls 210. The backing sheet 212 is supplied ~rom a paren~ roll 214. After the pads 206 have been superimposed on the spaced ribbons 208, the ribbons are plow folded by plows 216 over the side e~ges of the pad 206~ as shown in Fig. 31, to provide edge seals. After ~he ribbons are ~olded, ~he top sheet ~30 is applied over the ribbons and pad and the ~iapers are subsequently cut~ from the wPb by a cut-off assembly 232. In ~his method~ the ribbons are the ~ull leng~h o~ the diapQr rather ~han the lnegth o~ the pulp or p~d as with ~he method illustrated in Fig. 1.
Fig. 32 illus~rates a pad construc~ion with a thin conformable web sectiol~ 300 with thicker side margins 302, 304. Th~ thin web section 300 collapses or "necks down" to enable the diaper to better conform ~o 2~ the body and mai~tain a close fit during body movements.
he thick side margins 302 and 304 can includs a greater concentration of hydrocolloidaL material than ~he central cro~ch area.
3~
~207~04 Fig. 2~ shows the differential expansion of the pad 1~4 in comparison with Fig. 28 along the edges after being exposed to mois~ure as a resul~ or a larger quanti~y of hydrocolloid at the longitudinal m~rgins of the diaper rather than in the center of the diaper.
Fig. 30 bul~ pad material 200 is delivered to a cut-off knire assembly 202 by conveyor 204. Dis-creet lengths 206 of pad material are cut off by the cut-off assembly 202 and deli~ered to a pair of spaced ribbons 208 supplied from par~nt rolls 210. The backing sheet 212 is supplied ~rom a paren~ roll 214. After the pads 206 have been superimposed on the spaced ribbons 208, the ribbons are plow folded by plows 216 over the side e~ges of the pad 206~ as shown in Fig. 31, to provide edge seals. After ~he ribbons are ~olded, ~he top sheet ~30 is applied over the ribbons and pad and the ~iapers are subsequently cut~ from the wPb by a cut-off assembly 232. In ~his method~ the ribbons are the ~ull leng~h o~ the diapQr rather ~han the lnegth o~ the pulp or p~d as with ~he method illustrated in Fig. 1.
Fig. 32 illus~rates a pad construc~ion with a thin conformable web sectiol~ 300 with thicker side margins 302, 304. Th~ thin web section 300 collapses or "necks down" to enable the diaper to better conform ~o 2~ the body and mai~tain a close fit during body movements.
he thick side margins 302 and 304 can includs a greater concentration of hydrocolloidaL material than ~he central cro~ch area.
3~
Claims (13)
1. A disposable diaper having a generally rectangular outline and having an intermediate portion of less width than the end portions to provide a form fitting diaper crotch portion, said diaper comprising a moisture impervious backing sheet, an absorbent pad on the backing, with the pad being folded over upon itself in the crotch area to be of a thickness greater than the thickness in the waistband portions to provide increased absorbency in the crotch area, moisture impermeable strips between said pad and said backing, said strips being folded over the absorbent pad in the crotch area to lock the pad against shifting, and a moisture permeable facing sheet having a shape generally complementary to the backing sheet and sealed along its edges to the backing sheet, and including spaced elastic bands secured to one of said facing and backing sheets.
2. The diaper in accordance with claim 1 wherein the absorbent pad contains a hydrocolloidal material.
3. The improvement of claim 2 wherein said hydrocolloidal material is concentrated under said side seals whereby expansion of said hydrocolloidal material upon moisture absorption expands the thickness of the side margins of the diaper to provide a fluid seal against the body of the user.
4. The improvement of claim 2 wherein said side seals have an upper margin and said upper margins are foraminous in zones above the increased thickness absorbent pad assembly.
5. The improvement of claim 2 wherein said side seals have an upper margin and said upper margins are foraminous zones above the thin central crotch area.
6. The improvement of claim 2 wherein the absorbent pad contains hydrocolloidal material under the moisture impermeable strips and said strips being perforated above said material to permit moisture to strike through but prevent transfer of hydrocolloidal material to the facing sheet.
7. A diaper in accordance with claim 1 wherein said moisture impermeable strips are secured to said facing sheet.
8. Diaper construction of claim 1 wherein the sealing strips are inturned sides of a one-piece sealing sheet, said sides being folded over the longitudinal edges of the absorbent pad assembly.
9. A diaper construction in accordance with claim 8 wherein said sealing sheet is foraminous in the crotch area.
10. The diaper construction of claim 1 in which the sealing strips are part of a sealing sheet wrapped over the pad and said side edges of the sealing sheet are wrapped beneath the pad in contact with the backing sheet and selected areas of sealing sheet above the pad being foraminous.
11. A diaper construction in accordance with claim 1 in which the moisture impermeable strips are part of a one-piece sealing sheet and the side margins of the sealing sheet extend laterally outwardly and are secured to the side margins of at least one of the backing and facing sheets.
12. The diaper constructions of claim 1 in which the central crotch area is more flexible and conformable than the thicker side margins.
13. The diaper construction of claim 12 in which the greater thickness of the side margins is provided by a greater concentration of hypercolloidal material in the side margins rather than in the central crotch area.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000437183A CA1207104A (en) | 1983-09-21 | 1983-09-21 | Form fit diaper with inside seal and thickened crotch and method of making the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000437183A CA1207104A (en) | 1983-09-21 | 1983-09-21 | Form fit diaper with inside seal and thickened crotch and method of making the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1207104A true CA1207104A (en) | 1986-07-08 |
Family
ID=4126126
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000437183A Expired CA1207104A (en) | 1983-09-21 | 1983-09-21 | Form fit diaper with inside seal and thickened crotch and method of making the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1207104A (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5217447A (en) * | 1989-07-17 | 1993-06-08 | Michael E. Fedryna | Diaper system with detachable linings |
| US5509915A (en) | 1991-09-11 | 1996-04-23 | Kimberly-Clark Corporation | Thin absorbent article having rapid uptake of liquid |
| US5618347A (en) * | 1995-04-14 | 1997-04-08 | Kimberly-Clark Corporation | Apparatus for spraying adhesive |
| US5683752A (en) * | 1992-12-16 | 1997-11-04 | Kimberly-Clark Worldwide, Inc. | Apparatus and methods for selectively controlling a spray of liquid to form a distinct pattern |
| US6037009A (en) * | 1995-04-14 | 2000-03-14 | Kimberly-Clark Worldwide, Inc. | Method for spraying adhesive |
-
1983
- 1983-09-21 CA CA000437183A patent/CA1207104A/en not_active Expired
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5217447A (en) * | 1989-07-17 | 1993-06-08 | Michael E. Fedryna | Diaper system with detachable linings |
| US5509915A (en) | 1991-09-11 | 1996-04-23 | Kimberly-Clark Corporation | Thin absorbent article having rapid uptake of liquid |
| US5683752A (en) * | 1992-12-16 | 1997-11-04 | Kimberly-Clark Worldwide, Inc. | Apparatus and methods for selectively controlling a spray of liquid to form a distinct pattern |
| US5618347A (en) * | 1995-04-14 | 1997-04-08 | Kimberly-Clark Corporation | Apparatus for spraying adhesive |
| US6037009A (en) * | 1995-04-14 | 2000-03-14 | Kimberly-Clark Worldwide, Inc. | Method for spraying adhesive |
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| MKEX | Expiry |