DE9321560U1 - Absorbent article - Google Patents

Description

The registration of the utility model *. to be based on, U &rgr; te da ge &eegr; "» \[·

DIEHL-GLAESER HILTL & PARTNER

CIVIL LAW COMPANY

Patent attorneys ■ Augustenstrasse 46 · D - 80333 Munich Dr. Hermann O. Th. Diehl ■ qualified physicist Joachim W. Glaeser ■ qualified engineer* Dr. Elmar HiItI ■ Graduate chemist
Dr. Thomas Leidescher · Graduate Biologist In cooperation with Diehl & Partner AG CH - 7513 Silvaplana · Switzerland

Patent Attorneys · European Patent Attorneys Munich ■ Hamburg*

25 June 1999 K6075-EN-U

Kimberly-Clark Worldwide, Inc. 401 North Lake Street

Neenah, Wisconsin 54956 USA

ABSORBENT ARTICLE

L-

Law firm ■ Office: Munich

M:\6075DEU2.DOC

Telephone -Telephone
(089) 17 86 36-0

Fax · Facsimile (089) 1 78 40 33 (089) 1 78 40 34

EMAIL address: info@diehl.ccn.de Address ■ Address
Augustenstrasse 46
D - 80333 Munich

Postal address ■ Mailing address RO. Box 34 0115 D-80098 Munich

K6075-EP

The present invention relates to an absorbent article.

Absorbent articles such as infant diapers, training pants, adult incontinence products and the like are well known. Such articles have gained wide acceptance due to their ability to absorb body exudates without leaking. In order to achieve a high level of leakage protection, it has become increasingly common to rely on systems in which numerous components work together. For example, in infant diapers, urine is generally absorbed by an absorbent core which comprises a matrix of wood pulp fluff and highly absorbent material. Such an absorbent core is known to be particularly well suited to absorbing and retaining urine within a diaper structure. Unfortunately, it is not always possible for the absorbent core to absorb and retain urine to the extent that it is released. It has therefore become common practice to resort to various mechanical containment means to retain urine within the diaper until it can be absorbed and retained by the absorbent core.

For example, U.S. Patent 3,860,003, issued to Buell on April 18, 1989, describes a diaper with elastic leg cuffs. The leg cuffs are intended to help contain body exudates. Similarly, U.S. Patent 4,762,521, issued to Roessler et al. on August 9, 1988, describes the use of waist elastics to achieve a tighter seal around the waist of a wearer. This also helps to mechanically contain body exudates.

As an approach to mechanically retaining body exudates, it is known to use dual mechanical retaining means along the long sides of a diaper. One such system is described in US Patent 4704116

which issued to Enloe on November 3, 1987. The inner flaps are said to be particularly well suited to retaining feces, while the outer leg cuffs are designed to mechanically retain urine. As shown in U.S. Patent 4,704,116, the inner containment flaps are folded inward and the respective ends are attached to the bodyside liner to form a pocket-like structure. Such a dual containment system has been found to be particularly well suited to mechanically retaining body excreta.

From EP-0243013 a disposable diaper is known which has a front region, a rear region and a crotch region. The diaper comprises a liquid-permeable bodyside liner, an outer cover and an absorbent core arranged therebetween.

Such a diaper is also known from document WO 93/09739, which is a document according to Article 54(3) EPC. From both documents diapers are known which have a pair of containment flaps which extend longitudinally from the front region to the rear region and which have a proximal and a distal edge. The proximal edge may be connected to the bodyside liner and the distal edge may be connected to the bodyside liner in the front and rear regions at a location which is further from a longitudinal centerline than the point at which the proximal edge is connected.

Document WO 93/09739 also discloses a pair of longitudinally extending elastic leg cuffs arranged in the crotch region at the opposite longitudinal side regions.

Internal containment flaps, which are folded inward as described above, are best for absorbent articles with

a relatively wide crotch area. Absorbent articles where the crotch area is narrow provide a better, less bulky fit between the wearer's legs. As the crotch of an absorbent article becomes narrower, conventional containment flaps which are folded inward tend to effectively overlap, reducing their effectiveness.

There is a desire to create internal containment flaps that are particularly well suited for use with absorbent articles with relatively narrow crotch widths.

The object of the present invention is therefore to provide an absorbent article with improved leakage protection. This object is achieved by the absorbent article according to independent claim 1. Further advantageous features, aspects and details of the invention emerge from the dependent claims, the description and the drawings.

The present invention relates to an absorbent article having dual barrier means. More particularly, the present invention relates to an absorbent article having leg cuffs and containment flaps.

According to one aspect of the present invention, there is provided an absorbent article having a front region, a rear region and a crotch region connecting the front and rear regions, the crotch region having opposite longitudinal side regions. The absorbent article has a liquid-permeable bodyside liner, an outer cover and an absorbent core disposed between the bodyside liner and the outer cover. A pair of elastic, longitudinally extending leg cuffs are disposed in the crotch region at its opposite longitudinal side regions. A pair of containment flaps are also provided. The containment flaps extend longitudinally from the front region to the rear

•Φ ·· ··

m*

region and have a proximal edge and a distal edge. The proximal edge is connected to the bodyside liner in the crotch region and in the front and back regions. The distal edge is connected to the bodyside liner in the front region and the back region at a position farther from a longitudinal centerline of the article than the location at which the proximal edge is connected to the bodyside liner. The distal edge is not connected to the bodyside liner in at least a region of the crotch region and may be elasticated at least in the crotch region. The distal edge of the containment flap is connected to the bodyside liner in the back region along a first length and in the front region along a second length, the second length being greater than the first length.

According to another embodiment, the present invention consists in an absorbent article having a front region, a rear region, and a crotch region connecting the front and rear regions, the crotch region having opposite longitudinal side regions. The absorbent article includes a liquid permeable bodyside liner, an outer cover, and an absorbent core disposed between the bodyside liner and the outer cover. A pair of elastic, longitudinally extending leg cuffs are disposed in the crotch region at opposite longitudinal side regions thereof. A pair of containment flaps are also provided. The containment flaps extend longitudinally from the front region to the rear region and have a proximal edge and a distal edge. The proximal edge is connected to the bodyside liner in the crotch region and in the front and rear regions. The distal edge is connected to the body-side lining in at least one of the regions selected from the front region or the rear region such that the shortest distance between the point at which the proximal edge is connected to the body-side

Lining and a location where the distal edge is connected to the bodyside liner is less than the distance between the proximal edge and the distal edge in the unfastened state, thereby forming a C-shaped fold in the containment flap. The distal edge is not connected to the bodyside liner in at least a portion of the crotch region and may be elasticated at least in the crotch region.

Figure 1 shows a plan view of a diaper construction suitable for use in forming the absorbent article of the present invention.

Fig. 2 shows a plan view of a diaper according to the present invention.

Fig. 3 is a cross-sectional view of the diaper shown in Fig. 2 taken along line 3-3.

Fig. 4 is a cross-sectional view of the diaper shown in Fig. 2 taken along line 4-4.

Fig. 5 is a plan view of a diaper according to the present invention.

Fig. 6 is a plan view of a diaper according to the present invention.

Fig. 7 is a cross-sectional view of the diaper shown in Fig. 6 taken along line 7-7.

Fig. 8 is a cross-sectional view of the diaper shown in Fig. 6 taken along line 8-8.

Fig. 9 is a plan view of a diaper according to the present invention.

Fig. 10 is a cross-sectional view of the diaper shown in Fig. 9 taken along line 10-10.

Fig. 11 is a cross-sectional view of the diaper shown in Fig. 9 taken along line 11-11.

Figure 12 is a cross-sectional view through the front region of a diaper according to the present invention showing an alternative containment flap arrangement.

Fig. 13 is a cross-sectional view through the crotch region of a diaper according to the present invention having the cross-section shown in Fig. 12.

"The present invention relates to absorbent articles designed to absorb body exudates. While the preferred embodiments of the present invention are described with reference to a disposable infant diaper to be worn by children around the lower torso, it is to be understood that the present invention is equally applicable to other absorbent articles, such as adult incontinence undergarments, training pants, feminine hygiene products, and the like. *** "

The present invention is best understood by reference to the drawings in which like reference numerals indicate like elements. Fig. 1 is a plan view of an absorbent article, i.e., a diaper, suitable for use in accordance with the present invention. Fig. 1 shows a diaper without dual barrier means. It is merely for illustrating the general construction of a diaper. Referring to Fig. 1, there is shown a diaper 10 having an outer cover 12, a bodyside liner 14, and an absorbent core 16 disposed between the bodyside liner 14 and the outer cover 12. The diaper 10 includes a front region 18, a rear region 20, and a crotch region 22 connecting the front region 18 and the rear region 20. Where reference is made herein to a front region, this means that part of the diaper which is generally located at the front of a child during use. Where reference is made to the

When reference is made to the rear area, this means the area of the garment which, in use, is located at the back of the child and a reference to the crotch area refers to the area which, in use, is generally located between the child's legs.

The crotch region 22 has opposite longitudinal side portions which include a pair of elastic, longitudinally extending leg cuffs 24. The leg cuffs 24 are generally designed to fit around the legs of a wearer in use and serve as a mechanical barrier to lateral leakage of body exudates. The leg cuffs 24 are provided with elasticity by leg elastics 26. The diaper 10 further includes ears 28 which can be placed around the waist of a wearer. The ears 28 include a first fastening means 30 which is adapted to fasten and hold the diaper 10 around the waist of a wearer. In the embodiment shown in Fig. 1, a first fastening means 30 comprises a mechanical fastener, such as the hook portion of a hook and loop fastening system. In the embodiment shown, the first fastening means 30 is releasably engageable with a second fastening means 32 which is arranged on an outer surface of the outer shell 12 of the front region 18. The second fastening means 32 expediently comprises a loop material which is engageable with the hook material of the first fastening means 30.

The bodyside liner 14 desirably has a body-facing surface that is compliant, soft to the touch, and non-irritating to the wearer's skin. In addition, the bodyside liner 14 may be made less hydrophilic than the absorbent core 16 to provide a relatively dry surface to the wearer, and is porous enough to be liquid permeable, allowing liquid to pass quickly through its thickness. A suitable bodyside liner

may be made from a wide variety of sheet materials such as porous foams, reticulated foams, perforated plastic films, natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers), or a combination of natural and synthetic fibers. The bodyside liner 14 conveniently serves to isolate the wearer's skin from fluids held in the absorbent core 16.

Various woven and nonwoven fabrics may be used for the bodyside liner 14. For example, the bodyside liner may be a meltblown or spunbonded web of polyolefin fibers. The bodyside liner may also be a bonded carded web composed of natural and/or synthetic fibers. The bodyside liner may be formed from a substantially hydrophobic material, which hydrophobic material may optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. In accordance with a specific embodiment of the present invention, the bodyside liner 14 comprises a spunbonded polypropylene nonwoven fabric composed of fibers having a fineness of about 0.31-0.36 tex (about 2.8-3.2 denier) formed into a web having a basis weight of about 22 g/m ² and a density of about 0.06 g/cm ³ . The fabric is surface treated with about 0.28% by weight of a surfactant available from Rohm and Haas Co. under the trade designation Triton X-102.

The outer cover 12 may conveniently be formed from a material that is either liquid permeable or liquid impermeable. In general, it is preferred that the outer cover 12 be formed from a material that is substantially liquid impermeable. For example, a typical outer cover may be formed from a thin

plastic film or other flexible liquid impermeable material. For example, the outer cover 12 may be formed from a polyethylene film having a thickness of about 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). If it is desired that the outer cover 12 have a more cloth-like feel, the outer cover 12 may comprise a polyethylene film having a nonwoven web, such as a spunbonded web of polyolefin fibers, laminated to the outer surface. For example, a polyethylene film having a thickness of about 0.015 mm (0.6 mil) may have laminated thereto a spunbond web of polyolefin fibers, the fibers having a thickness of about 0.16 to 0.28 tex (about 1.5 to 2.5 denier) per filament and the nonwoven web having a basis weight of about 24 g/m ² (0.7 ounces/yard ² ). Methods of forming such fabric-like outer shells are known to those skilled in the art.

The outer cover may also be formed from a woven or nonwoven fibrous web layer which is wholly or partially formed or treated to impart a desired degree of liquid impermeability to selected areas adjacent or near the absorbent core 16. The outer cover 12 may also optionally be formed from a microporous, "breathable" material which allows vapors to exit the absorbent core 16 while preventing liquid exudates from exiting through the outer cover 12.

The absorbent core 16 conveniently comprises a matrix of hydrophilic fibers, such as a web of cellulose fluff mixed with particles of a highly absorbent material commonly known as superabsorbent material. In a specific embodiment, the absorbent core 16 comprises a mixture of superabsorbent hydrogel-forming particles and cellulose fluff. Instead of the cellulose fluff, synthetic, polymeric, meltblown fibers or a combination of

meltblown fibers and natural fibers. The superabsorbent particles may be substantially homogeneous with the hydrophilic fibers or may be non-uniformly mixed with them. Alternatively, the absorbent core may comprise a laminate of fiber webs and superabsorbent material or other suitable means for retaining a superabsorbent material in a localized area.

The absorbent core 16 may have any shape. For example, the absorbent core may be rectangular, I-shaped, or T-shaped. It is generally preferred that the absorbent core be narrower in the crotch region than in the back or front regions.

The highly absorbent material may be selected from natural, synthetic and modified natural polymers and materials. The highly absorbent materials may be inorganic materials such as silica gel or organic compounds such as cross-linked polymers. The term "cross-linked" refers to any means which serves to effectively render normally water-soluble materials substantially water-insoluble but swellable. Such means may include, for example, physical entanglement, crystalline domains, covalent bonds, ionic complexes and associations, hydrophilic associations such as hydrogen bonding, and hydrophobic associations or van der Waals forces.

Examples of synthetic polymeric superabsorbent materials include the alkali metal and ammonium salts of polyacrylic acid and polymethacrylic acid, polyacrylamides, polyvinyl ethers, maleic anhydride copolymers with vinyl ethers and alpha-olefins, polyvinylpyrrolidone, polyvinylmorpholinone, polyvinyl alcohol, and blends and copolymers thereof. Other polymers suitable for use in the absorbent core include natural and modified natural polymers such as hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, methyl cellulose,

Carboxymethylcellulose, hydroxypropylcellulose, and natural gums such as alginates, xanthum gum, locust bean gum, and the like. Blends of natural and wholly or partially synthetic absorbent polymers may also be useful in the present invention. Other suitable absorbent gelling agents are disclosed by Assarson et al. in U.S. Patent No. 3,902,236, issued August 26, 1975. Methods for preparing synthetic absorbent gelling polymers are disclosed in U.S. Patent No. 4,076,663, issued February 28, 1978, to Masuda et al. and U.S. Patent No. 4,286,082, issued August 25, 1981, to Tsubakimoto et al.

The highly absorbent material may be in a wide variety of geometric shapes. Generally, it is preferred that the highly absorbent material be in the form of discrete particles. However, the highly absorbent material may also be in the form of fibers, flakes, rods, spheres, needles, and the like.

Generally, the highly absorbent material is present in the absorbent core in an amount of about 5 to about 100 percent by weight based on the total weight of the absorbent core.

The outer cover 12 and bodyside liner 14 are generally adhesively secured together to form a pocket in which the absorbent core 16 is disposed. The leg cuffs 24 are therefore conveniently formed from portions of the outer cover 12 and/or the bodyside liner 14 which extend beyond the long sides of the absorbent core 16. Of course, the leg cuffs 24 may also be formed from separate materials which are secured to the outer cover 12 and/or the bodyside liner 14.

The leg cuffs 24 have leg elastics 26. Materials suitable for forming the leg elastics 26 are known to those skilled in the art. Examples of such materials are strands or bands of a polymeric, elastomeric material which are attached to the diaper at the

Leg cuffs 24 may be attached in the stretched state or may be attached to the diaper while the diaper is folded such that elastic contracting forces are exerted on the leg cuffs 24.

Rear ears 28 are conveniently formed by the outer shell 12 and/or the bodyside liner 14. Fastening means for securing the diaper around the waist of a wearer are known to those skilled in the art. In the embodiment shown, the fastening means comprise a first fastening means 30 which is releasably attachable to a second fastening means 32. The first fastening means 30 conveniently comprises a hook material of a hook and loop fastener, while the second fastening means 32 comprises the loop portion of the hook and loop fastener. The loop portion of the hook and loop fastener is attached to the outer surface of the outer shell in the front region of the diaper.

A wide variety of other diaper designs, such as training pants, incontinence garments and similar configurations are suitable for use in accordance with the present invention. Diapers suitable for use in accordance with the present invention may include numerous other elements such as waist elastics, tab fasteners and the like. Diapers suitable for use in accordance with the present invention are further disclosed in commonly assigned EP-A-0532002 and EP-A-0539703, both of which claim priority to U.S. Patent Application Serial No. 07/757760 entitled "Thin Absorbent Article Having Rapid Uptake of Liquid."

Fig. 2 is a plan view of a diaper. It should be understood that the diaper shown in Fig. 2 has the same general configuration as the diaper shown in Fig. 1. A number of components of the diaper of Fig. 1 are not shown in Fig. 2 in order to aid in the understanding of the invention.

Referring to Fig. 2, the diaper 10 includes containment flaps 34 extending longitudinally from the front region 18 to the back region 20. The containment flaps 34 have a proximal edge 36 and a distal edge 38. The proximal edge 36 of each containment flap 34 is connected to the bodyside liner 14 at least in the crotch region. The junction between the proximal edge 36 and the bodyside liner 14 can be located inward or outward from the leg cuff 24. In the preferred embodiment shown, the junction between the proximal edge 36 and the bodyside liner 14 is located inward from the leg cuff 24. The term "inward" as used herein refers to a position located more toward the longitudinal centerline 60 of the diaper 10. Similarly, the term "outward" refers to a position further away from the longitudinal centerline 60.

The distal edge 38 of each containment flap 34 is connected to the bodyside liner in the front region 18 and the rear region 20 outward from where the proximal edge 36 is connected to the bodyside liner. The distal edge 38 is not connected to the bodyside liner 14 in at least a portion of the crotch region 22. The distal edges 38 of the containment flaps 34 are preferably provided with elasticity by flap elastics 40 in at least a portion of the crotch region 22, most preferably along the entire length of the distal edge 38.

In the embodiment shown in Fig. 2, each distal edge 38 is secured to the bodyside liner 14 in a front attachment region 42 and a rear attachment region 44. The attachment of the proximal edge 36 and the distal edge 38 of the containment flap 34 in the front attachment region 42 can best be understood by reference to Fig. 3, which

2 along line 3-3. FIG. 3 shows a fastener 46 provided in the front fastening region 42 which secures both the proximal edge 36 and the distal edge 38 of the containment flap 34 to the body side liner 14. In the embodiment shown, the fastener 46 may be an adhesive material such as a hot melt adhesive. Other fastening means such as ultrasonic bonding or thermal bonding may be used in accordance with the present invention.

By having the distal edge 38 of the containment flap 34 outward from where the proximal edge 36 of the containment flap 34 is attached to the bodyside liner, it is possible to produce a disposable diaper which has a containment flap which stands relatively upright in the crotch region 22 and yet can maintain its functionality in a disposable diaper having a relatively narrow crotch. In particular, since the diaper 10 has a relatively narrow crotch, the distance between the proximal edges 36 of the containment flap 34 in the crotch region 22 is relatively narrow. If the distal edges 38 of the containment flaps 34 were attached inward from the proximal edge at the full width W of the containment flap 34, the distal edges 38 of the containment flaps 34 would be very close to one another. In such a case, much of the benefit of the containment flaps 34 may be lost. If the distal edges 38 of the containment flaps 34 are positioned close together, body wastes may be discharged onto the top of the containment flaps rather than into the pocket defined by the containment flaps. That is, the pocket defined by the containment flaps may have such a narrow opening that it is difficult for body wastes to enter the area between the proximal edges of the containment flap. By attaching the distal edges 38 of the containment flaps 34 outward from the point at which the proximal edges 36 of the containment flaps 34 are attached to the bodyside liner 14,

the opening of the pocket formed by the retaining flaps corresponds substantially to the distance between the proximal edges 36 of the retaining flaps 34.

Fig. 4 is a cross-sectional view of the diaper shown in Fig. 2 taken along line 4-4. As shown with reference to Fig. 4, the containment flaps 34 are maintained in a relatively upright position in the crotch region 22.

5 shows a preferred embodiment of the present invention in which the front fastening region 42 extends a greater distance along the length of the containment flaps 34 than the rear fastening region 44. In particular, it is often preferred that the front fastening region 42 extend to or nearly to the crotch region 22. In this way, urine discharge is more likely to occur on the bodyside liner than on the outboard sides of the containment flaps 34. This is particularly important when the containment flaps 34 are made of a liquid impermeable material, as discussed in more detail below. At the same time, by keeping the rear fastening region 44 relatively small compared to the front fastening region 42, the distal edges of the containment flaps 34 are still maintained in a relatively upright position in the crotch region 22 and rear region 20 of the diaper 10. In this way, the containment flaps 34 serve to contain feces.

In the embodiment shown in Fig. 5, it is particularly preferred that the distal edge 38 of the retention flaps 34 is connected to the bodyside lining in the rear region along a first length and in the front region along a second length, the second length being greater than the first length.

It is preferred that the second length be at least about 25 percent greater than the first length, preferably at least about 50 percent greater than the first length, and most preferably

at least about 100 percent greater than the first length. In the embodiment shown in Fig. 5, the distal edge 38 of the containment flaps 34 is connected to the bodyside liner along its entire length in the front region, while the distal edge 38 of the containment flaps 34 is not connected to the bodyside liner along its entire length in the rear portion 20.

Figures 6, 7 and 8 show an alternative embodiment of the present invention. As can be seen from Figures 6-8, the containment flap 34 can be folded into a C-shape such that the distal edge 38 is connected to the bodyside liner in at least one region selected from the front region 18 or the back region 20 such that the shortest distance (D) between a point at which the proximal edge 36 is connected to the bodyside liner and a point at which the distal edge 38 is connected to the bodyside liner is less than the distance between the proximal edge 36 and the distal edge 38 when the containment flap is in a relaxed, unconnected state (referred to above as the width W of the containment flap 34). In this way, a C-shaped fold is formed in the containment flap 34. As can be seen from Fig. 7, the distal edge 38 is attached to the bodyside liner in the front and rear attachment regions 42 and 44 such that the distal edge 38 is located just inward of the proximal edge 36. The distance between the locations in the front attachment region 42 and/or the rear attachment region 44 where the distal edge 38 is attached to the bodyside liner and the locations in the proximal edge 36 is attached to the bodyside liner is less than the distance between the proximal edge and the distal edge when the containment flap 34 is in an unconnected expanded state. That is, in the front and/or rear attachment area, the distance between the location where the distal edge 38 is attached to the body side lining and the location where the proximal edge 36 is attached to

the bodyside liner is less than the width of the containment flap 34 before the containment flap is connected to the diaper 10. As can be seen from Fig. 8, the fastening means described above forms a containment flap which extends relatively upright in the crotch region 22.

In the embodiment shown in Figs. 6-8, the distal edge 38 is located inwardly of the proximal edge 36 in the attachment areas 42 and 44. It is of course possible to form a C-shaped retention flap such that the proximal edge 36 is located inwardly of the distal edge 38 in the attachment areas 42 and 44.

In the embodiment shown in Figures 6-8, the containment flaps 34 define a fold line 48. The fold line 48 is defined by securing the outboard side of the containment flap 34 to the bodyside liner 14 by means of the securing means 46. The containment flap 34 is then folded over itself such that the inboard side of the containment flap 34 is then secured to itself and/or the bodyside liner 14 by a C-fold securing means 50. The securing means 50 is suitably an adhesive composition, ultrasonic bonding, thermal bonding, or the like. The containment flap shown in Figure 7 is an inwardly directed C-fold. When the containment flap 34 is folded in a C-shape, it is desirable to have an approximately 20 to 100%, preferably approximately 30 to 100%, and more preferably 40 to 100% overlap of the areas of the containment flap that form the C-shaped fold in an attachment area. For example, if the containment flap is folded in a C-shape such that the proximal edge and the distal edge coincide in an attachment area, there is a 100% overlap. The percentage of overlap therefore refers to the portion of the width of the containment flap that covers another area of the

Width of the retaining flap in a fastening area.

Reference is now made to Figures 9, 10 and 11 which illustrate the embodiment in which an outwardly directed C-fold is formed. The shortest distance between the point at which the proximal edge 36 is connected to the bodyside liner 14 and a point at which the distal edge 38 is connected to the bodyside liner 14 is again less than the width of the containment flap when in the unattached condition. As can be seen by referring to Figure 10, the fold line 48 is formed by attaching the inwardly facing side of the containment flap 34 to the bodyside liner 14 by the attachment means 46 and by attaching the outwardly facing side of the containment flap 34 to itself and/or the bodyside liner 14 by the C-fold attaching means 50.

It will be understood that while in the embodiments shown in Figures 6-8 and 9-11 the distal edge 38 is shown adjacent the bodyside liner 14, it is also possible for the distal edge 38 to be located adjacent the containment flap 34 such that the distal edge 38 of the containment flap 34 is secured to the containment flap 34. Since the containment flap 34 is secured to the bodyside liner 14 when the distal edge 38 is secured to the containment flap 34, the containment flap 34 is indirectly secured to the bodyside liner 14. For this reason, according to the present application, attachment of the distal edge 38 to the containment flap 34 at a point where the containment flap 34 is attached to the bodyside liner 14 is considered to be attachment of the distal edge 38 to the bodyside liner 14.

Figures 12 and 13 show an embodiment in which the containment flap 34 includes a second set of elastic material. In particular, the fold line flap elastics 52 are shown as being located at the fold line 48 when the

Retention flaps 34 are formed in a C-shaped folded configuration. The fold line flap elastics 52 are particularly well suited for use when the retention flaps 34 have a relatively large width.

Flap elastics 40 and fold line flap elastics 52 conveniently comprise one or more individual strands of elastomeric material. For example, a plurality of elastic strands may be formed in a spaced, generally parallel arrangement, with a suitable elastic strand being made, for example, from a 470 decitex Lycra® elastomer. Flap elastics 40 and fold line flap elastics 52 are conveniently joined at the distal edge of containment flap 34 in an elastically contractible state such that contraction of the elastic components thereof contracts and shortens the distal edge 38 of containment flap 34. This results in the distal edge of each containment flap tending to assume a generally upright and approximately vertical configuration spaced from bodyside liner 14, particularly in the crotch region of the diaper. Flap elastics 40 and fold line flap elastics 52 may conveniently be made of the same or different materials and provide the same or different contracting forces. For example, the flap elastics 40 may be made of Lycra® having a fineness of 470 decitex,

while the fold line flap elastics are made of Lycra® with a fineness of 620 decitex.

The containment flaps 34 may be formed from a material corresponding to the material from which the bodyside liner 14 is made or from a different material. Similarly, the containment flaps may be formed integrally with the bodyside liner or may be formed separately from and connected to the bodyside liner. When reference is made herein to the containment flap 34 being connected to the

When referring to the containment flap 34 connected to the bodyside liner 14, it is intended to encompass both the situation where the containment flap 34 is formed separately from the bodyside liner and the situation where the containment flap is formed of the same material as the bodyside liner and integral therewith. The containment flap may be formed to be either liquid permeable or liquid impermeable. A liquid impermeable containment flap may be formed from a polymeric film material or from a nonwoven material which is treated to be substantially liquid impermeable.

Methods of forming the containment flaps are known to those skilled in the art. In the embodiments shown, the containment flaps are formed from a bilayer of material which is folded upon itself to enclose the flap elastics 40 and/or the fold line flap elastics 52 and joined together. It is understood that the containment flaps could be formed from a single layer of material with the flap elastics 40 and fold line flap elastics 52 attached thereto.

Methods for joining the containment flaps to the bodyside liner are known to those skilled in the art. Suitable methods include heat sealing, ultrasonic bonding, adhesive bonding, and the like. It is generally preferred that the containment flap be attached to the bodyside liner near the lateral edge of the absorbent core in the crotch region.

As mentioned above, the containment flaps of the present invention are particularly well suited for absorbent articles having a relatively narrow crotch region. In particular, the present invention is best suited for absorbent articles having a relatively narrow overall crotch width (width at the bodyside liner and/or outer cover) and employing an absorbent core having a relatively narrow crotch width. The absorbent article has

desirably has a total crotch width of less than about 17.8 cm (about 7 inches), desirably less than about 15.3 cm (about 6 inches), desirably less than about 12.7 cm (about 5 inches), and preferably less than about 8.9 cm (about 3.5 inches). The absorbent core desirably has a crotch width of less than about 10.2 cm (about 4 inches), desirably less than about 8.9 cm (about 3.5 inches), desirably less than 7.62 cm (3 inches), and preferably less than about 6.4 cm (about 2.5 inches). The containment flaps 34 of the present invention desirably have a width of about 1.3 to about 8.9 cm (about 0.5 to about 3.5 inches), preferably about 2.5 to about 5.1 cm (about 1 to about 2 inches). When the width of the containment flaps 34 is greater than about 3.8 cm (about 1.5 inches), it is most suitable for incorporating fold line flap elastics 52 as described above.

Alternatively, it is preferred that the width of the crotch region at its narrowest point be less than about five times, preferably less than about four times, and most preferably less than about three times the width of the containment flap. These are the situations where it is most important to keep the distal edges of the containment flaps as far apart as possible while maintaining the effectiveness of the containment flaps.

While the invention has been described in detail with reference to specific embodiments thereof, it is to be understood that modifications, variations and equivalents of these embodiments will become apparent to those skilled in the art after gaining an understanding of the foregoing. Accordingly, the scope of the present invention should be judged in accordance with the appended claims.

Claims (18)

1. An absorbent article having a front region ( 18 ), a rear region ( 20 ) and a crotch region ( 22 ) connecting the front and rear regions ( 18 , 20 ), the crotch region ( 22 ) having opposite longitudinal side regions, the article comprising:
a fluid-permeable, body-side lining ( 14 ),
an outer shell ( 12 ),
an absorbent core ( 16 ) arranged between the body-side lining ( 14 ) and the outer cover ( 12 ),
a pair of containment flaps ( 34 ) extending longitudinally from the front region ( 18 ) to the rear region ( 20 ) and having a proximal edge ( 36 ) and a distal edge ( 38 ), the proximal edge ( 36 ) being connected to the bodyside liner ( 14 ) and in the front and rear regions ( 18 , 20 ) and the distal edge ( 38 ) being connected to the bodyside liner ( 14 ) in the crotch region ( 22 ) and in the front region ( 18 ) and the rear region ( 20 ) at a position further from a longitudinal centerline ( 60 ) of the article than the point at which the proximal edge ( 36 ) is connected to the bodyside liner ( 14 ), the distal Edge ( 38 ) is not connected to the body side lining ( 14 ) in at least one region of the crotch region ( 22 );
the article includes:
a pair of elastic, longitudinally extending leg cuffs ( 24 ) arranged in the crotch region ( 22 ) on the opposite longitudinal side regions,
wherein the distal edge ( 38 ) of the containment flap ( 34 ) is connected to the bodyside liner ( 14 ) in the rear region ( 20 ) along a first length and in the front region ( 18 ) along a second length, the second length being greater than the first length. 2. The absorbent article of claim 1, wherein the proximal edge ( 36 ) with the bodyside liner ( 14 ) in the crotch region ( 22 ) is disposed inwardly of the leg cuffs ( 24 ). 3. Absorbent article according to claim 1 or 2, wherein the containment flap ( 34 ) is folded in a C-shape in the front region ( 18 ) and the rear region ( 20 ). 4. The absorbent article of claim 3 wherein the C-shaped fold is inwardly directed. 5. The absorbent article of claim 3 wherein the C-shaped fold is directed outward. 6. The absorbent article of claim 2, wherein the distal edge ( 38 ) is joined to the bodyside liner ( 14 ) in at least one region selected from the front region ( 18 ) or the back region ( 20 ) such that the shortest distance between a point where the proximal edge ( 36 ) is joined to the bodyside liner ( 14 ) and a point where the distal edge ( 38 ) is joined to the bodyside liner ( 14 ) is less than the width of the containment flap ( 34 ), thereby forming a C-shaped fold with regions of the containment flap ( 34 ). 7. The absorbent article of claim 1 wherein the crotch region ( 22 ) has an overall width of less than about 12.7 cm (about 5 inches) and the absorbent core ( 16 ) has a width in the crotch region ( 22 ) of less than about 7.6 cm (about 3 inches). 8. The absorbent article of claim 7 wherein the crotch region ( 22 ) has an overall width of less than about 8.9 cm (about 3.5 inches) and the absorbent core ( 16 ) has a width in the crotch region ( 22 ) of less than about 6.4 cm (about 2.5 inches). 9. An absorbent article according to any preceding claim, wherein the absorbent core ( 16 ) is narrower in the crotch region ( 22 ) than in the front or rear regions ( 18 , 20 ). 10. The absorbent article of any preceding claim wherein the second length is at least about 25 percent greater than the first length. 11. The absorbent article of claim 10, wherein the second length is at least about 50 percent greater than the first length. 12. An absorbent article according to any preceding claim, wherein the distal edge ( 38 ) is joined to the bodyside liner ( 14 ) along its entire length in the front region ( 18 ). 13. An absorbent article according to any preceding claim, wherein the distal edge ( 38 ) is joined to the bodyside liner ( 14 ) along less than its entire length in the rear region ( 20 ). 14. An absorbent article according to any preceding claim, wherein the distal edge ( 38 ) is elastic in at least a portion of the crotch region ( 22 ). 15. The absorbent article of claim 14 wherein the distal edge is elastic along its entire length. 16. An absorbent article according to any one of claims 3 to 15, wherein there is 20 to 100 percent, preferably 30 to 100 percent, more preferably 40 to 100 percent overlap of the regions of the containment flaps ( 34 ) forming the C-shaped fold. 17. An absorbent article according to any one of claims 6 to 16, wherein an inwardly directed C-shaped fold is formed. 18. An absorbent article according to any one of claims 6 to 16, wherein an outwardly directed C-shaped fold is formed.