MXPA00010789A - Disposable absorbent article having an improved topsheet - Google Patents

Abstract

The present invention is a disposable absorbent article having a topsheet, a backsheet joined to the topsheet, and an absorbent core positioned between the topsheet and the backsheet. The topsheet includes a backing and a sheet of fibers. The sheet of fibers have anchor portions in the backing at spaced bonding locations and have arcuate portions of the sheet projecting from the backing between bonding locations.

Description

DISPOSABLE ABSORBENT ARTICLE THAT HAS AN IMPROVED UPPER SHEET FIELD OF THE INVENTION The present invention relates to articles that absorb and / or contain body exudates, including diapers, adult incontinence products, sanitary napkins and the like. More particularly, the invention relates to disposable absorbent articles which have a capacity to retain fecal material of low viscosity away from the user's skin, in order to reduce leakage and make it easier to clean the user when the article is removed. disposable absorbent dirty.

BACKGROUND OF THE INVENTION Disposable absorbent articles such as diapers and adult incontinence products are well known in the art. These disposable absorbent articles collect and retain urine and fecal material deposited thereon by the user. To date, most attempts in the art to handle urine and collect fecal material and retain them in the disposable absorbent article have been directed to the management of urine. Dealing with the fecal material collected by the disposable absorbent article is simply more difficult than dealing with urine, due to the complex rheology of the fecal material. Exemplary of the prior art of urine handling are several attempts to provide disposable absorbent articles having a first top sheet facing towards and in contact with the wearer's body, and a secondary top sheet beneath the first top sheet, which either absorbs urine, or transfers the urine to an underlying core for storage until the user's disposable absorbent article is removed. Typically, the first top sheet and the second top sheet have different material properties. The secondary upper sheet may have a pore size smaller than the first upper sheet, to aid in the transfer of urine through the upper sheet. The first top sheet can be hydrophobic and more elastic when wet than the secondary top sheet, in order to pass the fluids through the first top sheet towards the secondary top sheet. In still another attempt in the prior art, the disposable absorbent article has a first topsheet, a topsheet and core. The secondary topsheet consists essentially of hydrophilic fibers blown in the molten state and have a pore size greater than the pore size of the core. This arrangement allegedly allows the secondary upper sheet to quickly receive multiple insults of liquids and distribute liquid in the X-Y plane before absorption by the core. In yet another attempt, the improved vertical capillary action capacity for urine has been allegedly achieved by using inflated cellulose fibers which are free of a surface finish or cross-linked with each other. In another attempt in the prior art, an absorbent core suitable for acquiring and containing liquids such as urine in an efficient and effective manner particularly comprises multiple layers. The first layer, which is closer to the wearer, comprises hydrophilic fibrous material and has an acquisition zone of relatively lower average density than other parts of this layer, in order to rapidly acquire the discharged liquids. Beneath the first layer is a liquid handling layer comprising a low density elastic material, with high void volume, which is insensitive to moisture in order to quickly acquire insults of liquid on itself through the acquisition zone. and distributing these liquids through the liquid handling layer to the storage layer. The storage layer comprises a combination of fibrous material and particles of discrete gelling absorbent material, and allows the liquid handling layer to be drained of the liquids it has acquired, such that the liquid handling layer can be enough to acquire and distribute subsequent liquid loads. Examples of these attempts in the prior art include U.S. Patent No. 4,047,531 issued September 13, 1977 to Karami.; U.S. Patent No. 4,798,603 issued January 17, 1989 to Meyer et al .; U.S. Patent No. 5,037,409 issued August 6, 1991 to Chen et al .; U.S. Patent No. 5,124,198 issued June 23, 1992 to Bemardin et al .; and United States Patent No. 5,134,007 issued July 28, 1992 to Reising et al. Of course, gelling absorbent materials are also well known in the art for their ability to handle urine. The gelling absorbent materials are polymeric materials capable of absorbing large quantities of fluids, such as urine, and retaining these absorbed fluids under moderate pressure. The effectiveness of the gelling absorbent materials is very dependent on the shape, placement and percent by weight of the gelling absorbent materials that are incorporated in the core of the disposable absorbent article. Recent attempts have been made in the art to provide gelling absorbent materials that have the ability to swell against pressure. These teachings claim to provide the advantage that the gelling absorbent materials absorb fluid under actual pressures exerted by the body during use.

Still other teachings in the art provide gelling absorbent materials that have a particular free swelling rate and absorbency under load. The alleged advantages of these gelling absorbent materials are smaller volume and mass with approximately the same absorbent capacity, the ability to rapidly absorb a liquid discharged under pressures typically encountered during use, and the ability to retain the liquid absorbed under pressures typically encountered during the use. Examples of these attempts in the prior art include U.S. Patent Nos. 5,147,343 issued September 15, 1992 to Kellenberger and 5,149,335 issued September 22, 1992 to Kellenberger et al. However, all of these attempts to handle the urine make it scarce, if anything, to improve the handling of the low viscosity faecal material that may also be present in the disposable absorbent article. Attempts to deal with fecal material include providing a first top sheet that closely conforms to the user and has an opening. The opening is successfully in register with the opening of the anus. In such a way that the fecal material passes through it to a hollow space. The first top sheet may comprise various elastic panels in order to conform snugly to the wearer's skin, and / or may have elastic linear yarns. Improvements have been made in this area of the prior art, such as by optimizing the material properties of the first top sheet. This optimization makes the first top sheet more comfortable for the user and allows a simple disposable absorbent article to fit a larger range of user sizes. Still other attempts have been made in this area of the prior art to provide an absorbent core with a hole therein, in order to receive the fecal material. The hole may be oblong in shape, so that it is longer and narrower than the opening in the first top sheet or it may be diamond-shaped. The hole in the core can be placed under an opening that has elastic strips around its edge. Improvements for this type of disposable absorbent articles of the prior art also include the addition of spacers. The spacers may be interposed between the first top sheet and the core, in order to ensure a hollow space that is present to receive the fecal material. Still other attempts have been made in this prior art genre to provide barriers that limit movement of the fecal material to particular parts of the disposable absorbent article. The barriers limit the contact of fecal material to particular parts of the disposable absorbent article. The barriers limit the contact of the fecal material to a smaller portion of the user's skin, than a comparable disposable absorbent article which has no barriers. Still other attempts in the prior art provide barrier cuffs for the leg that are erect from the plane of the topsheet. The barrier cuffs for the leg prevent the fecal material from breaching the perimeter of the disposable absorbent article. Examples of these attempts to handle fecal material include U.S. Patent No. 4,892,536 issued January 9, 1990 to DesMarais et al .; U.S. Patent No. 4,909,803 issued March 20, 1990 to Aziz et al .; U.S. Patent No. 4,968,312 issued November 6, 1990 to Khan; the commonly assigned U.S. Patent No. 4,990,147 issued February 5, 1991 to Freeland; the commonly assigned United States Patent No. 5,037,416 issued August 6, 1991 to Alien et al .; U.S. Patent No. 5,062,840 issued November 5, 1991 to Holt et al., the commonly assigned U.S. Patent No. 5,171,236 issued December 15, 1992 to Dreier et al.; and European patent application 0,355,740 A2 published on February 28, 1990 to Enloe. However, none of these attempts to handle fecal material solve the problem of low viscosity faecal material that is prevalent in younger children, particularly those who are breastfeeding. The low viscosity faecal material easily migrates into the disposable absorbent article under the influence of gravity and movement or pressure by the user. The migration of fecal material often moves towards the perimeter of the disposable absorbent article, increasing the probability of leakage. The migration of the fecal material also gets dirty against the user's skin, making cleaning more difficult. In order to clean the user, the caregiver should rub the entire area of the skin that has found the fecal material and typically has to deal with a relatively large stained area. An attempt in the art to handle low viscosity fecal material is found in U.S. Patent Application Serial No. 08 / 076,713 filed June 11, 1993 in the name of Roe. This application is a disposable absorbent article having a first top sheet with a penetration through the raised top sheet and covering a secondary top sheet having a penetration through the lower top sheet. Accordingly, it is an object of this invention to provide a disposable absorbent article with a topsheet that reduces leakage of fecal material from the disposable absorbent article and that minimizes the amount of low viscosity fecal material remaining on the wearer's skin. once the disposable absorbent article is removed. It is a further object of this invention to provide a disposable absorbent article with a top sheet that separates fecal material into the components.

BRIEF DESCRIPTION OF THE INVENTION The present invention is directed to a disposable absorbent article. The disposable absorbent article comprises a liquid pervious topsheet, a backsheet attached to the topsheet, and an absorbent core positioned between the topsheet and the backsheet. The upper sheet member comprises a backing and a fiber sheet. The fiber sheet has fastening portions in the backrest at separate bonding sites and has arched portions of the sheet projecting from the backing between the bonding sites.

BRIEF DESCRIPTION OF THE DRAWINGS Although the description concludes with the claims pointing out in a particular way and claiming differently the exposed matter that is considered as present invention, it is believed that the description will be better understood from the following descriptions that are taken in combination with the drawings that accompany, in which similar designations are used to designate substantially identical elements. Figure 1 is a plan view of an absorbent article embodiment of the present invention having portions cut away to reveal the underlying structure, the surface that gives the garment of the diaper to the observer. Figure 2 is a perspective illustration of a top sheet of the present invention. Figure 3 is a perspective illustration of a second embodiment of a top sheet of the present invention.

Figure 4 is a perspective illustration of a third embodiment of a top sheet of the present invention. Figure 5 is a perspective illustration of a fourth embodiment of a top sheet of the present invention. Figure 6 is a perspective illustration of a fifth embodiment of a top sheet of the present invention. Figure 7 is a plan view illustration of another embodiment of a topsheet of the present invention. Figure 8 is a plan view illustration of another embodiment of a top sheet of the present invention. Figure 9 is a schematic illustration of a method and equipment for making the topsheet of the present invention. Figure 10 is a schematic illustration of another embodiment of a method and equipment for making the topsheet of the present invention.

DETAILED DESCRIPTION OF THE INVENTION As used herein, the term "absorbent article" refers to devices that absorb and contain exudates from the body, and more specifically, refers to devices that are placed against or close to the wearer's body to absorb and contain the various exudates. discharged from the body. The term "disposable" is used herein to describe absorbent articles that are not generally intended to be washed or restored or otherwise reused as an absorbent article (ie, they are intended to be disposed of after a simple use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). (As used herein, the term "discarded" is used to imply that a diaper element or elements is formed (attached and placed) at a particular location or position as a unitary structure with other diaper elements or as an element As used herein, the term "attached" encompasses configurations by means of which one element is directly secured to another element by attaching the element directly to the other element, and configurations by means of which one element is indirectly secured to the other element by fixing the element to a member or intermediate members which in turn is attached to the other element.) A "unitary" absorbent article refers to the absorbent articles that are formed of separate parts joined or together to form a coordinated entity in such a way that they do not require separate manipulated parts such as a separate fastener and liner. A preferred embodiment of an absorbent article of the present invention is the unitary disposable absorbent article., diaper 20, shown in Figure 1. As used herein, the term "diaper" refers to an absorbent article generally worn by infants and incontinent persons around the lower torso. The present invention is also applicable to other absorbent articles such as incontinence briefs, incontinence undergarments, absorbent inserts, diaper liners and liners, feminine hygiene garments, and the like. Figure 1 is a plan view of the diaper 20 of the present invention in its flattened state with parts of the structure that are cut away to more clearly show the construction of the diaper 20. The part of the diaper 20 that is given to the wearer is oriented toward the observer. As shown in Figure 1, diaper 20 preferably comprises a liquid-permeable upper sheet 24, a liquid-impermeable back sheet 26.; an absorbent core 28, which is preferably positioned between at least a portion of the topsheet 24 and the backsheet 26; side panels 30; elasticated folds for the leg 32; a characteristic of elastic waist 34; and a generally designated fastening system 40. The diaper 20 is shown in Figure 1 to have a front waist region 36, a rear waist region 38 opposite the front waist region 36 and a crotch region 37 located between the front waist region 36. frontal waist region and the posterior waist region. The periphery of the diaper 20 is * defined by the outer edges of the diaper 20 in which the longitudinal edges 50 run generally parallel to the longitudinal center line 100 of the diaper 20 and the end edges 52 run between the longitudinal edges 50 generally parallel to the lateral center line 110 of the diaper 20 The chassis 22 of the diaper 20 comprises the main body of the diaper 20. chassis 22 comprises at least a portion of the absorbent core 28 and preferably • an outer cover layer including the top sheet 24 and the back sheet 26. If the absorbent article comprises a separate fastener and liner, the chassis 22 generally comprises the fastener and the liner. (For example, the fastener may comprise one or more layers of material to form the outer cover of the article and the The liner may comprise an absorbent assembly including a topsheet, a backsheet, and an absorbent core. In these cases, the fastener and / or liner may include a fastener that is used to hold the liner in place throughout the time of use.) For unitary absorbent articles, the chassis 22 comprises the main structure • of the diaper 20 with other additional features to form a diaper structure mixed. Although the topsheet 24, the backsheet 26, and the chassis 22 can be assembled in a variety of well-known configurations, preferred diaper configurations are generally described in U.S. Patent No. 3,860,003, U.S. Pat. United No. 5,151,092; and in U.S. Patent No. 5,221, 274. Other suitable diaper chassis designs are disclosed in the U.S. Patent No. 5,569,232; United States Patent No. ,554,144; U.S. Patent No. 5,554; U.S. Patent No. 5,554,145, U.S. Patent No. 5,556,394. The backsheet 26 is generally that part of the diaper 20 positioned adjacent the garment-facing surface 45 of the absorbent core 28, which prevents the exudates absorbed and contained therein from staining articles that may be in contact with the diaper. 20, such as sheets and undergarments. In preferred embodiments, the backsheet 26 is impervious to liquids (eg, urine) and comprises a thin plastic film such as a thermoplastic film having a thickness of about 0.012 mm to about 0.051 mm. Suitable backsheet films include those manufactured by Tredegar Industries Inc. of Terre Haute, IN and sold under the trade names X15306, X10962 and X10964. Other suitable materials of the backsheet may include breathable materials that allow the vapors of the diaper 20 to escape while still preventing the passage of the exudates through the backsheet 26. Exemplary respirable materials may include materials such as woven wefts, nonwoven webs, composite materials such as nonwoven webs coated with film, and microporous films as manufactured by Mitsui Toatsu Co., of Japan under the designation ESPOIR NO and by EXXON Chemical Co., of Bay City, TX, under the EXXAIRE designation. Suitable composite breathable materials comprising polymer blends are available from Clopay Corporation, Cincinnati, OH under the name HYTREL mix P18-3097. These composite respirable materials are described in greater detail in PCT Application No. WO 95/16746, published June 22, 1995 in the name of E.l. DuPont and the co-pending United States patent application Serial No. 08 / 744,487, filed on November 6, 1996 in the name of Curro. Other breathable backsheets include nonwoven webs and films formed with openings that are described in U.S. Patent No. 5,571,096 issued to Dobrin et al. On November 5, 1996. The back sheet 26, or any part thereof, may be elastically extensible in one or more directions. In one embodiment, the backsheet 26 may comprise a film web in the form of a structural elastic (SEF). A film web in the form of a structural elastic is an extensible material that exhibits an elastic-like behavior in the direction of elongation without the use of additional elastic materials. The SELF frame includes a tensable network that has at least two contiguous, distinct and different regions. Preferably, one of the regions is configured in such a way that it will exhibit resistance forces in response to an axial elongation applied in a direction parallel to the predetermined axis before a substantial portion of the other region develops significant resistance forces to the applied elongation. At least one of the regions has a surface path length that is greater than that of the other region as measured substantially parallel to the predetermined axis while the material is in an unstressed condition. The region exhibiting the greater surface path length includes one or more deformations extending beyond the plane of the other region. The SELF frame exhibits at least two significantly different stages of resistance strength controlled to elongation along at least one predetermined axis when subjected to an elongation applied in a direction parallel to the predetermined axis. The SELF web exhibits first applied elongation resistance forces until the elongation of the web is sufficient to cause a substantial part of the region having the largest surface path length between the plane of the applied elongation, thereby SELF screen exhibits second strength forces for additional elongation. The total forces of elongation resistance are greater than the first elongation resistance forces provided by the first region. SELF frames suitable for the present invention are more fully described in U.S. Patent No. 5,518,801. In alternative embodiments, the backsheet 26 may comprise elastomeric films, foams, yarns, or combinations of these or other suitable materials with nonwovens or synthetic films. The backsheet 26 can be attached to the topsheet 24, the absorbent core 28 or any other element of the diaper 20 by any means of attachment known in the art. For example, the joining means may include a continuous uniform adhesive layer, a patterned adhesive layer, or an array of separate lines, spirals or spots of adhesive. A preferred attachment means comprises a network of adhesive filaments in an open pattern as disclosed in U.S. Patent No. 4,573,986. Other suitable joining means include several lines of adhesive filaments which are twisted in a spiral pattern, as illustrated by the apparatus and methods shown in U.S. Patent No. 3,911,173.; U.S. Patent No. 4,785,996; and in the patent of the United States No. 4,842,666. The adhesives that have been found to be satisfactory are manufactured by H.B. Fuller Company of St. Paul, Minnesota and marketed as HL-1258. Alternatively, the joining means may comprise thermal joints, pressure joints, ultrasonic joints, mechanical dynamic joints, or any other suitable joining means or combinations of these joining means as are known in the art. The absorbent core 28 can comprise any absorbent material that is generally capable of compressing, capable of shaping, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids such as urine and other certain exudates from the body. The absorbent core 28 can be manufactured in a wide variety of sizes and shapes (eg, rectangular, hourglass, "T", asymmetric, etc.) and can comprise a wide variety of commonly used liquid absorbent materials in disposable diapers and other absorbent articles such as crushed wood pulp, which is usually by air felt. Examples of other suitable absorbent materials include creped cellulose wadding; polymers or extruded by melting and blowing, including coform; chemically hardened, modified or entangled cellulosic fibers, tissue, including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; gelling absorbent materials; or any other known absorbent material or combinations of materials. The configuration and construction of the absorbent core 28 can also be varied (for example, the core or absorbent cores or other absorbent structures or structures may have zones of variable gauge, a hydrophilic gradient, a superabsorbent gradient, or acquisition zones with average density. minor and average average base weight, or may comprise one or more layers or structures). However, the total absorbent capacity of the absorbent core 28 must be compatible with the load design and intended use of the diaper 20. Exemplary absorbent structures for use as the absorbent assemblies are described in U.S. Patent No. 4,610,678 , U.S. Patent No. 4,834,735; U.S. Patent No. 0 4,888,231; U.S. Patent No. 5,137,537; United States patent No. 5,147,345; and in U.S. Patent No. 5,342,338. Figure 2 illustrates a first embodiment of a topsheet according to the present invention, generally designated by the reference number 24. Generally, the topsheet 24 is a sheet of corrugated material 118 having a backing 120 preferably comprising a back-molded thermoplastic layer 122 (e.g., polypropylene) having front and rear major surfaces 123 and 124, and a multiplicity of longitudinally oriented fibers in a specially formed fiber sheet 126 having generally undeformed fastening portions 127 attached for being fixed to the backing layer 122 at separate, elongated, generally parallel bonding locations 128 that are continuous in a direction along the front surface 123 with arcuate portions 130 of the fiber sheet 126 projecting from the front surface 123 of the backing layer 122 between the junction locations 128 in continuous rows that also extend tra perpendicularly through the sheet of the corrugated material 118. The arcuate portions 130 of the fiber sheet 126 have a generally uniform height from the backing layer 122 of more than about 0.5 millimeters and preferably greater than 1.0 millimeters, the height of the sheet of formed fibers 126 is at least a third, and preferably a half of one and a half times the distance between the bonding sites 128, the individual fibers in the fiber sheet 126 are less than 25 denier (preferably within the range of 1 at 10 denier) in size, and the fiber sheet 126 without the backing has a basis weight in the range of 5 to 300 grams per square meter (and preferably in the range of 15 to 100 grams per square meter) measured along the first surface 123 to provide sufficient open area between the fibers in the fiber sheet 126 along the arcuate portions 130 (i.e., about 10 and 90 percent of open area) to provide for easy penetration of the fecal material into the individual fibers along the arcuate portions 130. Materials suitable for use as backing 120 include but are not limited to thermoplastic films, porous films, apertured films, formed films with openings, films formed without openings, nonwoven webs, breathable materials such as breathable films, including but not limited to microporous films, nonwoven webs with openings and the like. The backing 120 is preferably a relatively thin layer having a thickness in the range of about 0.00125 to 0.025 centimeters. The fibers in the fiber sheet 126 may be disposed in various directions with respect to the parallel joining locations 128 and may or may not be joined together at points passing over the arcuate portions 130; they can be arranged in various directions with respect to the parallel joining locations 128 with the majority of the fibers in the fiber sheet 126 (ie, above 80 or 90 percent) extending in directions at approximately a right angle with respect to junction locations 128; or all of the individual fibers in the fiber sheet 126 may extend in directions generally at right angles to the generally parallel spaced joint locations 128. The fiber sheet 126 preferably has a hydrophilic capacity that is less than the hydrophilic backing capacity. In a preferred embodiment, the fiber sheet itself has a hydrophilic capacity gradient wherein the arcuate portions 130 have a hydrophilic capacity that is less than the hydrophilic capacity of the linked locations 128. Even in this configuration, it is preferred that the locations attached 128 of the fiber sheet 126 have a hydrophilic capacity that is less than the hydrophilic capacity of the backing 120. The topsheet 24 is preferably secured to the underlying absorbent core 28. The topsheet 24 can be attached to the absorbent core 28 by any means of bond known in the art. For example, the attachment means may include a uniform, continuous adhesive layer, a patterned adhesive layer, or an array of separate lines, coils, or spots of adhesive. A preferred attachment means comprises a network of adhesive filaments, in open pattern, as disclosed in U.S. Patent No. 4,573,986. Another suitable attachment means includes several lines of adhesive filaments which are twisted in a spiral pattern, as illustrated by the apparatus and methods shown in U.S. Patent No. 3,911,173; U.S. Patent No. 4,785,996; and in U.S. Patent No. 4,842,666. Adhesives that have been found to be satisfactory are manufactured by H. B. Fuller Company of St. Paul, Minnesota, and marketed as HL-1258. Alternatively, the joining means may comprise heat bonds, pressure joints, ultrasonic joints, mechanical dynamic joints, or any other means of joining or combinations of these joining means as are known in the art. A particularly preferred binding means is an adhesive having a hydrophilic capacity that is greater than the hydrophilic capacity of the fiber sheet 126, more preferably a hydrophilic capacity which is also greater than the hydrophilic capacity of the backing 120. The topsheet 24 of the present invention is shown in Figure 1 extending along the total longitudinal dimension of the diaper 20. Alternatively, the topsheet 24 of the present invention can be used in only a portion of the diaper. For example, the upper sheet of the present invention can be placed in only the rear waist region 38 while using a conventional prior art topsheet in the crotch region 37 and the front waist region 36. In another example, the The top sheet of the present invention can be placed in the rear waist region 38 and in all or a portion of the crotch region 37 while a conventional top sheet of the prior art is used in the remaining portion of the diaper. By placing the upper sheet 24 at least in the rear waist region 38, the upper sheet 24 is aligned with the user's anus where it can be more effective in handling fecal material deposited on the diaper 20. To be very effective in the Fecal handling of low viscosity, the upper sheet must have a bulky open structure. A key component of this equation is the height of the arcuate portions 130 of the fiber sheet 126 from the backing 120. As mentioned above, the arcuate portions of the fiber sheet 126 have a generally uniform height from the backing 120. of more than about 0.5 millimeters and preferably greater than about 1.0 millimeters. While higher heights would provide excellent handling of low viscosity fecal material, for example, heights of 5.0 cm, these heights would create unwanted volume in the diaper which may cause discomfort to the wearer. The other key component is the elasticity of the upper sheet 24, more particularly the elasticity of the fiber sheet 126. In order to remain open, the fiber sheet 126 must have sufficient elasticity to withstand the packing forces and those applied by the user. Preferably, the fiber sheet 126 has an elasticity of at least 50% after 30 seconds under an applied force of 100 g / cm2, more preferably, the fiber sheet 126 has an elasticity of at least 75% after 30 seconds under an applied force of 100 g / cm2, most preferably, the fiber sheet 126 has an elasticity of minus 85% after 30 seconds under an applied force of 100 g / cm2. The holding portions 127 are preferably of such dimension that a flat circle having a diameter of about 0.2 millimeters to about 20 millimeters may be inscribed thereon, more preferably, the holding portions 127 are preferably of such dimension that they are it can inscribe therein a flat circle having a diameter of about 0.4 millimeters to about 10 millimeters, and most preferably, the holding portions 127 are preferably of such dimension that it can be inscribed therein in a flat circle having a diameter of approximately 0.8 mm to approximately 5 mm. Figure 3 illustrates a second embodiment of a topsheet according to the present invention, generally designated by the reference numeral 140, whose topsheet 140 has the same structure as the topsheet 24 (the same reference numerals being used with respect to to the corresponding portions thereof) except that the backing 145 of the sheet of the corrugated material 118 includes a second sheet of backing material 147, which second sheet of the backing material 147 adheres to the side 124 of the backing layer 122. opposite to the fiber sheet 126. The second sheet of backing material 147 in the backing 145 of the sheet of the corrugated material 118 can be a polymeric film. Other materials suitable for use as the second sheet of backing material 147 include but are not limited to porous films, films with openings, films formed with 0 openings, films formed without openings, non-woven wefts, breathable materials, such as breathable films, including but not limited to microporous films, nonwoven webs with openings and the like. The second sheet of backing material 147 is preferably a relatively thin layer having a thickness in the range of about 0.00125 to 0.025 centimeters. Figure 4 illustrates a third embodiment of the topsheet according to the present invention, generally designated by the reference numeral 150, whose top sheet 150 has the same structure as the topsheet 24 (the same reference numerals being used with with respect to the corresponding parts thereof) except that the back 155 of the corrugated sheet 118 includes a plurality of 0 fibers 157. The fibers 157 of the back 155 may be disposed in various directions with respect to the parallel junction locations 128 and may or may not be united together; they may be arranged in various directions with respect to the parallel joining locations 128 with the majority of the fibers in the backing 155 (ie, above 80 or 90 percent) extending in directions at approximately a right angle to the junction locations 128; or all of the individual fibers 157 in the backing 155 may extend in directions generally at right angles to the parallel spaced apart locations 128 generally. Preferably, the individual fibers 157 are not joined together and are separated from one another by a distance of about 0.01 mm to about 10.0 mm. The fibers 157 have a denier in the range of about 0-50. Figure 5 illustrates a fourth embodiment of the topsheet according to the present invention, generally designated by the reference numeral 160, whose top sheet 160 has the same structure as the top sheet 24 (the same reference numbers being used with respect to the corresponding parts thereof) except that the top sheet 160 includes a second sheet of corrugated material 162, whose second sheet of corrugated material 162 is adhered to the side 124 of the backing layer 122 opposite the fiber sheet 126. The second sheet of corrugated material 162 comprises a multiplicity of longitudinally oriented fibers in a specially formed fiber sheet 176 having a generally undeformed fastening portion 177 that is embedded in the backing layer 122 at elongate, spaced apart, generally parallel bonding sites 178 that are continuous in a direction along the surface 124 with the arcuate portions 180 of the fiber sheet 176 projecting from the surface 124 of the backing layer 122 between the bonding sites 178 in continuous rows that also extend transversely through the sheet of corrugated material 162. The arched portions 180 of the sheet fibers 176 have a generally uniform height from the backing layer of more than about 0. 5 millimeters and preferably greater than about 1.0 millimeters, the height of the formed fiber sheet 176 is at least one third, and preferably one half of one and a half times the distance between the bonding sites 178, the individual fibers in the sheet of fibers 176 are less than 25 denier (preferably within the range of 1 to 10 denier) in size, and the fiber sheet 176 without the backing has a basis weight in the range of 5 to 300 grams per square meter (and preferably in the range of 15 to 100 grams per square meter) measured along the first surface 124. In the embodiment shown in Figure 5, the attachment sites 128 and 178 are aligned with each other, i.e., the attachment site 128. placed directly above the joining site 178, causing the arcuate portions 130 and 180 to be in phase. The attachment sites 128 and 178 may also be positioned along the backrest 120 such that they are not aligned with one another causing the arcuate portions 130 and 180 to be out of phase. Figure 6 illustrates a fifth embodiment of the topsheet according to the present invention, generally designated by reference numeral 190, whose top sheet 190 has the same structure as the topsheet 24 (the same reference numerals being used with respect to to the corresponding parts thereof) except that the backing 195 of the corrugated material sheet 118 is a sheet of corrugated material 196 that is directly adhered to the corrugated material 118. The sheet of the corrugated material 196 comprises a multiplicity of longitudinally oriented fibers in a specially formed fiber sheet having a generally non-deformed fastening portion 197 joined by thermally bonded to the corrugated material 118 at elongated, spaced apart, generally parallel bonding sites 198, the arcuate portions 200 of the fiber sheet 196 projecting from the holding portions 197 in continuous rows that also extend transverse In the embodiment of Figure 6, the rows of the arcuate portions of the sheet of corrugated material 118 and 196 extend parallel to one another in the transverse direction. Alternatively, the rows of the arcuate portions of the corrugated sheet 118 and 196 may not be parallel. For example, the rows of the arcuate portions of the sheet of corrugated material 118 may extend in the transverse direction while the rows of arcuate portions of the sheet of corrugated material 196 extend at an angle with respect to the transverse direction. Figure 7 is a plan view of another embodiment of the topsheet 202 of the present invention. The topsheet 202 represents one of many or possible configurations for arranging the rows of the arcuate portions 203. Figure 8 is a plan view of another embodiment of the topsheet 204 of the present invention. The topsheet 204 represents one of many possible configurations for arranging the rows of the arcuate portions 205. In addition to the configurations shown in Figures 7 and 8, other possible configurations can also be used for the arrangement of the rows of the rows. arched portions. Figure 9 schematically illustrates a method and equipment for forming the topsheet 24. The method illustrated in Figure 9 generally comprises forming longitudinally oriented polymer fibers in a fiber sheet 126, forming the fiber sheet 126 in such a way that it have arcuate portions 130 projecting in the same direction from the generally separate parallel holding portions 127 of the fiber sheet 126, and joining the generally separate parallel holding portions. 127 of the fiber sheet 126 projecting from the front surface 123 of the backing 120. This method is performed by providing first and second corrugation members or rollers 226 and 227 each having an axis and including a plurality of circumferentially spaced ridges extending generally from axial way 228 around it and defining its periphery, with the shoulders 228 having external surfaces and defining spaces between the shoulders 228 adapted to receive portions of the shoulders 228 of the other corrugation member 226 or 227 in gear engagement with the fiber sheet 126 between the engaged bosses 228 and to produce the rolling engagement between the shoulders 228 and the spaces of the corrugation members in a manner of gear teeth . The corrugation members 226 and 227 are mounted in axially parallel relationship with portions of the shoulders 228 of the corrugation members 226 and 227 that mesh generally in the manner of gear teeth; at least one of the corrugated members 226 or 227 is rotated; and the fiber sheet 126 is fed between the engaged portions of the shoulders 228 of the corrugation members 226 and 227 to generally form the fiber sheet 126 to the periphery of the first corrugation member 226 and form the arcuate portions 130 of the sheet of fibers 127 in the spaces between the shoulders 228 of the first corrugation member 226 and the generally parallel fastening portions 127 of the fiber sheet 126 along the outer surfaces of the shoulders 228 on the first corrugation member 226. fiber sheet 226 formed is retained along the periphery of the first corrugation member 226 after it moves past the engaged portions of the shoulders 228. The backing thermoplastic layer 120 is formed and attached to the fastening portions 127 of the fiber sheet 126 on the end surfaces of the shoulders 228 in the first corrugation member 226 by extruding the backing thermoplastic layer 120 (e.g., polypropylene) in a molten state from a die 240 in a gripping space between the gripping portions 127 of the fiber sheet 126 on the periphery of the first corrugation member 226 and a cooling roller 250 after which the upper sheet 24 is separated from the first corrugation member 226 and is carried partially around the cooling roller 250 and through a gripping space between the cooling roller and a nip roller 260 to complete the cooling and solidification of the thermoplastic layer of resp aldo 120. The fiber sheet 126 fed between the meshed portions of the shoulders 228 of the corrugation members 226 and 227 may be in the form of yarns distributed such that the fibers in the fiber sheet 126 fed between the intermeshing bosses 228 of the corrugation members 226 and 227 are evenly distributed across the width of the fiber sheet 126 and all extend generally perpendicular to the axes of the corrugation members 226 and 227, or the fibers in the fiber sheet 126 may be disposed in random orientation as in a nonwoven web or sheet. Said non-woven sheet of randomly oriented fibers 126 or without internal bond except for the friction between the fibers can be formed from loose fibers using a carding machine 270 as illustrated, whose non-woven sheet of randomly oriented fibers 126 has sufficient integrity for to be fed from the carding machine 270 to the gripping space between the corrugation members 226 and 227 (if needed, a conveyor (not shown) can be provided to help support and guide the non-woven sheet of randomly oriented fibers 126 which is used, preferably the first corrugation member 226 has a rough finish (eg, formed by sanding with sand), the second corrugation member 227 has a smooth polished finish, and the first corrugation member 226 is heated to a temperature slightly above the temperature of the second corrugation member 5 226 in such a way that the non-woven fiber sheet 126 pe It will preferentially run along the surface of the first corrugation member 226 and be brought into the gripping space between the first corrugation member and the cooling roller 250 after passing through the gripping space between the corrugation members 226 and 227. The corrugated members 226 and 227 adapted to have said fiber sheet 126 fed thereto may have their shoulders 228 oriented generally in the range of 0 to 90 degrees with respect to their axes., but preferably have their shoulders 228 oriented at 0 degrees with respect to (or parallel to) their axes which simplify the processing of the corrugation members 226 and 227. Instead of extruding a solid thermoplastic sheet 120 from the die 240, it is it can extrude a plurality of fibers from a die to form a backing layer, such as the backing layer 255 illustrated in Figure 4.

Instead of extruding a thermoplastic material from a die such as die 240, a non-cast backing can be used. The roller 250 is then heated to thermally attach the backing to the fiber sheet. Figure 10 illustrates schematically another embodiment of a method and equipment according to the present invention for forming the topsheet 140, which method is generally the same and uses more of the same equipment as illustrated in Figure 9 (with similar portions of that equipment having the same reference numbers), except for the addition of means including a nip roll 340 to feed the sheet of the backing material 147 into the gripping space between the first corrugating roll 226 and the cooling roll 250 along the surface of the cooling roller 250, which results in an extruded molten backing thermoplastic layer 120 from the die 240 that is deposited between the fiber sheet 126 formed along the periphery of the first corrugation member 226 and the sheet of the backing material 120 along the surface of the cooling roll 250 such that the molten backing thermoplastic layer 120 wraps and adheres the holding portions 127 of the fiber sheet 126 to the sheet of the backing material 147 after which the top sheet 140 is separated from the first corrugation member 226 and is partially carried around the cooling roller 250 with its backing 145 against the cooling roller 250 to complete the cooling and solidification of its thermoplastic backing layer 120. The molten backing thermoplastic layer 120 can be extruded into the gripping space, onto the holding portions 127 of the fiber sheet in the first corrugation member 226 before the gripping space, or on the sheet of the backing material 147 along the periphery of the cooling roller just before the gripping space as it may work best for any given application. The cooling roller 250 can be cooled with water and have a periphery coated with a chromium layer which is particularly useful for forming the upper sheet 140 because of its high heat transfer rate as a cooling roller 250 produced from the back molten thermoplastic layer 120, through the sheet of the polymeric backing material 147 and in the cooling roller 250. Alternatively, the cooling roller 250 may have an outer layer of rubber defining its surface, which may be preferred to form the fecal management member 140 if the sheet of the backing material is of a material (eg, paper) that tends to restrict said heat transfer to the cooling roller 250, after which the rubber layer provides an alternative advantage of deforming adjacent to its gripping space with the first corrugation roll 226 to provide intimate contact of the thermoplastic layer backing sheet 120 with the holding portions 127 of the fiber sheet 126 and the sheet of the backing material 147. The sheet of the material of the backing material 147 incorporated in the backing 145 may be a woven, sewn, woven layer random, needle punched, non-woven or other solid or porous layer of interwoven fibers, or it can be a continuous polymeric film. Said film used for the sheet of the backing material 21 may be a simple layer of a polymeric material such as polypropylene, polyester, or polyamide; or may have a plurality of layers such as a core layer of a material with relatively high strength such as polyester, a layer defining the first surface of a material more readily bonded to the layer of the thermoplastic material 120 such as ethylene vinyl acetate or polyethylene, and a layer defining an external surface of the backing 147 adapted to adhere the backing to a substrate such as polyethylene or a bonding layer of non-tacky thermoplastic material at room temperature. The sheet of the backing material may also be a layer of pressure sensitive adhesive along a release liner disposed in such a way that the release liner is in contact with the cooling roller 250., resulting in the layer of the pressure sensitive adhesive that is disposed along the back surface of the layer of the thermoplastic material 120 with the release liner on the layer of the pressure sensitive adhesive and capable of being removed in such a way that the pressure sensitive adhesive can be used to adhere the top sheet to a substrate, Preferably, the drive mechanisms for the corrugation member 226 and 227 and for the cooling roll 250 are removably controllable in such a way that the cooling roller 250 it can be rotated at a surface speed that is the same as or different from the surface velocity of the first corrugation member 226. When the cooling roller 250 and the first corrugation member 226 are rotated such that they have the same surface velocity, the fiber sheet 126 will have approximately the same shape along the backing 120 as it did along the periphery of the prim Corrugated member 226 as illustrated in Figures 2 to 5. When rotating the cooling roller 250 and the first corrugation member 226 such that the cooling roller has a surface velocity that is less than the surface velocity of the first member of corrugated 226 the fastening portions 127 of the fiber sheet 126 will be moved closely together in the backing layer 120 in the gripping space between the cooling roller 250 and the first corrugation member 226, resulting in higher density of the corrugated portions 130 along the backing 120 when the cooling roll 250 and the first corrugation member 226 are rotated in such a way that they have the same surface velocity. This technique of increasing the amount of the corrugated portions 130 or the population of corrugations is useful both for making upper sheets having different corrugated portion numbers 130 per centimeter of back length using the same equipment, as for making upper sheets with larger portions. corrugations 130 per centimeter of back length that can be formed between the bosses 228 machined on the corrugation member 226 and 227 because of physical limitations in machining these ridges 228 closely together. The diaper 20 may also comprise at least one elastic waist feature 34 that helps provide improved notch and containment. The elastic waist feature 34 is generally intended to stretch and contract elastically to dynamically entangle the wearer's waist. The elastic waist feature 34 preferably extends at least longitudinally outwardly from at least one waist edge 62 of the absorbent core 28 and generally forms at least a portion of the end edge 52 of the diaper 20. Disposable diapers are often constructed to have two elastic waist features, one placed in the first waist region 36 and one positioned in the second waist region 38. In addition, although the elastic waist feature 34 or any of its constituent elements may comprise one or more separate elements fixed to the diaper 20, the elastic waist feature 34 can be constructed as an extension of other diaper elements 20, such as the back sheet 26, the top sheet 24, or both the back sheet 26 and the top sheet 24. The characteristic of Elastic waist 34 can be constructed in a number of different configurations including those described in the United States No. 4,515,595 issued to Kievit et al. on May 7, 1985; U.S. Patent No. 4,710,189 issued to Lash on December 1, 1987; patent of the United States No. 5,151, 092 issued to Buell on September 9, 1992; and in U.S. Patent No. 5,221, 274 issued to Buell on June 22, 1993. Other suitable waist configurations may include waist covering features such as those described in U.S. Patent No. 5,026,364. issued to Robertson on June 25, 1991 and the United States patent No. 4,816,025 issued to Foreman on March 28, 1989. All of the aforementioned references are incorporated herein by reference. The diaper 20 may also include a fastening system 40. The fastening system 40 preferably holds the first waist region 36 and the second waist region 38 in an overlapping configuration to provide lateral stresses around the circumference of the diaper 20 for retaining the diaper 20 in the user. The fastening system 40 preferably comprises tape tabs and / or hook and loop fastening components, although any other known fastening means is generally acceptable. Some exemplary fastening systems are disclosed in U.S. Patent No. 3,848,594 entitled "Tape Fastening System for Disposable diaper "issued to Buell on November 19, 1974, U.S. Patent No. B1 4,662,875 entitled" Absorbing Article "issued to Hirotsu et al. On May 5, 1987, U.S. Patent No. 4,846,815 entitled" Diaper " Disposable Having an Improved Fastening Device "issued to Scripps on July 11, 1989; United States Patent No. 4,894,060 entitled" Disposable Diaper with Portion Enhanced Hook Clamp "issued to Nestegard on January 16, 1990; United States Patent No. 4,946,527 entitled" Pressure Sensitive Adhesive Clamp and Method for Making the Same "issued to Battrell on August 7, 1990; hereinabove referred to U.S. Patent No. 5,151,092 issued to B on September 9, 1992, and U.S. Patent No. 5,221,274 issued to B on June 22, 1993. The fastening system may also provide a means to maintain the article in a disposal configuration as disclosed in United States Patent No. 4,963,140 issued to Robertson et al. On October 16, 1990. Each of these patents is incorporated herein by reference. The diaper 20 can also comprise side panels 30. The side panels 30 can be elastic or extensible to provide greater comfort and contour notch initially conformably fitting the diaper 20 to the wearer and holding this notch at all convenient time of use after the diaper 20 has been loaded with the exudates, since the side panels 30 allow the sides of the diaper 20 to contract and expand. The side panels 30 can also provide the most effective application of the diaper 20 because even if the diaper 20 pulls an elasticized side panel 30 farther than the other during the application, the diaper 20 will "self-adjust" during use. While the diaper 20 of the present invention preferably has the side panels 30 disposed in the second waist region 38, the diaper 20 may be provided with the side panels 30 disposed in the first waist region 36 or both of the first region. of waist 36 and second waist region 38. Side panels 30 may be constructed in any of the known configurations. Examples of diapers with elasticized side panels are disclosed in U.S. Patent No. 4,857,067 entitled "Disposable Diaper Having Frustrated Ears" issued to Woods et al. On August 15, 1989; patent of the States United No. 4,381, 781 issued to Sciaraffa et al. On May 3, 1983; U.S. Patent No. 4,938,753 issued to Van Gompel et al. on July 3, 1990; the above-referenced here patent of the United States No. 5,151,092 issued to B on September 9, 1992; and U.S. Patent No. 5,221, 274 issued to B on June 22, 1993; U.S. Patent No. 5,669,897 issued to LaVon et al. on September 23, 1997 entitled "Absorbent Articles that Provide Sustained Dynamic Adjustment"; U.S. Patent Application Serial No. 08 / 155,048 entitled "Absorbent Article with Extensible Side Panels in Multiple Directions", filed November 19, 1993 in the name of Robles et al .; each of which are incorporated herein by reference.

The diaper 20 preferably further comprises leg cuffs 32 which provide for improved containment of liquids and other exudates from the body. The leg bends can also be referred to as leg bands, fins, atera, es, do., Eces de b ^ t, or cec s alzeos. The footprint of No. 3,860,003 discloses a disposable diaper that provides a collapsible leg opening having a side flap and one or more elastic members that provide an elasticated leg fold (a fold of the leg). packing). U.S. Patent Nos. 4,808,178 and 4,909,803 issued to Aziz et al. On February 28, 1989 and March 20, 1990, respectively, describe disposable diapers having "upright" elastified fins (barrier folds) which improve the containment of leg regions. U.S. Patent Nos. 4,695,278 and 4,795,454 issued to Lawson on September 22, 1987 and to Dragoo on January 3, 1989; respectively, describe disposable diapers having double folds, including packing folds and barrier folds. The diaper embodiment 20 of the present invention can be applied to a user by placing one of the waist regions, preferably the rear waist region 38, below the user's back and pulling the rest of the diaper 20 between the user's legs. . The other waist region, preferably the front waist region 36, is positioned across the front of the wearer. The person placing the diaper then wraps the side panels 30 around the wearer such that the front waist region 36 and the rear waist region 38 are in an overlapping configuration. The side panels 30 will typically extend and tension during this operation to conform to the size and shape of the user. The fastening system 40 is secured to effect a lateral closure. Although the particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the invention. Therefore, attempts are made to protect all these changes and modifications within the scope of this invention in the appended claims.

Claims (19)

1. A disposable absorbent article comprising: a top sheet comprising a backing and a sheet of fibers, said sheet of fibers having arcuate portions in said backing at sites of spaced joints and having arcuate portions of the sheet projecting from the backing between the bonding sites , a back sheet attached to the top sheet; and an absorbent core placed between the top sheet and the back sheet.

2. The disposable absorbent article according to claim 1, wherein the backing comprises a plurality of fibers.

3. The disposable absorbent article according to claim 1, wherein the backing comprises a porous film.

4. The disposable absorbent article according to claim 1, wherein the backrest comprises a breathable material.

5. The disposable absorbent article according to claim 4, wherein the backrest comprises a breathable film.

6. The disposable absorbent article according to claim 1, wherein the backrest comprises a nonwoven web.

The disposable absorbent article according to claim 6, wherein the backrest comprises a nonwoven web with openings.

The disposable absorbent article according to claim 1, wherein the arcuate portions have a height from the back of at least 0.5 mm.

The disposable absorbent article according to claim 8, wherein the arcuate portions have a height from the back of at least 1.0 mm.

The disposable absorbent article according to claim 1, wherein the topsheet has an elasticity or resilience of at least 85% after 30 seconds under an applied force of 100 g / cm2.

The disposable absorbent article according to claim 1, further comprising a second backing attached to said backing opposite to the fiber sheet.

12. The disposable absorbent article according to claim 1, wherein the fiber sheet has a hydrophilic capacity that is less than the hydrophilic capacity of said backing.

The disposable absorbent article according to claim 1, wherein the arcuate portions have a dimension such that a planar circle having a diameter of about 0.2 mm to about 20 15 mm can be inscribed on them.

The disposable absorbent article according to claim 1, wherein the topsheet is secured to the absorbent core with an adhesive having a hydrophilic capacity that is greater than the hydrophilic capacity of the fiber sheet.

15. The disposable absorbent article according to claim 1, wherein the fibers are oriented in the longitudinal direction.

The disposable absorbent article according to claim 1, wherein the diaper has a back waist region and a front waist region, the top sheet being placed in at least the waist region 25 of the disposable absorbent article.

17. The disposable absorbent article according to claim 1, further comprising a second fiber sheet, the second fiber sheet having arcuate portions in said backing opposite the fiber sheet at separate bonding sites and having arched portions projecting from the backing between the binding sites.

18. The disposable absorbent article according to claim 1, wherein the backing is thermally bonded to the fiber sheet.

19. The disposable absorbent article according to claim 1, wherein the backrest comprises a sheet of corrugated material.