MXPA97000790A

MXPA97000790A - Absorbent article with elastified side panels connected by a member of pue

Info

Publication number: MXPA97000790A
Application number: MXPA/A/1997/000790A
Authority: MX
Inventors: Edsel Huntoon Andrew; Donald Fries Merlin; Arthur Peterson Dale; Ann O Rourke Kathleen; Beatrice Strohbeen Irene
Original assignee: Kimberleyclark Corporation
Priority date: 1994-08-03
Filing date: 1997-01-30
Publication date: 1997-06-01

Abstract

The present invention relates to an article is configured with a front section, a rear waistband section, and an intermediate section which interconnects the front and back waistband sections. The article includes a backing sheet layer having a width that extends laterally and an extension that extends longitudinally. A liquid-permeable upper sheet layer is overlaid on the backing sheet layer, and the upper sheet layer has a laterally extending width and a longitudinally extending extension. A body is located between the backing sheet layer and the top sheet layer. An elasticized side panel is connected to the article in each laterally opposite end region of at least one of the front and back waistband sections. The side panels are constructed to be elastically stretchable at least along a lateral transverse direction of the article. A bridge member which is spaced from the backsheet and top sheet layers, extends laterally to interconnect between the elasticized side panels and to maintain desired lateral spacing and alignment between the side panels. At least a part of the bridge member is arranged in an overlapping relationship with a longitudinal end section of the absorbent body, and is connected to at least one of the top sheet and backsheet layers. Mounting means are provided to secure the article to a user. The fastening means are connected to the laterally distant end regions of the side panels

Description

ABSORBENT ARTICLE WITH ELASTIFIED SIDE PANELS CONNECTED BY A BRIDGE MEMBER Field of invnción The present invention relates to an elasticized article. More particularly, the invention relates to an absorbent article having elasticized side panels connected to a bridge member to provide a composite bridge member which can be assembled more efficiently within the article, and can provide improved performance attributes.

Background of the Invention Conventional absorbent articles, such as disposable diapers, have been constructed with elasticised waistbands. The particular article designs have incorporated a stretchable outer cover composed of an elastomeric fabric material, such as a bonded and stretched laminate which includes a nonwoven fabric layer. Other conventional designs have included the elastomeric side panel members connected to the edges of lateral sides of a polymer film material. For example, see U.S. Patent No. 4,861,652 issued to Lippert et al .; U.S. Patent No. 4,701,170 issued October 20, 1987, issued to Wilson et al .; and U.S. Patent No. 5,019,073 issued May 28, 1991, issued to Roessler et al.

Conventional absorbent articles, such as those described above, have not been completely satisfactory when subjected to higher loads of liquids, such as urine. As a result of this, there continues to be a continuing need for absorbent articles that can provide improved comfort and notch, and increase drip resistance.

Brief Description of the Invention The present invention provides an absorbent article having a front waistband section, a rear waistband section and an intermediate section which interconnects the front and back waistband sections. The article includes a resilient sheet layer having a width that extends laterally and an extension that extends longitudinally. A liquid-permeable top sheet layer is placed over the backing sheet layer, and the top sheet layer has a laterally extending width and a longitudinally extending extension. An absorbent body is located between the backing sheet layer and the top sheet layer, and an elasticized side panel is connected to the article in each laterally opposite end region of at least one of the front and back waistband sections. . The side panels are constructed to be elastically stretchable at least along a transverse and lateral direction of the article. A bridge member, which is separated from the top sheet and backsheet layers, extends laterally to interconnect between the elasticized side panels. The bridge member is arranged in an overlapping relationship with a longitudinal end section of the absorbent body, and is connected to at least one of the backsheet and top sheet layers. Mounting means for securing the article to a user are connected to a laterally distant end region of at least one of the side panels.

Brief Description of the Drawings The invention will be better understood and the additional advantages will become apparent when reference is made to the following detailed description and the accompanying drawings in which: Figure 1 representatively shows a partially sectioned top view of an article of the invention having the bridge member positioned on a main front surface of a backing sheet layer of the article; Figure 2 representatively shows a cross-sectional, side and schematic view taken through section 2-2 of Figure 1; Figure 3 representatively shows a longitudinal and schematic cross-sectional view taken through section 3-3 of Figure 1; Figure 4 representatively shows a partially sectioned top view of an article of the invention having the bridge member generally located on one side of an outward facing surface of the top sheet layer in an arrangement which overlaps an end section longitudinal of an absorbent body of the article; Figure 5 representatively shows a schematic side cross-sectional view taken along section 5-5 of Figure 4; Figure 6 representatively shows a schematic longitudinal cross-sectional view taken through section 6-6 of Figure 4; Figure 7 representatively shows a partially sectioned top view of an article of the invention having a bridge member located generally on one side of a body side surface of the top sheet layer of the article; Figure 8 representatively shows a cross-sectional, side, and schematic view taken along section 8-8 of Figure 7; Figure 9 representatively shows a cross-sectional, longitudinal and schematic view taken through section 9-9 of Figure 7; Figure 10 representatively shows a partially sectioned top view of an article of the invention having the elastified containment fins and having the bridge member lying on the fins; Figure 11 representatively shows a cross-sectional, side and schematic view taken along section A-A of Figure 7; Figure 12 representatively shows a cross-sectional, longitudinal and schematic view taken through section B-B of Figure 7.

Detailed description of the invention The structures of the present invention are described herein in relation to their use in disposable absorbent articles, but it should be understood that the potential uses of the structures of the present invention do not require limitation to disposable absorbent articles. As used herein, the term "disposable absorbent article" refers to articles which absorb and contain exudates from the body and are intended to be disposable after a period of limited use. The articles are not intended to be washed or otherwise restored in order to be reused. The articles can be placed against or in proximity to the user's body to absorb and contain various exudates discharged from the body. While the present disclosure will be made particularly in the context of a disposable article, it should be understood that the present invention is also applicable to other disposable personal care absorbent articles, such as adult incontinence garments, sanitary napkins, breeches of training for children and similar.

With reference to Figures 1, 2 and 3, an absorbent article, such as diaper 10, has a lateral dimension in transverse direction 24 and a longitudinal dimension in the direction of length 26. Representative diaper 10, has the band section of front waist 12, a rear or rear waistband section 14, and an intermediate section 16 which interconnects the front and back waistband sections. The article includes a backing sheet layer 30 having a width extending laterally and an extension extending longitudinally. A porous and liquid permeable upper sheet layer 28 has a laterally extending width and a longitudinally extending extension, and is superimposed on the upper sheet layer 30. An absorbent structure, such as the absorbent body 32 e-sta located between the backing sheet layer 30 and the top sheet layer 28. An elasticized side panel 56 is connected to the article in each laterally opposite end region 72 and 74 of at least one of the front and back waistband sections. The side panels 56 are constructed to be elastically stretchable at least along a laterally extending transverse direction 24 of the article. A bridge member 40 which is separated from the backsheet and top sheet layers extends laterally along a transverse direction 24 to interconnect between the elastified side panels 56 and 58, and is constructed to maintain a desired lateral separation and alignment between the side panels. At least a portion of the bridge member 40 is arranged in an overlapping relationship with a longitudinal end section 60 of the absorbent body 32, and is connected to at least one of the backsheet and top sheet layers. Securing means, as provided by the tape appendage clips 36, are provided to secure the article to a user. The fastening means is connected to a laterally distant end region 76 and / or 78 of at least one of the side panels 56 and 58. In the illustrated embodiment, for example, a first tape tab fastener 36 is connected to the far end region 76 of the side panel 56, a second tape tab fastener is connected to the far end region 78 of the elasticized side panel 58.

Figure 1 is a representative plan view of the diaper 10 of the present invention in its non-contracted and planar state (for example, with all elastic-induced shrinkage and shrinkage removed). The parts of the structure are partially cut to more clearly show the interior construction of the diaper 10, and the surface of the diaper that contacts the wearer faces the observer. In the embodiment shown, the diaper 10 has a front waistband region 12, a rear waistband region 14, and an intermediate crotch region 16 which interconnects the front and back waistband regions. The outer edges of the diaper define a periphery 18 in which the longitudinally extending lateral edge margins are designated with the number 20 and the laterally extending end edge margins are designated with the number 22. The lateral edges define the edges of the diaphragm. leg openings for the diaper, and optionally curvilinear and contoured. The end edges are shown as straight, but optionally they can be curvilinear. The diaper additionally has a transversely extending side width dimension 24 and a longitudinal extension dimension 26.

The diaper 10 typically includes a topsheet permeable to the porous liquid 28; a backing sheet virtually impermeable to liquid 30; an absorbent structure 32, positioned between the upper sheet and the backing sheet; a part of emergence management 46; and the elastic members, such as the leg elastics 34 and the waist elastics 42. The emergence management part is placed in communication of the liquid with the absorbent structure, and the absorbent structure includes a retention portion 48. The sheet 28, the backing sheet 30, the absorbent structure 32, the emergence management part 46 and the elastic members 34 and 42 can be assembled in a variety of well-known diaper configurations. In addition, the diaper may include a containment fin system 62, and a side panel member system 56 and 58.

As shown representatively, the topsheet 28 and the backsheet 30 may be generally coextensive and may have length and width dimensions which are generally larger than the corresponding dimensions of the absorbent structure 32. The topsheet 28 is associated and imposed on the backing sheet 30, thereby defining the periphery 18 of the diaper 10. The periphery delimits the outer perimeter of the diaper 10, and in the embodiment illustrated, comprises the laterally marginal end edges 22, and the side edges longitudinally extending and contoured margins 20. The diaper 10 has the front and back waistband regions 12 and 14, respectively, extending from the laterally extending end edges 22 of the periphery of the diaper 18 toward the transverse centerline of the diaper over a distance of from about 2 percent to about 10 percent of the general length of the diaper 10. The waistband regions comprise those upper portions of the diaper 10, which when worn, cover or completely or partially surround the lower middle waist or torso of the wearer. The intermediate crotch region 16 lies between and interconnects the waistband regions 12 and 14, and comprises that portion of the diaper 10 which, when worn, is placed between the legs of the wearer and covers the lower torso of the wearer. Therefore, the crotch region 16 is an area where the emergence of repeated fluid in the diaper or other disposable absorbent article typically occurs.

The topsheet 28 represents a face-to-body surface which is docile, soft-feeling, and non-irritating to the wearer's skin. In addition, the topsheet 28 may be less hydrophilic than the retention portion 48, and sufficiently porous to be permeable to the liquid, allowing the liquid to penetrate through its thickness. The top sheet layer has the margin regions 94 and 96, and has the marginal end regions 108.

A suitable top sheet 28 can be made from a wide selection of fabric materials, such as porous foams, cross-linked foams, perforated plastic films, natural fibers (e.g., wood or cotton fibers), synthetic fibers (for example, polyester or polypropylene fibers) or a combination of natural and synthetic fibers. The topsheet 28 is typically employed to help isolate the wearer's skin from liquids maintained in the absorbent structure 32. Various woven and non-woven fabrics can be used for the topsheet 28. For example, the topsheet can be composed of a fabric formed by meltblown or bonded by spinning polyolefin fibers. The top sheet may also be a carded-bonded fabric composed of natural and / or synthetic fibers.

For the purposes of the present invention, the term "non-woven fabric" means a fabric of material which is formed without the aid of a textile weaving or weaving process. The term "fabrics" is used herein to refer to all woven, woven and non-woven fibrous tissues.

The top sheet fabrics can be composed of a virtually non-wettable and virtually hydrophobic material, and the hydrophobic material can optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. In a particular embodiment of the invention, the topsheet 28 can be a nonwoven woven polypropylene fabric composed of fibers of about 2.8-3.2 deniers formed into a fabric having a basis weight of about 22 grams per square meter and a density of about 0. 06 grams / cubic centimeter. The fabric can be treated on the surface with a selected amount of the surfactant, such as about 0.28 percent Triton X-102 surfactant. The surfactant can be applied through any conventional means, such as spraying, printing, brush coating or the like.

The surfactant material, such as the conventional wetting agent can be applied to a middle section of the top sheet layer 28 to provide a greater wettability of the middle section, compared to the remainder of the top layer 28. In particular configurations, the width in the transverse direction of the middle section can be virtually equal to or less than the width in the transverse direction of the emergence management part 46. In alternate configurations, the width of the middle section can be virtually equal to or less than spacing in the transverse direction between a pair of adhesive strips used to secure the containment fins 62 on the upper sheet 28 and to form a leak resistant barrier seal on the backing sheet 30.

The middle section treated with surfactant may be centered approximately with respect to the longitudinal center line of the diaper, and may extend along virtually the entire length of the top sheet layer. Alternatively, the middle section treated with surfactant can be constructed to extend along only a predetermined part of the length of the top sheet.

The various configurations of the invention may include the elasticized containment fins 62. The configurations shown, for example, include two containment fins 62 which are connected to the body-side surface of the top sheet layer 28. The constructions and Suitable arrangements for containment fins 62 are described, for example, in U.S. Patent No. 4,704,116 issued November 3, 1987, to K. Enloe, the disclosure of which is incorporated herein by reference in a manner that is consistent with it (not contradictory). Other configurations of containment fins 62 are described in U.S. Patent Application Serial No. 208,816 of R. Everett et al., Filed March 4, 1994 and entitled ABSORBENT ARTICLE HAVING IMPROVED EMERGENCY MANAGEMENT (Subject of Attorney No. 11,375), the disclosure of which is incorporated herein by reference in a manner that is consistent therewith.

Such containment fins can be attached to the upper sheet layer 28 along the fixed longitudinally extending fixed regions, such as the fixed edges 64, of the fins. A mobile edge 66 of each containment fin includes an elastic fin member 68 comprising one or more individual threads of elastomeric material. For example, a plurality of elastic yarns may be configured in a generally parallel and spatially separate array, and a suitable elastic yarn may, for example, be comprised of a Lycra elastomer of 470 decitex. The elastic member 68 is connected to the mobile edge of the containment flap in an elastically contractible condition so that the contraction of the elastic components thereof, folds and shortens the edge of the containment flap. As a result of this, the movable edge of each containment flap tends to be placed asymmetric, in a spaced relationship away from the side-to-body surfaces of the topsheet 28 and / or of the emergence management part 46 toward a generally vertical and approximately perpendicular configuration, especially the crotch section of the diaper. In the embodiment shown, for example, the movable edge of the barrier flap is connected to the flap elastics by partially folding the flap material back onto itself for a limited amount which is sufficient to enclose the flap elastics. 68 At least one pair of barrier or containment fins 62 are connected to the laterally opposite and longitudinally extending regions of the upper sheet layer 28, and the connected upper sheet regions are generally located at one side of the regions of the upper sheet 28. edge of the laterally opposite side of the midsection of the top sheet layer 28. The connected top sheet regions are also located virtually laterally inwardly from the elasticized side margins of the diaper article 10.

The containment fins can, for example, be constructed of a fibrous material which is similar to the material comprising the top sheet 28, or similar to the material comprising the emergence management part 46. Other conventional materials can also be used, such as polymer films. In other aspects of the invention, the barrier fins 62 are constructed of a material which is permeable to gas, such as ambient air. The alternate configurations of the invention may include the barrier fins which are constructed of a material which is resistant to the passage of an aqueous liquid, such as urine, therethrough. For example, the barrier fins 62 may be constructed of a melt-spunbond (SMS) spin-melt-bonded laminate. In the illustrated embodiment, for example, the barrier fins can be constructed of an SMS material having a basis weight of about 0.85 ounces per square yard (about 28 grams per square meter). The yarn-bonded layers are composed of polypropylene fibers, and the melt-blown layer is composed of polypropylene fibers formed by meltblowing.

In the various configurations of the invention, such as where the barrier fins 62 are configured to be gas permeable while having a limited resistance and permeability to the aqueous liquid, the liquid resistant material can have a construction which is capable of support a hydro head of at least about 45 centimeters of water with virtually no runoff through it. A suitable technique for determining the resistance of a material to liquid penetration is method 5514 of the Federal Standard FTMS 191 test method, dated December 31, 1968.

With reference to Figure 2, each of the barrier fins 62 may include a laterally extending base section 116 thereof with at least a portion of the base section fastened to the upper sheet layer 28 in a upper leaf securing section 118, which is located laterally outward of the retention portion 48 and laterally outside of the emergence management portion 46. The upper sheet securing section 118 of the topsheet layer 28 is operably sealed to the sheet layer backing 30 to prevent or virtually block a liquid from trickling through the securing section 118. The securing section can be constructed by employing various conventional techniques, such as adhesive bonding, thermal bonding, sonic bonding, stitched, stapled or similar. The illustrated embodiment, for example, is configured with the top sheet securing section 118 sealed to the backing sheet layer 30 with a virtually continuous adhesive strip or score 120 composed of a pressure sensitive hot melt adhesive.

The adhesive strip can advantageously provide a barrier count which extends generally in the longitudinal direction of the diaper, and at least a portion of the barrier count is located in the crotch region of the diaper 16. The crotch portion of the The barrier bill may be constructed to operably join and virtually seal the corresponding portion of the securing section 118 of the topsheet layer 28 to both the fin base section 116 and the backsheet layer 30 by effectively "bleeding" through the top sheet layer 28 to make an operable contact with the backing sheet layer. When a virtually continuous seal is provided, the liquid can be more effectively contained between the two fins 62. The representative adhesive strip 120 is cleaned or otherwise applied over the designated section of the base of the fin 116 in a position which interposed the strip between the terminal lateral edge of tissue wrap 70 and the leg elastic carrier sheet. The additional pressure can be applied to the adhesive strip area to help secure a desired seal.

At least a portion of the base section can be attached to the top sheet layer 28 along a top sheet seam section located along the fixed edge 64 of the containment flap. Suitable connecting means, such as a virtually continuous adhesive bead, operably secure the fixed barrier fin edge to the upper sheet seam section.

The backing sheet 30 may be composed of a liquid-permeable material, but preferably, it comprises the material which is configured to be virtually impervious to liquids. For example, a typical backing sheet can be made of a thin plastic film, or another material impervious to flexible liquid. As used in the present description, the term "flexible" refers to materials which are docile and which will readily conform to the shape and general contours of the user's body. The backsheet 30 can help to prevent the exudates contained in the absorbent structure 32 from wetting articles such as bed sheets and outer garments that contact the diaper 10.

In the particular embodiments of the invention, the backing sheet 30 is a polyethylene film having a thickness of from about 0.012 millimeters (0.5 mil) to about 0.051 millimeters (2.0 mils). In the embodiment shown, the backing sheet is a film having a thickness of about 1.25 mil. The alternate constructions of the backsheet may comprise a woven or non-woven fibrous fabric layer which has been constructed or treated in whole or in part to impart the desired levels of liquid impermeability to the selected regions that are adjacent to or close to the absorbent body. . The backsheet 30 typically provides the outer cover of the article. Optionally, however, the article may comprise a separate outer cover member which is in addition to the backing sheet.

The backsheet 30 can optionally be comprised of a "breathable" microporous material which allows the vapors to escape from the absorbent structure 32 while still preventing the exudates of the liquid from passing through the backing sheet. For example, the breathable backing sheet may be composed of a microporous polymer film or a nonwoven fabric which has been coated or otherwise treated to impart a desired level of liquid impermeability. For example, a suitable microporous film is a PMP-1 material which is available from Mitsui Toatsu Chemicals, Inc., a company having offices in Tokyo, Japan or a polyolefin film XKO-8044 available from 3M Company of Minneapolis, Minnesota. The backing sheet may also be engraved or otherwise provided with a matte finish to exhibit a more aesthetically pleasing appearance.

The size of the backsheet 30 is typically determined by the size of the absorbent structure 32 and the exact diaper design selected. The backing sheet 30, for example, may have a T-shape generally, an I-shape generally or a modified hourglass shape, and may extend beyond the end edges of the absorbent structure 32 by a selected distance, such as a distance within the range of about 1.3 centimeters to 2.5 centimeters (about 0.5 to 1.0 inches), to provide lateral margins.

The topsheet 28 and the backsheet 30 are connected or otherwise associated together in an operable manner. As used herein, the term "associated" encompasses configurations in which the topsheet 28 is directly attached to the backsheet 30 by attaching the topsheet 28 directly to the backsheet 30, and the configurations wherein the sheet upper 28 is attached to the backing sheet 30 by attaching the backing sheet 28 to intermediate members which in turn are fixed to the backing sheet 30. The top sheet 28 and the backing sheet 30 can be directly attached to each other. another on the periphery of the diaper 18 by the fastening means (not shown) such as an adhesive, sonic joints, thermal joints or any other fastening means known in the art. For example, a uniform continuous layer of adhesive, an adhesive pattern layer, an adhesive spray pattern, or an array of separate lines, swirls, or patches of adhesive construction can be used to secure the top sheet 28 to the backing sheet 30 .

It should be readily appreciated that the fastening means described above can also be used to interconnect and assemble together the various other component parts of the article described herein.

In the representatively shown embodiment of the invention, the top sheet layer 28 is positioned and secured in a front relationship with the backing sheet layer 30 to retain and hold the retention portion 48 and the emergence management portion 46 between the backing sheet. layer of back sheet and top sheet layer. The marginal side regions of the top sheet layer 28 are operably connected to the corresponding marginal side regions of the backsheet layer 30. Each of the marginal side regions fastened to the top sheet and backsheet layers are located laterally outside its corresponding associated side edge region of the emergence management part 46. In the particular configurations of the invention, the marginal regions attached to the topsheet 28 may include the marginal end regions. The attached marginal end regions are located longitudinally outside the end edge regions of the retention portion 48 and / or the emergence management portion 46. Similarly, the marginal regions held on the backing sheet 30 may include marginally abutted end regions, which may be located longitudinally outside the end edge regions of the retention portion and / or the emergence management portion.

The elastic members 34 are positioned on one side of the periphery 18 of the diaper 10 along each of the longitudinal side edges 20. The elastic leg members 34 can be connected to either or both of the backing sheet layers and of top sheet to provide the elasticized side margins of the diaper article, and can be arranged to pull and hold the diaper 10 against the user's legs. The waist elastic members 42 can also be placed on one side of either or both of the end edges of the diaper 10 to provide the elasticized waistbands.

The elastic members 34 and 42 are secured to the diaper 10 in an elastically collapsible condition so that in a configuration under normal tension the elastic members effectively contract against the diaper 10. The elastic members can be secured in an elastically contractible condition at at least two ways, for example, the elastic members can be stretched and secured while the diaper 10 is in an uncontracted condition. Alternatively, the diaper 10 can be contracted as, for example, by folding, and the elastic members secure and connect to the diaper 10 while the elastic members are in their non-relaxed or undrawn condition. Still other means, such as the heat-shrinkable elastic material, can be used to pick up the garment.

In the embodiment illustrated in Figure 1, the elastic leg members 34 extend essentially along the entire length of the crotch region 16 of the diaper 10. Alternatively, the elastic members 34 may extend to the full length of the diaper. 10 or any other suitable length providing the arrangement of elastically contractible lines desired for the particular diaper design.

The elastic members 34 and 42 can have any of a multitude of configurations. For example, the width of the individual elastic members 34 can be varied from 0.25 millimeters to 25 millimeters or more. The elastic members may comprise a single strand of elastic material, or may comprise several parallel or non-parallel strands of the elastic material, or may be applied in a rectilinear or curvilinear arrangement. Where the threads are not parallel, two or more of the threads can intercept or otherwise connect with the elastic member. The elastic members can be fixed to the diaper in any of several ways which are known in the art. For example, the elastic members can be ultrasonically bonded, sealed with heat and pressure using a variety of bonding patterns, or adhesively attached to the diaper 10 with hot melt spray or swirl patterns or other type of adhesive.

In the illustrated embodiments of the invention, for example, the elastic leg members 34 may comprise a carrier sheet to which are attached a set of elastic bands composed of a plurality of individual elastic threads 39. The elastic threads may intercept or be interconnected or be completely separated from each other. The carrier sheet shown can comprise, for example, a 0.002 centimeter thick film of a non-etched polypropylene material. The elastic yarns shown can, for example, be composed of a Lycra elastomer available from DuPont, having offices in Wilton, Delaware. Each elastic yarn is typically within the range of about 620-1050 decitex (dtx), and preferably is about 940 decitex in one embodiment of the invention where three yarns are used for each elasticized leg band. In addition, the leg elastics 34 may be generally straight or optionally curved. For example, the curved elastics can be arched inward toward the longitudinal centerline of the diaper with the innermost point (or vertices, relative to the transverse direction of the article) of the set of curved elastic yarns placed approximately 0.75-1.5 inches from the outermost edge of the set of elastic threads. In particular arrangements, the curvature of the elastics may not be configured or placed symmetrically in relation to the lateral center line of the diaper. As representatively shown in Figure 1, the curved elastics can have an inwardly arched, arcuate, outwardly curved curvature and the longitudinally-oriented center of the elastics can be off-center by a selected distance within the range of about 0- 8 centimeters towards either the front or rear waistband of the diaper to provide the desired fit and appearance. In the particular embodiments of the invention, the innermost point (apex) of the set of curved elastics may be offset by about 0-12 centimeters toward the front or back waistband of the diaper, and the reflected portion arched outward may be placed towards the front waist band of the diaper.

An absorbent body, such as the absorbent structure 32, is positioned between the topsheet 28 and the backsheet 30 to form the diaper 10. The absorbent body has a construction which is generally conformable compressible, non-irritating to the wearer's skin , and capable of absorbing and retaining liquid body exudates. It should be understood that, for purposes of this invention the absorbent structure may comprise a single integral piece of material, or alternatively may comprise a plurality of separate pieces of material which will be operably assembled together. Where the absorbent structure comprises a virtually integral and unique piece of material, the material can include the desired structural characteristics formed within the selected spatial regions thereof. Where the absorbent structure comprises multiple pieces, the multiple pieces can be configured as discrete layers or other layers and configurations without layers. In addition, the individual pieces can be coextensive or non-coextensive depending on the requirements of the product. It is preferred, however, that each of the individual pieces be arranged in an intimate and operable contact along at least a portion of its boundary with at least one other adjacent part of the absorbent structure. Preferably, each piece is connected to an adjacent part of the absorbent structure by a suitable joint and / or a fiber entanglement mechanism, such as ultrasonic or adhesive bonding, or hydraulic sewing.

In the embodiment shown representatively in Figure 1, the absorbent structure 32 includes a liquid acquisition target area 44, and has the contoured curvilinear periphery, particularly along its lateral edges. The two side edges, arched inward, generally identical, provide a narrower intermediate section suitable for placement in the wearer's crotch. In the absorbent structure shown 32, a front section thereof includes two transversely spaced ear regions and a central region. The target zone 44 encompasses the area where repeated liquid surges typically occur in an absorbent structure 32.

The particular location where the liquid is discharged, such as during urination, may vary depending on the age and gender of the user. For example, male infants tend to urinate forward towards the front end of the diaper. The target area of the female is located closer to the center of the crotch. As a result of this, the shape and relative longitudinal positioning of the emergence management part 46 can be selected to better correspond to the actual target area of either or both categories of users. Stated generally, the target zone is a section of the absorbent structure 32 which is located at the front 60 percent of the length of the absorbent structure. With reference to the percentage of the total length of the absorbent structure 32 measured in the absorbent structure from the front waistband edge thereof, the target zone may preferably comprise a region which begins in a line placed approximately 10 percent. of the length of the absorbent structure remote from the front waistband edge and terminates at approximately 60 percent of the length of absorbent structure remote from the front waistband edge.

The ear regions of the absorbent structure comprise portions which extend generally inwardly from the outermost side-side edges of the absorbent structure toward its longitudinal center line. Therefore, when the diaper is worn, the ear regions are configured to generally engage the sides of the wearer's waist and torso, and the central region is configured to generally engage the middle part of the waist and the wearer's torso. .

The absorbent structure 32 can be manufactured in a wide variety of sizes and shapes (e.g., rectangular, trapezoidal, T-shaped, I-shaped, hourglass-shaped, etc.) and a wide variety of materials. The size and absorbent capacity of the absorbent structure 32 must be compatible with the size of the intended user and the liquid load imparted by the intended user of the absorbent article. In addition, the size and absorbent capacity of the absorbent structure 32 can be varied to accommodate users ranging from infants to adults. Furthermore, it has been found that with the present invention, the densities and / or basis weights of the respective emergence management parts 46 and retention 48, as well as their relative proportions, can be varied. In a particular aspect of the invention, the absorbent structure has an absorbent capacity of at least about 300 grams of synthetic urine. Alternatively, the absorbent structure may have an absorbent capacity of at least about 400 grams of synthetic urine to provide improved performance.

Various types of wettable fibrous hydrophobic materials can be used to form the component parts of the absorbent structure 32. Examples of suitable figures include naturally occurring organic fibers composed of an intrinsically wettable material, such as cellulosic fibers.; synthetic fibers composed of cellulose or cellulose derivatives, such as rayon fibers; inorganic fibers composed of an inherently wettable material, such as glass fibers; synthetic fibers made of inherently wettable thermoplastic polymers, such as particular polyester or polyamide fibers; and synthetic fibers composed of a non-wettable thermoplastic polymer, such as polypropylene fibers, which have been hydrophilized by the appropriate means. The fibers may be hydrophilized, for example, by a treatment with silica, a treatment with a material which has a suitable hydrophilic group and is not easily removable from the fiber, or by the packing of the hydrophobic fiber not wettable with a hydrophilic polymer. during or after fiber formation. For the purposes of the present invention it is contemplated that mixtures selected from the various types of fibers mentioned above may also be employed.

As used herein, the term "hydrophilic" describes fibers or fiber surfaces which are wetted by aqueous liquids in contact with the fibers. The degree of wetting of the materials can, in turn, be described in terms of the contact angles and the surface tensions of the liquids and materials involved. Equipment and techniques suitable for measuring the wettability of the particular fiber materials or blends of the fiber materials used for the emergence management part 46 can be provided by the Cahn SFA-222 surface force analyzer system, or a system Virtually equivalent. When measured with this system, fibers having contact angles of less than 90 degrees are designated "wettable" or hydrophilic, while fibers having contact angles greater than 90 degrees are designated as "non-humidifying" or hydrophobic.

The retention portion 48 may comprise a matrix of hydrophilic fibers, such as a cellulose fluff fabric, mixed with particles of a high absorbency material. In particular arrangements, the retention portion 48 may comprise a mixture of superabsorbent hydrogel-forming particles and fibers formed by melting synthetic polymer melt or a mixture of superabsorbent particles with a fibrous Coform material comprising a mixture of natural fibers and / or of synthetic polymer fibers. The superabsorbent particles can be mixed in virtually homogeneous form with the hydrophilic fibers, or they can not be mixed uniformly. For example, the concentrations of the super absorbent particles can be arranged in a non-stepped gradient across a substantial part of the thickness (zeta-direction) of the absorbent structure, with the lower concentrations towards the body side of the absorbent structure and the relatively higher concentrations towards the outer side of the absorbent structure. Suitable gradient-zeta configurations are described in U.S. Patent No. 4,699,823 issued October 13, 1987 to Kellemberger et al., The disclosure of which is incorporated herein by reference in a manner that is consistent with the present disclosure. The superabsorbent particles may also be arranged in a generally discrete layer within the hydrophilic fiber matrix or may be configured as separate discrete bag regions of superabsorbent material. In addition, two or more different types of superabsorbents can be selectively placed at different locations within or along the fiber matrix.

The high-absorbency material may comprise absorbent gelation materials, such as superabsorbents. The absorbent gelation materials can be polymers and natural, synthetic and modified natural materials. In addition, the absorbent gelation materials may be inorganic materials, such as silica gels, or organic compounds such as crosslinked polymers. The term "cross-linked" refers to any means for effectively making the materials normally water-soluble virtually insoluble in water but swellable. Such media may include, for example, physical entanglement, crystalline domains, covalent bonds, complexes and ionic associations, hydrophilic associations, such as hydrogen bonding, and hydrophobic associations or Van Der Waals forces.

Examples of the synthetic absorbent gelation material polymers include the ammonium and alkali metal salts of poly (acrylic acid) and poly (ethacrylic acid), poly (acrylamides), poly (vinyl ethers), maleic anide copolymers with vinyl ethers and alpha-olefins, poly (vinyl pyrrolidone), poly (vinylmorpholinone), poly (vinyl alcohol), and mixtures and copolymers thereof. Additional suitable polymers for use in the present absorbent structure include natural and modified natural polymers, such as hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, methyl cellulose, carboxymethyl cellulose, hydroxypropyl cellulose, and natural gums, such as alginates, xanthan gum, locust bean gum and the like. Mixtures of natural and fully or partially synthetic absorbent polymers can also be used in the present invention. Other suitable absorbent gelation materials are discussed by Assarsson et al. In United States Patent No. 3,901,236 issued August 26, 1975. Processes for preparing synthetic absorbent gelation polymers are written in the United States Patent. from North America number 4,076,663 issued February 28, 1978 to Masuda et al. and in United States Patent No. 4,286,082 issued August 25, 1981 to Tsubakimoto et al.

Synthetic absorbent gelation materials are typically xerogels which form hydrogels when wetted. The term "hydrogel" however has been commonly used to refer to both wet and unmoistened forms of the material.

As mentioned previously, the high-absorbency material used in the retention portion 48 is generally in the form of discrete particles. The particles can be of any desired shape, for example, spiral or semi-spiral, cubic, rod-type, polyhedral, etc. Also contemplated for use here are the shapes having a large proportion of smaller dimension / larger dimension, such as needles, leaflets and fibers. The conglomerates of the particles of the absorbent gelation material can also be used in the retention portion 48.

The particles having an average size of from about 20 microns to about one millimeter are preferred for use. The "particle size" as used herein means the heavy average of the smallest dimension of the individual particles.

Suitable high-absorbency materials may also have particular characteristics of Absorbent Capacity (sometimes referred to as "AC"), Deformation Under Load (sometimes referred to as "DUL"), and Transmission Index (sometimes referred to as "Wl"). ). These parameters are described in detail in the patent application of the United States of America series number 750,787 of S. Byerly et al. Entitled ABSORBENT COMPOUNDS AND ABSORBENT ARTICLES CONTAINING THEMSELVES and filed on September 11, 1991 (attorney's issue number 10,174 ), the description of which is incorporated herein by reference in a manner that is consistent with the present disclosure.

In a particular aspect of the invention, the absorbent retention portion 48 comprises a matrix of virtually hydrophilic fibers having an amount of high absorbency material distributed therein. Selected superabsorbent polymers having improved absorbent properties can be important to maximize performance while retaining the desired thinness of the absorbent article. To provide improved performance, the particles of superabsorbent material can be selected to provide an absorbency value under load (AUL) which is within the range of about 25-40, and provide a value of Absorbent Capacity (AC) which It is within the range of around 32-48. The rate of the liquid for the superabsorbent material is within the range of about 3-15 g / g (grams liquid per grams superabsorbent) to 30 seconds of absorbency under load, 6.5-21 g / g to 5 minutes of absorbency under load and -40 g / g 60 minutes of absorbency under load.

A suitable method for determining absorbency under load was described in detail in U.S. Patent Application Serial No. 184,302 of S. Kellenberger entitled "ABSORBENT PRODUCTS CONTAINING HYDROGELS WITH ABILITY TO BLOCK AGAINST PRESSURE" (subject of lawyer No. 8786); in the European Patent Application number EP 0 339 461 Al, published on November 2, 1989; whose description is incorporated herein by reference in a manner that is consistent with the present disclosure.

An example of the superabsorbent polymer suitable for use in the present invention is the SANWET IM polymer 3900 available from Hoechst Celanese, a business having offices in Portsmouth, Virginia. Other suitable superabsorbents may include polymer W45926 obtained from Stockhausen, a business having offices in Greensboro, North Carolina.

The matrix of the hydrophilic fibers comprising the retention portion 48 can be a cellulosic wood pulp fluff, and the particles of the superabsorbent polymer can be distributed within the matrix of hydrophilic fibers. Hydrophilic fibers and high-absorbency particles can be supplied in a fiber-to-particle ratio which is not more than about 75:25, alternatively, it is not more than around 70:30, and optionally, it is not more than around 55:45, by weight. In additional aspects of the invention, the fiber to particle ratio is not less than about 25:75, preferably it is not less than about 30:70 and more preferably is not less than about 45:55 by weight , such fiber to particle ratios may be particularly desirable in the target zone of the absorbent structure. In the particular embodiments of the invention, the ratio by weight of fiber to particle is not more than about 65:35 and is not less than about 50:50 to provide the desired performance.

The hydrophilic fibers and high-absorbency particles can form an average composite basis weight which is within the range of about 400-900 grams per square meter. Again such a basis weight is particularly desirable in the target area of the absorbent structure. In certain aspects of the invention, the average composite basis weight is within the range of about 500-800 grams per square meter and preferably is within the range of about 550-750 grams per square meter to provide the desired performance.

In order to provide the desired thinness dimension to the various configurations of the absorbent article of the invention, the retaining portion 48 can be configured with a volume thickness which is not more than about 0.6 centimeters. Preferably, the volume thickness is not more than about 0.53 centimeters, and more preferably is not more than about 0.5 centimeters to provide the improved benefits. The volume thickness was determined under a restrictive pressure of 0.2 psi (1.38 kPa).

The density of the retention portion 48 or other component of the absorbent article can be calculated from its basis weight and thickness. With respect to diapers, for example, the weight and thickness are measured on newly unpacked diapers, unfolded and dried at a restrictive pressure of 0.2 psi (1.38 kPa). Conventional thickness measuring devices can be used to determine the thickness needed to calculate the density.

In the illustrated embodiments of the invention, the absorbent retention portion 48 includes 4-22 grams of wood pulp fluff, preferably includes about 8-14 grams of fluff and more preferably includes about 10-12 grams of fluff to provide The desired benefits. The fluff generally provides the shape and contour to the diaper 10, and carries and places the particles of superabsorbent polymer or other high-absorbency material. The retention portion 48 may contain about 7-12 grams of superabsorbent polymer, and in the embodiment shown, contains about 8.5 grams of the superabsorbent polymer. Sufficient superabsorbent polymer is incorporated within the retention portion 48 to provide a suitable total absorbent capacity of at least about 300 grams of urine. For example, a medium-sized diaper for an infant weighing about 13-23 pounds can typically have a total retention capacity of around 500 grams of urine.

The fluff and superabsorbent particles can be selectively placed within desired zones of the retention portion 48. For example, the base weight of fluff can vary across the width dimension of the retention portion 48. Alternatively, the relatively large amounts can be placed towards the front waist band end of the holding part. For example, U.S. Patent No. 4,585,448 issued April 29, 1986 to K. Enloe. In the illustrated embodiment, the majority of the superabsorbent material can be distributed to an average region of the retention portion 48 which extends along the length dimension of the retention portion and measures around 3.5-4.5 inches of width. In addition, the superabsorbent material may have a zoned placement selected to reduce the amount of superabsorbent material located near the side and end edges of the retaining portion. The reduced amounts of the superabsorbent material at the edges of the retention portion can improve the containment of the superabsorbent particles within the fibrous fluff matrix of the retention portion 48. The zoned and pulsed placement of the superabsorbent material can, for example, be achieved by the method and apparatus described in U.S. Patent No. 5,028,224 to C. Pieper et al, entitled METHOD AND APPARATUS FOR INTERMITTENTLY DEPOSITING PARTICULATE MATERIAL IN A SUBSTRATE and issued July 2, 1991 (attorney's issue No. 8761), the description of which is incorporated herein by reference in a manner that is consistent therewith.

In a particular aspect of the invention, the absorbent structure 32 may be generally T-shaped with the transverse bar extending laterally from the "T" generally corresponding to the front waistband portion of the absorbent article for improved performance, especially for male infants. In the illustrated embodiments, for example, the retention portion through the ear section of the front waist band region of the article has a width in the transverse direction of about 9.0 inches, the narrowest part of the section of The crotch has a width of about 3.5 inches and the rear waistband region has a width of about 4.5 inches.

With reference to Figures 2 and 7, the complete absorbent structure 32, or any individual part thereof, such as the retaining portion may be over wrapped in a fabric of high hydrophilic moisture resistance, such as a tissue resistance to high humidity or a synthetic fibrous tissue. Such an envelope fabric may also increase the integrity in the use of the absorbent structure. The fabric can be suitably joined, such as with adhesive, to the absorbent structure 32 and to other components of the product construction.

Due to the high concentrations of the superabsorbent particles, or other high-absorbency material, in the retention portion 48, there may be an increased difficulty with respect to containing high-absorbency particles within the retention portion and restricting the movement or migration of the retentate. superabsorbent on the side to the body of the diaper. To improve the containment of the high-absorbency material, the absorbent structure 32 can include an improved wrap-around, such as a wrapping sheet 70, placed immediately on one side and around the retaining portion 48. The wrapping sheet is preferably a layer of absorbent material which covers the side-to-body surfaces and the main exterior side of the retention portion, and preferably encloses virtually all of the peripheral edges of the retention portion to form a virtually complete envelope around it. Alternatively, the wrapping sheet can provide an absorbent wrap which covers the side-to-body and main-side surfaces of the retaining portion, and covers virtually only the side-side edges of the retaining portion. Therefore, both curved inward and linear sides of the side edges of the wrapping sheet can cover around the retaining portion. In such an arrangement, however, the end edges of the wrapping sheet may not be completely closed around the end edges of the retaining portion of the waistband regions of the article.

At least the side-to-body layer of the wrapping sheet 70 has a pore distribution where no more than about 5 percent of the pores, as measured by a Coulter pore, are greater than about 50 micrometers in diameter. . For example, the entire wrapping sheet 70, or at least the side-to-body layer of the wrapping sheet, may comprise a sheet formed by melt blowing composed of polypropylene fibers formed by melt blowing having a fiber size. about 5 micrometers and arranged to form a basis weight within the range of about 8-20 grams per square meter.

Another example of the absorbent wrapper 70 may comprise a low porosity cellulose tissue composed of a blend of approximately 50/50 softwood / hardwood fibers. The tissue has a basis weight of 13 pounds on the reel and a porosity of around 90 cfs / square foot. Similar to the meltblown wrap sheet material, the whole tissue wrap sheet material, or at least the body-side layer thereof, does not have more than about 5 percent of its weight. pores larger than about 50 micrometers in diameter.

Preferably, no more than about 1 percent of the pores are greater than 50 microns in diameter.

The absorbent envelope 70 may comprise a multi-element wrapping sheet which includes a separate side-by-side wrapping layer and a separate outer side wrapping layer, each of which extends beyond all or some of the outer wrapping layers. the peripheral edges of the retaining portion 48, as representatively shown in Figure 2. Such a configuration of the wrapping sheet can, for example, facilitate the formation of a virtually complete seal and seal around the peripheral edges of the portion of the wrapping. retention 48. In the back waistband portion of the illustrated diaper, the absorbent wrapper may also be configured to extend for an increased distance outwardly from the periphery of the retainer portion to add opacity and strength to the posterior ear sections of the retainer portion. diaper. In the illustrated embodiment, the side-to-body and outer-side layers of the absorbent wrapper 70 extend at least about one-half inch beyond the peripheral edges of the retaining portion to provide a bonding area of the type of the retaining portion. flange projecting outwardly over which the periphery of the body side portion of the absorbent casing can be completely or partially connected to the periphery of the side portion to the outside of the absorbent casing.

The side-to-body and outer-side layers of the wrapping sheet 70 may be composed of virtually the same material, or they may be composed of different materials. For example, the outer side layer of the wrapping sheet may be composed of a relatively lower basis weight material having a higher porosity, such as a moisture resistant cellulosic tissue composed of soft wood pulp. The side-to-body layer of the wrapping sheet may comprise one of the previously described wrapping sheet materials which have a relatively low porosity. The low porosity side-to-body layer can better prevent migration of the superabsorbent particles onto the wearer's skin, and the lower porosity base-side layer of lower weight can help reduce costs.

To provide the connection between the side-to-body and exterior-side portions of the absorbent wrapper 70, an adhesive, such as National Starch 72-3723 adhesive, can be printed over the designated bond areas 74 of the absorbent wrapper with, for example, a rotogravure type system. The adhesive is available from National Starch and Chemical Company, a business having offices in Bridge ater, New Jersey, and rotogravure type adhesive applicators are available from Egan Machinery Division, a business having offices in Oconto Falls, Wisconsin. The retaining portion 48 can then be placed between the outer-side and the body-side portions of the absorbent wrapper 70, and the matching edges of the absorbent wrapper parts can be joined together to provide a generally complete peripheral seal as required. length of virtually the entire perimeter of the retaining portion 48. In the illustrated embodiment, the adhesive is applied at an aggregate rate of about 5 grams of solids per square meter of bond to hold the overlapping edges of the side portions together body and side to the outside of the absorbent wrapper 70.

With alternating arrangements having an absorbent envelope composed of a fibrous tissue formed by meltblown non-woven, the peripheral sealing of the side-to-body and side-to-side wrapping layers can be achieved by employing hot calendering to provide a region of sealed strip around the periphery of the retaining portion.

Due to the thickness of the retention portion 48 and high concentrations of superabsorbent within the retention portion, the liquid intake rates of the retention portion, by themselves, may be very low, or may not be adequately supported on three insults of liquid on the absorbent structure. The addition of the porous liquid permeable layer of the emergence management part, however, can advantageously improve the overall intake rate of the composite absorbent structure. The emergence management part 46 is typically less hydrophilic than the retention portion 48, and has an operable level of density and a basis weight to quickly and temporarily collect the surges of the liquid, to transport the liquid from its initial entry point. and to virtually completely release the liquid to other parts of the absorbent structure 32, particularly the retaining portion 48. This configuration can help to prevent the liquid from stagnating and collecting on the part of the absorbent garment placed against it. the user's skin, thus reducing the user's wet feeling.

Various woven and non-woven fabrics can be used to construct the emergence management part 46. For example, the emergence management part can be a layer composed of a fabric formed by meltblown or spin-bonded polyolefin fibers.

The emergence management layer may also be a bonded-carded fabric or an air-laid fabric composed of natural and synthetic fibers. The bonded-carded fabric can, for example, be a carded-bonded fabric, a powder, a carded-attached and infrared fabric or a carded fabric-linked through air. The carded fabrics-bonded through air and infrared can optionally include a mixture of different fibers and the fiber lengths within a fabric of selected fabrics can be within the range of about 1.0-3.0 inches.

The emergence management part may be composed of a virtually hydrophobic material, and the hydrophobic material may optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity.

The emergence management part 46 can have a virtually uniform thickness and cross-sectional area. Alternatively, a configuration may be used where the surface area of the body side of the emergence management part is greater or less than the surface area of a section taken along the XY plane located below the surface of the surface. side to body of the emergence management part.

The representative diaper 10 can include an emergence management part 46 which is arranged in a direct contact liquid communication with an adjacent absorbent retention portion 48. As representatively shown, the emergence management part 46 can be configured to placed adjacent to the outward facing side of the upper sheet 28. Optionally, the emergence management part can be placed on one side of a face-to-face surface facing the inside of the top sheet layer 28. The configuration shown of the emergence management part is operably connected to the top sheet layer with a conventional pattern of adhesive, such as a swirl adhesive pattern. In addition, the emergence management part can be operably connected to the side-to-body layer of the wrapping sheet 70 with a conventional adhesive pattern. The amount of adhesive added must be sufficient to provide the desired levels of bonding, but it must be sufficiently low to avoid excessively restricting the movement of the liquid from the top sheet layer, through the emergence management part and through the layer of top sheet.

In the various embodiments of the invention, at least a portion of the emergence management part 46 is located within the target area 44, and optionally, the emergence management part may have an area extension that extends completely over the target area 44. The retention portion 48 is placed in liquid communication with the emergence management part 46 to receive the liquids released from the emergence management part, and to retain and store the liquid. In the embodiments shown, the emergence management part 46 comprises a separate layer which is placed on another separate layer comprising the retaining layer, thereby forming a dual layer array. The emergence management part serves to quickly collect and temporarily retain the discharged liquids, to transport such liquids from the initial point of contact and to spread the liquid to other parts of the emergence management part, and then to release in virtually complete form such liquids inside the layer or layers comprising the retention portion 48.

The configuration shown representatively of the emergence management part is virtually free of the absorbent gelation material. The emergence management part 46 may, however, contain a very small amount of a particulate gelation material to assist in acquiring an initial liquid surge, but the amount should not be excessive. When excessive amounts of particulate absorbent gelation material are maintained in the target area 44, however, the particles can cause the structure to retain and maintain unacceptably high amounts of liquid. In addition, the transport of the liquids out of the target zone 44 to other sections of the absorbent structure 32, particularly the retaining portion 48, can be undesirably impaired.

As mentioned previously, the emergence management layer 46 may be a separately formed layer, which lies on one side of the face-out surface of the topsheet 28 between the retaining portion and the topsheet. Therefore, the emergence management part 46 need not comprise the full thickness of the absorbent structure 32. The retention portion may optionally include a recess area which completely or partially surrounds the emergence management part 46, or the part Retention can be placed completely below the emergence management part. The arrangement which includes the recess in the retention portion 48 can advantageously increase the contact area and the liquid communication between the retention part and the emergence management part 48. It should be understood, however, that the handling part The emergence 46 may optionally be constructed to extend through the full thickness of the absorbent structure 32 so that the capillary flow of the liquid into the retention portion 48 occurs primarily in a generally sideways (XY) direction.

A capillary force differential created at the interface between the retention portion 48 and the material immediately adjacent to the body side can improve the containment characteristics of the absorbent structure 32. For example, if the emergence management part is composed of the layer 46 positioned immediately to one side of the retention portion, and if the emergence layer is appropriately configured to provide and maintain a relatively lower capillary attraction, as compared to the capillary attraction exhibited by the retention portion 48, then the surges liquids that occur in the target zone 44 tend to be desorbed more rapidly from the emergence management part within the retention part. Because the retention portion 48 can therefore have a capillarity relatively greater than that of the emergence management part 46, liquid surges tend to be pulled into the retention portion 48 and distributed to the more remote regions. of the same by transmission along the plane generally defined by the retention part.

The emergence management part can be any desired shape consistent with the absorbency requirements of the absorbent structure 32. Suitable shapes include, for example, circular, rectangular, triangular, trapezoidal, oblong, bone dog, the hourglass or oval shape. Preferred forms of the emergence management part are those that increase the contact liquid communication surface area between the emergence management part 46 and the retention portion 48 so that the relative capillary difference between the parts can be completely used In certain embodiments, for example, the emergence management part may be generally rectangular in shape.

In the various configurations of the invention, the emergence management part 46 may extend over the entire length of the retention portion 48., or may extend over only a part of the extent of the retention part. Where the emergence management part extends only partially along the length of the retention portion, the emergence management part can be selectively placed on either side along the absorbent structure 32. For example, the The emergence management part 46 can operate more efficiently when it is off-center towards the front waistband of the garment and transversely centered within a front section of the absorbent structure 32. Thus, the emergence management part 46 can be centered approximately around the longitudinal center line of the absorbent structure 32, it may be located primarily in a central region of a front section of the absorbent structure 32.

In other aspects of the invention, the end edges of the emergence management part may be spaced longitudinally inward from the end edges of the retaining portion 48. In the particular configurations of the invention, the front end edge relatively The corresponding adjacent portion of the emergence management part 46 may be spaced apart by a discrete but determined distance from a front waistband end edge of the retainer portion 48.

It has been found that an effective fabric for constructing the emergence management part can be characterized distinctly by particular parameters. Such parameters include, for example, the basis weight, the permeability, the porosity, the surface area per hollow volume (SA-W), the compression elasticity and the saturation capacity. Additional parameters may include a binding matrix which will help to stabilize the pore size structure, and hydrophilicity. The bonding matrix and the fiber denier blend can advantageously provide and maintain virtually a desired pore size structure.

Additional details regarding the source materials and suitable techniques for determining the parameters described above are set forth in U.S. Patent Application Serial No. 206,986 of C: Ellis and D. Bishop, entitled "CAPA DE FIBROUS NON-TRAMED FABRIC EMERGEMENT FOR ABSORBENT PERSONAL CARE AND SIMILAR ITEMS ", and filed on March 4, 1994 (attorney's issue number 11,256), and US Pat. No. 206,069 of patent application. Ellis and R. Everett, entitled "TISSUE NO FIBROUS TRAPPING OF IMPROVED EMERGENCY MANAGEMENT FOR ABSORBENT PERSONAL CARE AND SIMILAR ITEMS ", and filed on March 4, 1994 (attorney's issue number 11,387), whose descriptions are incorporated herein by reference in a manner that is consistent therewith .

In particular configurations of the invention, the emergence material may include bicomponent fibers.

For example, polypropylene / polyethylene bicomponent fibers can be employed to form the bicomponent fiber portion of any of the fabrics described. In addition, the bicomponent fibers can be curled, flat or helically crimped.

In particular aspects of the invention, the nonwoven fibrous fabric comprising the emergence management part 46 can be a single layer structure, uniformly mixed and joined having a basis weight of at least 20 degrees per square meter, a volume hollow within about 40 and 60 cubic centimeters per gram of tissue at a pressure of 689 dynes per square meter (0.01 psi), a permeability of 5,000 to about 8,000 darcy, a porosity of about 97.2 percent to about 98.8 percent and a surface area per hollow volume of about 24 to about 49 square centimeters per cubic centimeter. The tissue fibers can be thermoplastic, and can be heat bonded to one another. In addition, the fabric structure can have a density within the range of about 0.017-0.025 gm / cc, as determined at a pressure of 689 dynes per square meter (0.01 psi).

In other aspects of the invention, the fibrous non-woven fabric can be made or include a plurality of fibers bonded together to form a high non-woven fabric having a basis weight of at least 20 grams per square meter. In more refined modes, the basis weight can vary from about 40 to about 68 grams per square meter. The fabric can be made entirely of bicomponent fibers which are typically crimped and which will generally have a fiber denier equal to or greater than two deniers. Alternatively, the fabric can be made from a combination of fibers such as bicomponent fibers and polyester fibers. In such modalities, the fabric will usually include at least 50 percent by weight of bicomponent fibers. The resulting fabric will have a hollow volume of between about 80 and about 117 cubic centimeters per gram of tissue at 689 dynes per square centimeter pressure, a permeability of about 8,000 to about 15,000 darcy, a porosity of about 98.6 a about 99.4 percent, a surface area per hollow volume of about 10 to about 25 square centimeters per cubic centimeter, a saturation capacity of between about 55 and about 80 grams of 0.9 percent salt water solution per gram of tissue and a compression elasticity in both the wet and dry state of at least 60 percent. In addition, the fabric structure can have a density within a range of about 0.008-0.013 grams / cubic centimeter, as determined at a pressure of 689 dynes per square meter (0.01 psi).

The basis weight of the emergence part 46 may be important to provide a total retention capability which is adequate to temporarily retain the amount of liquid that is typically discharged by a user during a single surge / insult of liquid within the absorbent article. It will be readily apparent that absorbent articles requiring more emergence capability may also require proportionally larger amounts of emergence handling material. The emergence management material, however, does not need to be of a uniform basis weight throughout its area extension, but instead can be arranged so that some sections have more emergence management material compared to other sections. . For the purposes of the present invention, the effective basis weight will be the weight of the emergence management material divided by the area over which it extends into the emergence management part. The emergence handling material employed with the present invention will be at least about 20 grams per square meter with no actual upper limit, with the target range being from about 40 to about 68 grams per square meter.

To ensure rapid intake of the liquid, the general structure of the emergence part 46 must have hydrophilic tendencies. At least part of the fibers must have a contact angle of less than 90 degrees. As a result of this, the fibrous non-woven fabric will have sufficient hydrophilic tendencies when the fabric has a saturation capacity greater than 55 grams of 0.9 percent salt water solution per gram of tissue.

Another important feature of the emergence material employed with the present invention is its elasticity in both wet and dry states. A unique feature of the emergence material is the amount of liquid which the material is capable of absorbing with a quick insult. In addition, once the liquid has been absorbed, the sprouting material does not easily collapse. Excessive collapse would be detrimental to the general functioning of the material in the sense that the collapse of the material will result in a reduced capacity for fluid retention. The emergence materials used with the present invention should have compression elasticity values in both wet and dry states of at least about 60 percent.

The distinctive permeability, specific volume, porosity, and ratio of surface area parameters to hollow volume within the emergence management part of the invention can advantageously provide a sufficiently rapid take of liquid surges delivered over the area of objective, and also allow a controlled spreading of the liquid through the hollow volume of its structure to fill it temporarily. Over a relatively short period of time, the emergence management part can be desorbed through the cooperating operation of the underlying liquid retention part or otherwise adjacent.

The emergence management part is configured to cooperate with the other components of the diaper, such as the topsheet 28 and the retention portion 48, to provide a quick take of the user's liquid discharges. It is appreciated that emergence material with relatively small pore sizes may exhibit a liquid penetration rate within the retention portion which may be too slow. A layer of emergence handling material having relatively large pore sizes, however, can provide an insufficient restriction to the movement to the sides of the liquid through the material along the plane of the material layer. As a result of this, the liquid can drain to the sides of the layer and run off from the article before the absorbent retention material can collect and contain the liquid. Such excessive and unwanted run may become more evident when the absorbent material has already absorbed one or more previous discharges of the liquid.

To help reduce the occurrence of excessive run, the emergence management part of the present invention can be configured to have edge barriers constructed along selected edge regions thereof. In particular aspects, the edge barriers may be provided for separate layers of barrier material or by edge regions which are otherwise configured to include the relatively small pores therein. The small pore regions may be located along the end edge regions and / or the lateral edge regions of the emergence management part, and are configured to be sufficiently continuous to provide operable barriers to sideways movement of the edge. liquid.

In the various configurations of the invention, the edge barrier can be provided on only the end edges 88 of the emergence material. Alternatively, the edge barrier may be provided on only the side edges 84 and 86 of the emergence material, and optionally both the end and side edges of the emergence handling material may be provided to provide the desired performance.

In the configuration shown, the panel members 56 and 58 are separate members operably connected and fastened to the laterally opposite end sections of the rear waistband portion of the backsheet 30. The side panels may be composed of a material virtually non-elastomeric, such as polymer films, woven fabrics, non-woven fabrics or the like, as well as combinations thereof. In particular aspects of the invention, the side panels are composed of a virtually elastomeric material, such as a stretched-bonded-laminate (SBL) material, a narrow-bonded-laminate (NBL) material, an elastomeric film, a foam material elastomeric, or similar. For example, suitable melt blown elastomeric fibrous fabrics are described in U.S. Patent No. 4,663,220 issued May 5, 1987 to T. Wisneski et al., The disclosure of which is incorporated herein by reference. Examples of composite fabrics comprising at least one layer of a nonwoven textile fabric secured to a fibrous elastic layer are described in European Patent Application No. EP 0 010 published on April 8, 1987 with the inventors listed as "J". Taylor and others, whose description is incorporated herein by reference. Examples of NBL materials are described in U.S. Patent No. 5,226,992 issued July 13, 1993, to Moron, the disclosure of which is incorporated herein by reference.

The fastening means, as provided by the tape appendage fasteners 36, are typically applied to the posterior waistband region 14 of the diaper 10 to provide a mechanism for retaining the diaper on the wearer. The tape tab fasteners 36 may be any of those well known in the art, and are typically applied to the corners of the diaper 10. For example, adhesive fasteners, mechanical fasteners, hook and loop fasteners, boteroles, the bolts or buckles can be used alone or in combination. In the configuration shown, the fasteners are adhesive fasteners, which are constructed to releasably adhere to a placement zone patch attached to the front waistband section of the diaper to provide a resilient adhesive fastening system. More particularly, the fastener appendages 36 are connected to the associated laterally outer edge regions of the side panels 56 and 58 along a designated factory attachment region of the appendage clips. In particular aspects of the invention, the fastener appendages may have a relatively wide user attachment section in combination with a relatively narrower intermediate section. The intermediate section is positioned between the user attachment and factory attachment sections of the fastener appendage.

The articles which include the elastomeric side panels and the distinctively shaped fasteners are described in the patent application of the United States of America series number 168,615 of T. Roessler et al., Entitled "DYNAMIC ADJUSTMENT DIAPER" and presented on December 16. of 1993 (attorney's issue number 10,961), whose description is incorporated herein by reference in a manner that is consistent therewith. The fastening systems may include a tension beam member for distributing the applied stresses to the area of the side panel material, and may include the fastening appendages which incorporate a tapered intermediate region in combination with a relatively more user attachment section. wide of it. The techniques for forming the desired fastening systems are described in U.S. Patent Application Series No. 200,593 of T. Roessler et al., Entitled "METHOD FOR MAKING A DYEING SYSTEM FOR A DYNAMIC ADJUSTMENT DIAPER" and presented on February 23, 1994 (attorney's issue number 11,186) whose description is incorporated herein by reference in a manner that is consistent therewith.

With reference to Figure 1, the bridge member 40 is a component which is separated from a backing sheet layer 30 and a top sheet layer 28. In addition, the bridging member may be a component which is separate of each of the side panels 56 and 58. The bridge member 40 extends laterally along the transverse direction 24 of the article, and operably interconnects between the pair of side panels 56 and 58. More particularly, the bridge member 40 may include the opposite side end sections 84 and 86, with the elasticized side panel 56 operably fastened to the end section 84 and with the elastified side panel 58 operably fastened to the side end section 86. In particular aspects of the invention , the bridge member provides means for defining and maintaining a desired lateral spacing and a relatively lateral positioning and alignment between the side panels and elasti 56 and 58. Thus, the bridge member and the side panels can form an integrated sub-assembly which can be placed more reliably in a desired orientation and location within the final article, and can more effectively avoid undesired offsets and delays. no alignments The bridge member 40 can more effectively maintain the desired characteristics of cooperation between the bridge member and the side panels, and can reliably support the side panel members in the desired spacing and alignment during the high speed manufacturing processes. In addition, the composition of the bridge member material and the relative positioning of the bridge member component with respect to the backsheet and top sheet layers can be selectively configured to provide distinct advantages.

As representatively shown in Figure 1, the bridge member 40 has a longitudinal extension 80 which is smaller than the longitudinal extension of the backsheet 30. In addition, the longitudinal extent of the bridge member 80 may be smaller than the extension longitudinal of the upper sheet 28. In particular aspects of the invention, the extension of the bridge member 80 is not less than about 2 centimeters. The extension of the bridge member is not alternately less than about 3 centimeters, and optionally is not less than about 5 centimeters. In other aspects of the invention, the extension of the bridge member 80 is not more than about 25 centimeters. Alternatively, the extension of the bridge member is not more than about 18 centimeters, and optionally is not more than about 10 centimeters to provide the desired performance.

In the various aspects of the invention, the bridge member may also be selectively positioned relative to the backsheet and top sheet layers to provide different operating advantages; with reference to Figures 1-3, for example, the bridge member can be located in a laminated configuration on a main surface facing away from the backing sheet layer 30. As a result of this, the bridge member it can provide a band type function and can help provide improved waist adjustment and reduced drainage.

With reference to an alternate configuration shown respresentatively in Figures 4-6, the bridge member 40 may be placed in the form of a sandwich between the backsheet 30 and the topsheet 28, and may be arranged with at least a portion of the member. bridge located in a generally adjacent overlapping position to cover a surface facing the inner body 54 of the absorbent body 32. As a result of this, the bridge member can provide a more consistent waist adjustment and an internal "hold" for help reduce runoff. The bridge member may have a fixed edge region extending laterally 96, and a pair of laterally extending, laterally opposed fixed side regions 102 to provide a more effective prey structure. In addition, the fixed edge regions 96 and 102 can be attached to the backing sheet 30 and the top sheet 28 and configured to provide an operable seal which can virtually prevent undesired dripping of the liquid beyond the fixed edge fasteners.

The bridge member 40 may alternatively be positioned to lie on a body side surface 88 of the topsheet 28 and cooperate with the longitudinally extending restraining tabs in a general manner 62 to provide additional advantages. With reference to Figures 7-9, the bridge member can be interposed between the containment fins and the top sheet. The longitudinally spaced end sections 90 and 92 of the containment fins 62 are generally oriented parallel to a plane generally defined by the top sheet 28, and can be operably fastened to the bridge member or the top sheet to maintain the configuration placed below . In the embodiment shown, for example, the bridge member 40 includes a longitudinally-fixed, fixed-edge region 96, the laterally-fixed edge regions 102 and a moving-edge region 98. The fixed-edge region 96 is operably fastened to immediately contacting parts of the top sheet 28 and of the containment flaps 62. In particular configurations, the fasteners of the fixed edge regions 96 and 102 are constructed to provide an operable seal which can virtually prevent unwanted draining of the liquid beyond the fixed edge clamps.

At least a portion of the inner edge region 98 of the bridge member 40 is movable. In the second embodiment, for example, a middle section of the inner edge 98 can move while the lateral end sections of the inner edge are subject to the corresponding immediately adjacent sections of the top sheet 28. As a result of this, the movable part of the inner edge 98 can cooperatively provide a containment bag 100 in the waistband section of the article.

The bridge member 40 may optionally be placed to lie on a body side surface 88 of the topsheet 28 and further cooperate with the containment tabs that generally extend longitudinally 62 to provide additional advantages. With reference to Figures 10-12, the longitudinally spaced end sections 90 and 92 of the containment fins 62 are generally oriented parallel to a plane generally defined by the top sheet 28., and can be operably attached to the top sheet to keep the configuration placed below. The bridge member 40 is arranged to extend over the containment fins 62. Thus, a body side surface 94 of the bridge member 40 is designed to be placed against the user. With reference to Figures 10 and 11, the bridge member 40 includes a longitudinally fixed edge region 96, the laterally fixed edge regions 102, and the movable edge region 98. The fixed edge region 96 is operably fastened to the immediately contacting parts of the topsheet 28 and the containment fins 62. In particular configurations, the fasteners of the fixed edge regions 96 and 102 are constructed to provide an operable seal which can substantially prevent unwanted runoff from a liquid beyond the fixed edge clamps.

At least a portion of the inner edge region 98 of the bridge member 40 is movable. In the embodiment shown, for example, a middle section of the inner edge 98 can move while the lateral end sections of the inner edge are attached to the corresponding immediately adjacent sections of the topsheet 28 and of the containment fins 62. In the In particular configurations, the moving part of the inner edge 98 extends between the generally mobile remote edges 66 of the containment fins 62. As a result of this, the moving part of the inner edge 98 can cooperatively provide a containment bag 100 in the section. of waist band of the article.

In particular aspects of the invention, the edge member 40 can be constructed of a hydrophobic material that is virtually non-wettable. The bridge member material can also be virtually impermeable to a passage of the liquid through its thickness. In other configurations, the bridge member may be constructed of a material which is permeable to the passage of gas, such as air, therethrough.

Thus, where the bridge member is capable of restricting the passage of the liquid therethrough, the configuration wherein a portion of the bridge member 40 overlaps the side surface to the body 54 of the absorbent body can provide a structure of type of dam that can operably restrict a liquid runoff beyond the waistband part of the article. The part, of bridge member 40 which is connected and laminated between the backing sheet 30 and the top sheet 28 is suitably joined and sealed to operably restrict the runoff of the liquid through the laminated structure.

In other aspects of the invention, the bridge member material may be elastomeric or virtually non-elastomeric. The configuration shown representatively, for example, may include a bridging member material composed of a fibrous material which is similar to the material comprising the topsheet 28. Other conventional materials, such as polymer films, may also be employed. In other aspects of the invention, the bridge member 40 is constructed of a material which is permeable to gas, such as ambient air. The alternate configurations of the invention may include a bridge member which is constructed of a material which is resistant to a passage of the aqueous liquid, such as urine therethrough. For example, the bridge member 40 may be constructed of a meltblown-spunbond (SMS) spunbonded laminate. In the illustrated embodiment, for example, the bridge member may be constructed of an SMS material having a basis weight of about 0.85 ounces per square yard (about 28 grams per square meter). The spin-bonded layers are composed of polypropylene fibers, and the melt blown layer is composed of polypropylene fibers formed by meltblowing.

In the various configurations of the invention, such as where the bridge member 40 is configured to be permeable to gas while having a limited resistance and permeability to the aqueous liquid, the liquid resistant material can have a construction which is capable of support a hydro head of at least about 45 centimeters of water with virtually no runoff through it. A suitable technique to determine the resistance of a material to the penetration of the liquid is the Federal Test Method FTMS 191, Method 5514, dated December 31, 1968.

Having described the invention in a detailed and complete manner, it will be readily apparent that various changes and modifications can be made without departing from the spirit of the invention. All such changes and modifications are contemplated as being within the scope of the invention, as is requested by the appended claims.

Claims

1. An absorbent article having a front waistband section, a back waistband section and an intermediate section which interconnects said front and back waistband sections, said article comprising: a backing sheet layer having a laterally extending width and an extension extending longitudinally; a liquid-permeable top sheet layer superimposed on said backing sheet layer, said top sheet face having a laterally extending width and a longitudinally extending extension; an absorbent body located between said backing sheet layer and said top sheet layer; an elasticized side panel connected to said article in each laterally opposite end region of at least one of the front and rear waistband sections, said side panels being constructed to be elastically stretchable at least along a transverse direction side of said article; Y a bridge member which is separated from the backsheet and top sheet layers and extends laterally to interconnect between the elasticized side panels, at least a portion of said bridge member arranged in an overlapping relationship with a section of longitudinal end of said absorbent body and connected to at least one of the upper sheet and backsheet layers; fastening means for securing said article on a user, said fastening means being connected to the laterally distant end region of at least one of the side panels.

2. An absorbent article as claimed in clause 1, characterized in that said bridge member is configured to maintain a desired lateral separation and alignment between said side panels.

3. An absorbent article as claimed in clause 2, characterized in that said bridging member has a longitudinal extension which is smaller than the extension of the backing sheet and smaller than the extension of the upper sheet.

4. An absorbent article as claimed in clause 3, characterized in that said bridge member is connected between the layers of back sheet and upper sheet and is arranged to overlap one side of a side surface to the inner body of said sheet. absorbent body.

5. An absorbent article as claimed in clause 4, characterized in that said bridge member has a fixed edge region extending laterally, and a pair of fixed lateral regions extending longitudinally and laterally opposite.

6. An absorbent article as claimed in clause 5, characterized in that the bridge member is constructed to virtually prevent a passage of the liquid through a thickness thereof.

7. An absorbent article as claimed in clause 6, characterized in that said bridge member is permeable to the passage of the gas therethrough.

8. An absorbent article as claimed in clause 3, characterized in that said bridge member is connected in an adjacent frontal relationship with a side surface to the main body of said upper sheet layer.

9. An absorbent article as claimed in clause 8, characterized in that said bridge member is constructed to virtually prevent a passage of the liquid through its thickness.

10. An absorbent article as claimed in clause 9, characterized in that said bridge member is gas permeable.

11. An absorbent article as claimed in clause 10, further characterized in that it comprises a pair of longitudinally extending containment fins, wherein said bridge member is interposed between said containment fins and said top sheet layer.

12. An absorbent article as claimed in clause 11, characterized in that said bridge member has a laterally extending fixed edge region, and a pair of fixed lateral regions, extending longitudinally and laterally opposite.

13. An absorbent article as claimed in clause 12, characterized in that said laterally extending fixed edge region and said longitudinally extending fixed lateral regions of said bridge member are clamped to be provided and operable use which can virtually avoid the unwanted runoff of the liquid beyond the fixed edge regions.

14. An absorbent article as claimed in clause 3, characterized in that said article further comprises a pair of longitudinally extending containment fins and said bridge member is connected to extend over the containment fins and to provide a side surface to the body to make contact with the user.

15. An absorbent article as claimed in clause 14, characterized in that said bridge member has a laterally extending fixed edge region, and a pair of fixed lateral, longitudinally extending, and laterally opposed side regions.

16. An absorbent article as claimed in clause 15, characterized in that said bridge member is constructed to virtually prevent the passage of liquid through its thickness.

17. An absorbent article as claimed in clause 16, characterized in that said bridge member is gas permeable.

18. An absorbent article as claimed in clause 17, characterized in that said fastening means includes a first fastener connected to a laterally distant end region of a first side panel and a second fastener connected to a laterally distant end region of a fastener. second side panel.

19. An absorbent article as claimed in clause 17, characterized in that the first and second fasteners include the adhesive user attachment regions.

20. An absorbent article as claimed in clause 17, characterized in that said first and second fasteners include the mechanical user attachment regions. SUMMARY An article is configured with a front section, a back waistband section, and an intermediate section which interconnects the front and back waistband sections. The article includes a backing sheet layer having a width that extends laterally and an extension that extends longitudinally. A liquid-permeable top sheet layer is superimposed on the backing sheet layer, and the top sheet layer has a laterally extending width and an extension extending longitudinally. An absorbent body is located between the backing sheet layer and the top sheet layer. An elasticized side panel is connected to the article in each laterally opposite end region of at least one of the front and back waistband sections. The side panels are constructed to be elastically stretchable at least along a lateral transverse direction of the article. A bridge member which is spaced from the backsheet and top sheet layers, extends laterally to interconnect between the elasticized side panels and to maintain a desired lateral clearance and alignment between the side panels. At least a portion of the bridge member is arranged in an overlapping relationship with a longitudinal end section of the absorbent body, and is connected to at least one of the top sheet and backsheet layers. Mounting means are provided to secure the article to a user. The fastening means are connected to the end regions which are laterally distant from the side panels.