PH27102A - Absorbent garment having air previous flaps - Google Patents

Description

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ABSORBENT GARMENT HAVING AIR PERV1IQUS FLAPS

FIELD OF THE INVENTION

The present {nvention relates to disposable absorbent garments such as disposable diapers, and more particularly, to absarbent garments having flaps extending from an absorptive menns. The flaps are pro- vided with an air pervious zone so as to improve the breathability and as a result increase the wearing comfort of the article.

BACKGROUND OF THE INVENTION

The major function of absorbent garments such as disposable diapers is to absorb and contain body exudates. Such articles are thus in- tended to prevent body exudates from soiling, wetting, of otherwise contaminating clothing or other articles, such as bedding, that come in contact with the wearer. It is known that the exterior of dispo- sable diapers can be covered with a flexible and impermeable sheet to prevent any absorbed liquid from passing through the diaper and soiling adjacent articles. These covering sheets are known as back-

sheets and are generally constructed from a waterproof plastic such as polyethylene. While preventing liquid from passing therethrough and while helping to contain liquid within the diaper, these back- sheets, unfortunately, sometimes make the diaper feel hot and uncom- fortable to the wearer because they are air, as well as liquid, im- permeable. This is most evident in adult size diapers due to the relatively large area of skin coveted by the article.

In an effort to provide a cooler and hence a more comfortable gar- ment, breathable backsheets intending to allow the passage of vaporii through them while retarding the passage of liquids have been deve- loped. For example, U.S. Patent number 3,881, 489, issued to Hart- well on May 6, 1975, teaches a breathable backsheet comprising, in combination, two layers, the first of which is a low void volume ; perforated thermoplastic film and the second of which is a porous high void volume hydrophobic tissue. U.S. Patent number 3,989,867, issued to Sisson on November 2, 1976, teaches a breathable backsheet provided with tapered, hollowed bosses which prevent the passage of liquids while allowing vapors to flow readily therethrough, U.S.

Patent number 4,341,216, jssued to Obencur on July 27, 1982, teaches a two-ply breathable hacksheet which extends beyond the ends of an absorbent core, comprising, in combination, an outer sheet being vapor pervious and relatively liquid impervious in a longitudinally extend- ing central region while being totally impervious on either side of the central region, and a totally impermeable inner panel located in the crotch region of the diaper being from about 25% to about 85% of the length of the absorbent core. while the backsheets discussed above do provide some measure of im- provement over the more common impermeable backsheets, and while the last named device is of particular value, the devices fail to ade- quately address the need for a more efficient transfer of air im those areas of the garment which extend beyond the absorptive part of the garment.

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Therefore, it is an object of the present invention to provide an absorbent garment which has improved breathability beyond the ends of the absorptive means. 1t is an additional object of the present invention to provide an absorbent garment having flaps joined to an / 5 absorptive means, the flaps having an air pervious zone.

These and other objects of the present invention will be more readily apparent when considered in reference to the following description and when taken in conjunction with the accompany Lng drawings.

SUMMARY OF THE INVENTION ’

In accordance with the present invention, an integral disposable ab- sorbent garment, such as a diaper, is provided with an absorptive means comprising an absorbent core having a garment surface and a body surface; a liquid jmpervious backsheet positioned adjacent the garment surface of the absorbent cores and a liquid pervious topsheetl positioned adjacent the body surface of the absorbent core. Joined to the absorptive means, and extending beyond the ends thereof, are flaps. The flaps are provided with an air pervious zone, The air pervious zone permits air to pass from the interior of the garment to the exterior of the garment. Thus, the article is made cooler 0 in the non-absorptive areas of the article located beyond the ends of the absorptive means, resulting in increased comfort for the wearer.

BRIEF DESCRIPTION OF THE DRAWINGS ’ i . Cae a while the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as

Co 25 forming the present invention, it is believed that the inventiovd will be better saderstood fron the following descriptions which are taken in conjunction with the accompanying drawings in which like designa- tions are used to designate substartially {dentical elements and in whichs

Figure 1 is a plan view of a disposable diaper embod iment of the present {nvention having portions cut away to reveal underlying structure.

» _ Figure 2 is a fragmentary sectional view taken along section line

F

; 2-2 of Figure Ll.

Figure 3 is a side view of the disposable diaper of Figure 1. :

Figure 4, is a side view of another disposable diaper embodiment of the present invention.

Figure 5 is a dide view of still another disposable diaper embod iment of the present invention.

Figure 6 is a side view of still another disposable diaper embodiment of the present invention.

Figure 7 is a plan view of yet another disposable diaper embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates to integral disposable absorbent gar- ments such as disposable diapers, and more particularly, to fntegral disposable absorbent garments comprising an absorptive means and at least one flap joined to and extending beyond a longitudinal end of said absorptive means. The flap has an air pervious zone,

As used herein, the term "integral disposable absorbent garment’ re- fers to articles which absorb and contain body exudates and more spe- cifically refers to garments which are placed against or in proximity to the body of a wearer to absorb and contain the various exudates discharged from the body and which are intended to be discarded after a single use ({f.e., they are not intended to be laundered or other- wise restored or reused); and which do not require separate manipu- lative parts like a separate holder and liner. A preferred embodi- ment of the integral disposable absorbent garment of the present invention is shown in Figure 1 as it would be used in a diaper 20.

As used herein, the term "diaper" refers to a garment generally worn by infants and incontinent persons about the lower torso. 1t should be understood, however, that the present invention is also applicable

, gat to other disposable absorbemt garments such as incontinent briefs, and the like.

Referring now to the drawings, and in particular Figure 1 thereof, there is shown a preferred embodiment of the present invention as it would be used in a diaper {ntended to be worm by an incontinent person. Figure 1 is a partially cut away plan view of the diaper 20 of the present invention in {ts flat out, uncontracted state (i.e., with all elastic induced contraction puiled out) with the por- tion of the diaper 70 which crutacts the wearer facing the viewer,

Basically, the diaper 20 comprises an absorptive nesn: 3i and two flaps 32. The absorptive means may be any means which is generally compressible, conformable, non-irritaténg to the wearer's skin, and which is capable of absorling and containing body exudates, such as feces, urine, blouid, pus, and the like. In a preferred embodiment, rha absorptive means 31 comprises a liquid pervious topsheet 38; a liquid impervious backsheet 423; and an absorbent core 44 positioned between sald topsheet 38 and said backsheet 42. The absorbent core : 44 has core side edges 46 and core waist edges 47 which define the lateral and longitudinal edges, respectively, of the absorptive means 31. The absorbent core 44 further comprises an absorbent layer 48 and first and second tissue layers 50 and 52, respectively, which envelope the absorbent layer 48,

Joined to the absorptive means 31 and positioned adjacent to the core waist edges 47 of the st aorptive core 44 and extending outwardly away therefrom, are the flaps 32. As used herein, the term "joined" in- cludes any means for affixing the flaps 32 to the absorptive means 31, and includes embodiments wherein the flaps 32 are separate mem- bers directly or indirectly secured to the absorptive means 3l (i.e., integral) or embodiments wherein the flaps 32 are constructed from the same member or material as an element of the absorptive means 31 so that the flaps 32 are continuous and undivided elements of the absorptive means 31 (i.e.,, unitary). A flap 32 may be any member - 5 = ¥ Co

BAD ORIGINAL d ~ \ }

yA or combination of members which is generally conformable and non- irritating to the wearer's skin and has an afr pervious zone 33 which allows air, vapor, or other gases to pass from the interior of the garment and the wearer's skin to the exterior of the garment and the surrounding air.

The diaper 20 has 8 liquid receiving top surface 40 which is gene- / rally defined by the topsheet 38 and a hack surface 54 which is generally defined by the backsheet 42. Preferably, the topsheet 3° and the backsheet 42 have length and width dimensions generally Lar- ger than the absorhent core 44, so that they extend beyond the core side edges 46 and the core walat edges 47 of the absorbent core Nh where they are associated together in a anitable manner. As usad herein, the term "ocsociated" cncompasses cenffgurat ions whereby the topsheet 38 is directly joined to the backsheet 42 by affixing the topsheet 38 directly to the backsheet 42 and configurations whereby the topsheet 38 is indirectly joined to the backsheet 42 by affixing the topsheet 38 to intermediate members which in turn are affixed to the backsheet 42. The extension of the topsheet 38 and/or the backsheet 42 beyond the core side edges 40 of the absor- bent core 44 forms the longitudinal edges 30 of the diaper 20. The furthest extending ends of the flaps 32 form the end edges 41 of the diaper 20. The end edges 41 and the longitudinal edges 30 of the diaper 20 comprise the periphery 28 of the diaper 20. In a preferred embodiment, the topsheetl 38 and the backsheet 42 extend beyond the core side edges 46 of the absorbent core 44 a minimum distance of at least about 1.3 cm to about 2.95 cm (about 0.5 to about :1,0 inch) where they are joined directly to each other in the longitudinal edge 30 of the diaper 20 by attachment: means as are known in the art. Also, tn a preferred embodiment of the diaper 20, as depicted in Figure 1, the flaps 32 are unitary with the absorptive means 31; the topsheet 38 extending beyond the core waist edges 47 about 16.25 cm (6.5 in- ches) while the backsheet 42 terminates about 2.5 cp (1.0 inch) - 6 - |”

BAD ORIGINAL d ye beyond the core waist edges 47 where it is associated with the top- sheet 38 by attachment means as are known in the art. The attach- ment means may be, for example, a uniform continuous layer of adhe- sive, a patterned layer of adhesive, or an array of separate lines or spots of adhesive.

Figure 2 is a fragmentary sectional view taken along line 2-2 of

Figure 1 and depicts a preferred diaper construction in the crotch region 26 of the diaper 20. The absorbent core 44 comprises the absorbent layér 48 that is shown as being completely enveloped by the first and second tissue layers 50 and 52. The absorbent core 44 is disposed between the topsheet 38 and the backsheet 423 the backsheet 42, extending beyond the core side edges 46 of the absor- bent core 44,auThe topsheet 38 ‘covers the body surface of the absor- bent core 44 and extends beyond the core side edges 46 of the absox- bent core 44 inwardly and preferably adjacent the longitudinal edges 30, where it is preferably associated with the backsheet 42,

Looking at some of the elements of the diaper 20 more specifically, the topsheet 38 is positioned adjacent the body surface of the absor- bent core 44 and overlays a major portion of the absorbent core 44 to so that exudates are discharged onto the topsheet 38 and penetrate © through the topsheet 38 where they sre absorbed by the absorbent cere 44. The topsheet 38 extends outwardly toward the edges of the absor- bent core 44 so that a major portion of the absorbent core 44 is dis- posed between the backsheet 42 and the topsheet 38, In a preferred embod iment as shown in Figure 1, the topsheet 38 has length and width dimensions generally larger than those of the absorbent core 44, The topsheet 38 preferably extends toward the edges of the absorbent core 44, preferably beyond the core waist edges 47 and the core side edges 46 in at least the crotch region 26.

The topbheet 38 is compliant, soft feeling, and non-irritating to the wearer's skin, Further, the topsheet 38 is liquid pervious,

/ at permitting liquids to readily penetrate through its thickness. A suitable topsheet may be manufactured from a wide range of materials, such as porous foams, reticulated foams, apertured plastic films, natural fibers (e.g., wood or cotton fibers), synthetic fibers (eeler polyester or polypropylene fibers) or from a combination of natural and synthetic fibers. Preferably, it is made of hydrophobic material to isolate the wearer's skin from liquids in the absorbent core 44.

A particularly preferred topsheet 33 comprises staple length polypro- pylene fibers having a denier of about 1.5, such as Hercules Type 151 polypiopylene, marketed by Hercules, Inc. of Wilmington, Delaware.

As used herein, the term "staple length fibers" refers to those fibers having a length of at least about 15.9 mm (0.625 inches).

There are a number of manufacturing techniques which may be used to manufacture the.topsheet 38. For example, the topsheet 38 may be woven, non-woven, spunbonded, carded, or the like. A preferred top- sheet 38 is carded and thermally bonded by means well known to those skilled in the fabrics art. preferably, the topsheet 38 has a weight from about 18 to about 25 grams per square meter, a minimum dry ten- sile strength of at least about 400 grams per centimeter in the machine direction and a wet tensile strength of at least about 55 grams per oo centimeter in the cross machine direction. . .The absorbent core 44 may be any means which is generally compressible, conformable, non-irritating to the wearer's skin and capable of absorb- ing and containing liquids and certain body exudates. A preferred Co absorbent core 44 has first and second opposed faces (a body surface and a garment surface) and comprises an absorbent layer 48 and first and second tissue layers 50 and 52, respectively, The first and second tissue layers 50 and 32 overlay the major surfaces of the absorbent layer 48 to form the garment surface and the body surface of the ab=- sorbent core 44.

The absorbent layer 43 may be manufactured in a wide variety of sizes . and shapes (e.8., rectangular, hourglass, etc.) and from a wide variety

. ye of liquid absorbent materials commonly used in disposable diapers and other absorbent articles, such as comminuted wood pulp which is generally referred to as airfelt,

Examples of other suitable absorbent materials include creped cellu- lose wadding, absorbent foams, absorbent sponges, super absorbent polymers, absorbent gelling materials, or any equivalent materials or combination of materials, The total absorbent capacity of the absorbent layer 48 should, however, be compatible with the design exudate loading in the intended use of the diaper 20, Further, the size and absorbent capacity of the absorbent layer 43 may be varied to eccommodate wearers ranging from infants to adults.

A preferred embodiment of the diaper 20 has a rectangular-shaped ab- sorbent layer 48 and is {ntended to be worn by adults. The absorbent layer 48 1s preferably a bhatt of airfelt about 11.25 cm (4.5 inches) wide (lateral dimension) and about 40 cm (16. 0 inches) long (longi- tudinal dimension). The airfelt used in the absorbent. layer 48 weighs from about 30 grams to about 56 grams, has a generally uniform caliper of about 1.0 cm (0.40 inch), and has an absorbent capacity of from about 8 grams to about l6 grams of water por gram of absorbent material. "0 It should be understood, however, that the size, shape, configuration, and total absorbent capacity of the absorbent layer 48 may be varied to accommodate wearers ranging from infants through adults. Therefore, the dimensions, shape, and configuration of the absorbent layer 48 may be varied (e.g., the absorbent layer may have a varying caliper, or a hydrophilic gradient, or may contain absorbent gelling materials).

The first and second tissue layers 50 and 52 improve the tensile strength of the absorbent core 44 and reduce the tendency of the absorbent layer 48 to split, lump or ball when wetted. The first and second tissue layers 50 and 52 also help to improve lateral wicking of the absorbed exudates, thereby providing a more even distribution of the exudates throughout the absorbent layer 48. While a number of materials and manufacturing techniques may be used to manufacture the first and pate second tissue layers 50 and 52, satisfactory results have been obtained with sheets of tissue paper having a basis weight of about 16 grams per square meter (10 lbs. per 3,000 square feet) and having an air permeability of about 30.5 cubic meters per minute per square meter (100 cubic feet per minute per square foot) at a pressure differential of about 12.8 millimeters of water (0.5 inch). While the first and second tissue layers 50 and 52 are preferably coterminous with the absorbent layer 48, they may have different dimensions, a different configuration, or they may be omitted entirely.

The backsheet 42 is positioned adjacent the garment surface of the . absorbent core 44 and 1s preferably attached thereto by attachment means (not shown) such as those well known in the art, For example, the backsheet 42 may be secured to the absorbent core 44 by a uniform cont inuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines or spots of adhesive. Adhesives which have been found to be satisfactory are manufactured by Eastman Chemical

Products Company of Kingsport, Tennessee, and marketed under the tradename Eastobond A-3 and by Century Adhesives, Inc.,, of Columbus,

Ohio, and marketed under the tradename Century 5227.

The backsheet 42 is impervious to liquids and is preferably manufac- tured from a thin plastic film, although other flexible liquid imper- vious materials may also be used. The backsheet 42 prevents the exu- dates absorbed and contained in the absorbent core 44 from wetting articles which contact the diaper 20 such as bedsheets and undergar- ments. Preferably, the backsheet 42 is a polyethylene film having a thickness of from about 0.012 mm (0,5 mil) to about 0.051 mm (2.0 mils) although other flexible, liquid impervious materials may be used. As used herein, the term “flexible” refers to materialy which are compliant and which will readily conform to the general shape and contours of the human body.

p21”

A suitable polyethylene {ilm is manufactured by Monsanto Chemical

Corporation and marketed in the trade as Film No. 8020. The back- sheet 42 is preferably embossed and/or matte finished to provide a more clothlike appearance. Further, the backsheet 42 may permit vapors to escape from the absorbent core 44 while still preventing exudates from passing through the backsheet 42,

The size of the backsheet 42 is dictated hy the size of the absorbent core 44 and the exact diaper design selected, In a preferred embodi- ment, backsheet 42 has a2 rectangular shape extending beyond the absor- bent core 44 a minimum distance of at least about 1,3 cm to about 2.5 cm (about G,5 to about 1.0 inch) around the entire core.

The flaps 32 may be any member or combination of members or materials which are generally conformable, non-irritating to the wearers's skin and huve an air pervious zone 33, The air pervious zone 33 may com~ prise discrete and separate areas. Preferably, the flaps 32 are air pervious over their entire area. liowever, the flaps 32 might be air pervious in only certain zones. For instance, the air pervious zones 33 of the flaps 32 might be located in the center of the flaps 32, or around the perimeter of the flaps 32, or borizontally across the 70 width of the flaps 32, or any other configuration. In a preferred ~ embodiment of the diaper 20, as depicted in Figure 1, the flaps 32 are air pervious over their entire area excluding a 2.5 cm (1.0 inch) by 5 cm (2.0 inches) area in each of the furthest extending corners of each flap 32 where a poly tape reinforcing member 36 is applied, resulting in a total air pervious are of about 308.75 square centi- meters (47.5 square inches) for each flap 32, However, in alterna- tively preferred embodiments the air pervious area is preferably from at least about 6.5 to at least about 455.0 square centimeters (about 1.0 to about 70.0 square inches), and more preferably from at least about 58.5 to at least about 455.0 square centimeters (about 9.0 to about 70.0 square inehes), and most preferably from at least about

321° 195.0 to at least about 455,0 square centimeters (about 30.6 to about 70.0 square jnches). Furthermore, the air pervious zones 33 of the flaps 32 may not be totally air pervious. The air pervious zones 33 of the flaps 32 preferably have an air porosity of at least about 400 1/sec/m?, more preferably at least about 3800 1/sec/m?, and most preferably at least about 2,000 1/sec/mt. In a preferred embodiment of the diaper 20 as depicted in Figure 1, the flaps 32 comprise the topsheet 38 and have an air porosity of 6,488 1/sec/n’.

The air porosity of the nonwoven fabrics is determined in accordance with the ASTM test method D-737, with the material to be tested first being conditioned at 23° c.+1° ¢. and 50%+27 relative humidity for a minimum of 12 hours prior to testing. The air porosity is reported as liters per second per square meter at 12.7 mm H,0 differential pressure. A high volume of air passing through the test material is desired.

In a particularly preferred embodiment of the invertion, the diaper has a pair of side flaps 58, one or more side flap elastic members . 60 associated with each of said side flaps 58, and a pair of gasket- ing cuffs 56, The side flaps 58 comprise those portions of the diaper "0 20 between the core side edges 46 and the longitudinal edges 30. The sidei flap elastic members 60 are operatively associated with the side flaps 58 so that they effectively contract or gather the side flaps 58 to provide gasketing cuffs 56 about the legs of the wearer. While the topsheet 38, the absorbent core 44, the backsheet 42, the side flaps 58, the side flap elastic members 60, and the gasketing cuffs 56 may be assebled {n a variety of well known configurations, a pre- ferred diaper configuration is described generally in U.5. Patent 3,860,003 entitled "Contractable Side Fortions For Disposable pDlaper”, which issued to K. B. Buell on January l4, 1975, which patent is in- corporated herein by reference. In addition, a method and apparatus suitable for manufacturing a disposable diaper having elastically con- tractible gasketing cuffs are described in U.S. Patent 4,081, 301 alt entitled "Method and Apparatus for Continuously Attaching Discrete, stretched Elastic Strands to Predetermined Isolated Portions of Dis- posable Absorbent Products’, which issued to K, B, Buell on March 28, 1979 and which patent is incorporated herein by reference, In a pre- 3 ferred embodiment of the diaper 20, as depicted in Flgure 1, the flaps 32 are unitary with the absorptive means 31; the topsheet 38 extending beyond the core walst edges 47 about 16.25 cm (6.5 inches)while the backsheet 42 terminates about 2.5 cm (1.0 foch) beyond the core walst edges 47 where it is joined directly to the topshaet 38.

It (s also necessary that the diaper 20 have a means for holding the . diaper on the wearer. A number of fastening means can be used to hold the diaper on the wearer as are well known in the diaper art. A pre- ferred fastening means, especially for adult size garments, is the suspension system disclosed in U,S. Patent 4,316,508, which issued to

M. E. Bolick on February 16, 1982, which patent is incorporated herein by reference. A preferred fastening means 80, as depicted in Figure 1, has buttonholes 82 adjacent each corner of the diaper 20 and a pair of elastic strips 84 having at each end buttons 86 for use in asso- ciation with buttonholes 82. Alternatively, tape tab fasteners can be applied to the back upper wast region of the diaper 20 to provide a fastening means to hold the diaper on the wearer. The tape tab fasteners can be any of those well known im the art, such as the fastening tape disclosed in U.S. Patent 3,848,594, which' issued to /

K. B. Buell on November 19, 1974, which patent is incorporated herein / by referance. The suspension systems, or tape tab fasteners, or other diaper fastening means, such as pins, are typically applied near the top edge of a diaper in its "in-use" configuration. h

The diaper 20 can also be divided into regions. The diaper 20 has front and back upper waist regions 21 and 22, respectively, eath con= prising those portions of the diaper 20 which extend outwardly foom the core waist edges 47, or in other words, the flaps 32. The upper ! t waist regions comprise those portions of the diaper 20 which, when worn, encircle the upper waist of the wearer, The diaper 20 also has front and back lower waist regions 23 and 24, respectively, each extending inwardly from the core waist edges 47 toward the lateral centerline 34 of the diaper 20 a distance from about 1/4 to about 1/3 the length of the absorptive means 31. The lower waist regions com- prise those portions of the dfaper 20 which, when worn, encircle the lower waist of the wearer. The diaper 20 also has a crotch egion 26 which is that portion of the Aiaper 20 between the Lover waist regions 23 and 24, and comprises that portion of the disper 20 which, when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer. The longitudinal centerline of the diaper 20 is designated 35.

In use, the diaper 20 is positioned between the wearer's legs so that the crotch region 26 covers the lower torso, the front waist regions 23 and 21 are positioned adjacent to the front wast area of the wearer and cover the front waist, and the back regions 24 and 22 are positioned adjacent to the pack waist area of the wearer and cover the back walst.

An elastic strip 84 is then brought across each hip of the wearer so that the buttons 86 can be inserted into the bottonholes 82 thereby forming a fastening means 80 for holding the diaper 20 on the wearer,

In this position, the flaps 32 of the diaper 20 are adjacent the wearer's front and back upper waist areas. The diaper 20 has improved breathabi- lity in these upper waist areas due to the fact that the flaps 32 have air pervious zones 33 which allow air, vapor, and other gases to pass from the interior of the diaper 20 and the wearer's skin to the exterior of the garment and the surrounding air. The result is nat the wearer remains cooler and dryer and hence, more comfortable. | :

An alternatively preferred embodiment of the gdiupeéF 20 td shown in \

Figure 4. In this embodiment, the backsheet 42 extends about 16.25 cm (6.5 inches) beyond thc core waist edges 47 of the absomtive means 31, while the topsheet 38 terminates about 2.5 cm (L.0 inch) beyond the core waist edges 47 of the absorptive means 31 where it is associated y 1° with the backsheet 42, The flaps 32 comprise those parts of the back- sheet 42 and the topsheet 38 which extend beyond the core waist edges 47 of the absorptive means 31. The flaps 32 (backsheet 42) each have an air pervious zone 33,

In another alternatively preferred embodiment, as shown in Figure 5, the topsheet 38 and the backsheet 42 of the absorptive means 31 extend beyond the core waist edges 47, each terminating about 2.5 cm (1.0 inch) beyond the core waist edges 47 where they are associated together. An overlay sheet 39 is joined to the absogptive means 31 adjacent the gar- ment surface of the backsheet 42, The overlay sheet 39 is continuous between the core waist edges 47 of the absorptive means 31 and it extends beyond each of the core waist edges 47 of the absorptive mesens 31. As used herein, the word "continuous" is intended to include embo- diments wherein the overlay sheet 39 is unhroken and unitary between the core waist edges 47. In an alternatively preferred embodiment, the overlay sheet 39 extends about 16,25 cm (6.5 inches) beyond the core waist edges 47 of the absorptive means 31. The flaps 32 comprise the overlay sheet 39, and those parts of the teopsheet 38 and the lhack- sheet 42 which extend beyond the core waist edges 47 of the absorptive means 31, The flaps 32 (overlay sheet 39) each have an air pervious zone 33,

In still another alternatively preferred embodiment, as shown in Figure 6, the topsheet 38 and the backsheet 42 of the absorptive means 31 ax- tend beyond the core waist edges 47, each terminating about 2.5 cm (1.0 inch) beyond the core waist edges 47 where they are associated together. Separate sheets 37 having distal ends 72 and proximal ends 70 are joined to the absorptive means 31 adjacent the garment surface of the backsheet 42 in such a wey that the proximal ends 70 of the ’ separate sheets 37 are located between the core waist edges 47 of the absorptive means 31 and thecdistal ends 72 of the separate sheet 37 extend about 16.25 cw (6.5 inches) beyond the core waist edges 47 of

33 10° the absorptive means 31. As used herein, the words "located between the core waist edges" are Intended to encompass embodiments wherein the proximal ends 70 of the separate sheets 37 are between or adjac~nt to the core waist edges 47 of the absorptive means 31. The flaps 3? 3 comprise the separate sheets 37 and those parts of the topsheet ne and the backsheet 42 which extend beyond the core waist edges #7 of the absorptive means 31. The flaps 32 (separate sheets 37) each have an air pervious zone 313,

Overlay sheet 39 and separate sheets 37 are preferably attached to the backsheet 42 of the absorptive means 31 by attachment means (not shown) such as those well koown in the art, For example, overlay sheet 39 and separate sheets 37 may he secured to the backsheet 42 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or any array of separate lines or spots of adhesive. Adhesives which have been found to be satisfactory are manufactured by Eastman Chemical

Products Company of Kingsport, Tennessee and marketed under the trade~ name Eastobond A-3.

Yet another alternatively preferred embodiment of the diaper 20 is depicted in Figure 7. In this embodiment, the air pervious zones 33 of the flaps 32 do not extend to the furthest extanding ends of the flaps 32, or in other words, the end edges 41 of the periphery 28, but instead the air pervious zones 33 are centrally located in the flaps 32 and extend across the width of the flaps 32. Non-pervious poly-tape reinforcing members 95 are added to the furthest extending ends of the flaps 32 to increase the strength and integrity of the diaper 20 during use,

While particular embodiments of the present invertion have been illus- trated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without depart- / 30 ing from the spirit and scope of the invertion., For example, the back- sheet 42 of the absorptive means 31 need only be greater than about le BAD OFIGINAL 9

85% of the length of the absorbent core 44, Alternatively, the flaps 32 preferably extend at least about 2.5 cm (1.0 inch), or greater than about 2.5 cm (1.0 inch), or at least about 7.5 cm (3.0 inches), or at least about 12.5 cm (5.0 inches), or at least about 17.5 cm (7.0 inches), or at least about 22.5 cm (9.0 inches), or at least about 27.5 cm (11.0 inches) beyond the core waist edges 47 of the absorptive means 31, Alternatively, overlay sheet 39 and separate sheets 37 may not be joined to the garment surface of the backsheet 42 of the diaper 20, but might be disposed anywhere throughout the layers of the diaper 20. Also, alternatively, there may be only one flap 32, or one flap 32 might be of a different size or extend fur- ther than the other flap 32.

WHAT IS CLAIMED 1S3 ) “U 1 0 9 1. An integral disposable absorbent garment, comprisingt a. an absorptive means for absorbing and containing body exu- dates, said absorptive means having two core waist edges; and b. at least one flap, said flap being joined to and extending from said absorptive means, said flap being positioned adja- cent to one of said core waist edges, said flap having an 0 air pervious zone, and said alr pervious zone of said flap having an air porosity of at least about 400 1/sec/m?. 2. The integral disposable absorbent garment as claimed in Claim 1, wherein said flap extends beyond one of said core walst edges at least about 2.5 cm (1.0 inch). 3, The integral disposable absorbent garment as claimed in Claim 2, wherein said air pervious zone of said flap has an area of at least about 6.5 to at least about 455.0 square centimeters (at least about 1.0 to at least about 70.0 square inches). 4, The integral disposable absorbent garment as claimed in Claim 2, wherein sald air pervious zone of said flap has an area of at

Claims (1)

1. . } 3? jt P least about 58.5 to at least ahout 455.0 square centimeters (at least about 9.0 to at least about 70.0 square inches).

   . 5. The integral disposable absorbent garment Aas claimed in Claim 2, wherein said air pervious zone of said flap has an area of at least about 195.0 to at least about 455.0 square centimeters (at least about 30.0 to at least about 70.0 square inches).

   6. The integral disposable absorbent garment as claimed in Claim 5, wherein said air pervious zone of said flap has an air porosity of at least about 800 1/sec/m’.

   7. The integral disposable ahsorhent garment as claimed in Claim 5, wherein said air pervious zone of said flap has an air porosity of 2 at kast about 2000 l/sec/m .

   8. The integral disposable absorhent garment 3s claimed in Claim 1, wherein said absorptive means comprisess a. a liquid permeable topsheet; b, ‘a liquid impermeable backsheet associated with said topsheetj and c¢. an absorbent core positioned between said topsheet and said backsheet.

   9. The integral disposable absorbent garment as claimed in Claim 8, wherein said flap comprises said topsheet.

   10. The integral disposable absorbent garment as claimed in Claim 3, wherein said flap comprises an overlay sheet, said overlay sheet being joined to said absorptive means such that said overlay sheet extends longitudinally beyond each of said core walst edges of said absorptive means.

   11. The integral disposable absorbent garment as claimed in Claim 3, wherein said flap comprises a separate sheet, sald separate sheet having a distal end and a proximal end, and said separate sheet being joined to said absorptive means such that said proximal end of said separate sheet is located between said core waist edges of said absorptive yo : means and said distal end of gain separate cheat is located beyond : 4 one of said core waist edgn” nf said absorptive meses, ¥ ny

   12. the integral disposable abheopbent garment a8 claimed in Claim 8, wherein said backsheet is preater than 5% as Jong AS gaid absor- bent cota. * x ¥* x Ye pe * ht i *%® A Fd J te de * 5k ticholas A. ALR jnven.ot B =i A » - 19 - AD ORIGINAL ¢ are,