Note: Descriptions are shown in the official language in which they were submitted.
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llld 118BOR881~?T 11'~tTIChE 811VI~ta DU1~ COFFS
F~eLL OF THE :INVENTION
The present invention relates to absorbent articles
such as disposable diapers, and more particularly, to
absorbent articles having a gasketing cuff and a barrier
cuff which improve the containment characteristics of the
article.
BA,~KGRO,jt~TO OF THE T'~'jj~'ION
The major function of absorbent articles such as
disposable diapers and adult incontinent briefs, is to
absorb and contain body exudates. Such articles are also
intended to prevent body exudates from soiling, wetting, or
otherwise contaminating clothing or other articles, such as
bedding, that come in contact with the wearer. The most
common mode of failure for such products occurs when body
exudates leak out of the gaps between the article and the
wearer's leg or waist to adjacent clothing because they are
not immediately absorbed within the article. This is most
evident with loose fecal material which is not easily
absorbed by the absorbent article and tends to "float" on
the top surface of the absorbent article.
Contemporary disposable diapers, such as those
disclosed in U.S. Patent 3,860,003 issued to Kenneth
Barclay Buell on January 14, 1975, have a topsheet, a
backsheet, an absorbent core, and elasticized leg flaps to
improve both wearing comfort and the ability to contain
body exudates. These elasticized leg flaps prove effective
generally to prevent wicking and overflow from the fluid
laden diaper to clothing contacting the edges of the diaper
in that the elasticized leg flaps present a fluid
impervious barrier between the edge of the diaper and the
contacting clothing, and in addition, provide a gasketing
action about the legs of the wearer. Despite the
effectiveness of such structures, however, body exudates, -
especially loose fecal material, can leak through the
I
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elasticized leg flaps and soil the wearer's clothing
because the diaper does not constrain the free flow of such
material nor provide a structure to hold it within the
diaper so that as such material freely floats on the top
surface of the topsheet, it tends to work its way past the
elasticized leg flaps.
Therefore, it is an object of an aspect of the present
invention to provide an absorbent article which has
improved containment characteristics.
It is an object of an aspect of the present invention
to provide an absorbent article having a barrier cuff which
acts as a restraint against the leakage of body exudates.
It is an object of an aspect of the present invention
to provide an absorbent article having an elastically
contractible gasketing cuff and a barrier cuff so as to
provide a dual restraint against the leakage of body
exudates, thereby improving the containment characteristics
of the absorbent article, especially in regard to loose
fecal material.
It is an object of an aspect of the invention to
provide an absorbent article having a barrier cuff that is
raised above the top surface of the topsheet when the
article is fitted on the wearer such that a channel is
formed which constrains and holds body exudates within the
article.
These and other objects of the invention will be more
readily apparent when considered in reference to the
following description and when taken in conjunction with
the accompanying drawings.
~~Y OF THE INVENTION
In accordance with they present invention, an integral
disposable absorbent article such as a diaper is provided
with a liquid pervious topsheet, a liquid impervious
backsheet, an absorbent sore disposed betweew the topsheet
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and the backshest, at least one elastically contractible
gasketing cuff, and at least one barrier cuff. The barrier
cuff has a proximal edge and a distal ~dge. The absorbent
article is additionally provided with spacing means for
spacing the distal edge away from the top surface of the
topsheet. In addition, adhesive means secure the end
portions of the barrier cuffs closed. A channel is formed
between the proximal edge and the distal edge in at least
the crotch region because the distal edge is spaced away
from the topsheet top surface.
When a diaper embodiment of the present invention is
applied to a wearer, the barrier cuff rides up along the
inner thigh and the perineum of the wearer in the crotch
region and along the buttocks in the back waist region.
Leakage prevention is enhanced because body exudates which
are not immediately absorbed by the absorbent core,
typically loose fecal material, contact the barrier cuff
and are contained and held within the channel so that they
do not Leak out of the diaper at the gaps between the
diaper and the legs or waist of the wearer. Additionally,
should such exudates flow beyond the barrier cuff, leakage
prevention is further enhanced by the gasketing cuff
because it forms an additional fluid impervious barrier
about the leg or waist of the wearer.
Various aspects of the invention are as follows:
An integral disposable absorbent article comprising:
a liquid pervious topsheet;
a liquid impervious backsheet associated with said
topsheet;
an absorbent core disposed between said topsheet and
said backsheet:
an elastically contractible gasketing cuff disposed
adjacent to an edge of the absorbent article: '
a barrier cuff having a proximal edge and a distal
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edge, said barrier cuff disposed inboard of said gasketing
cuff; and
spacing means associated with said barrier cuff for
spacing said distal edge away from the top surface of said
topsheet.
An integral disposable absorbent article having a
front waist region, a crotch region and a back waist
region, said absorbent article comprising:
a liquid pervious topsheet;
a liquid impervious backsheet associated with said
topsheet;
an absorbent core disposed between said topsheet and
said backsheet;
an elastically contractible gasketing cuff disposed
adjacent each longitudinal edge of the absorbent article in
at least the crotch region;
a barrier cuff disposed adjacent each of said
gasketing cuffs, each of said barrier cuffs having a
proximal edge and a distal edge, said proximal edge
disposed laterally inboard of said gasketing cuff:
a spacing means associated with each of said barrier
cuffs, for spacing said distal edge away from the top
surface of said topsheet, whereby a channel is formed to
improve the containment characteristics of the article.
An integral disposable absorbent article having a
front waist region, a crotch region and a back waist
region, said absorbent article comprising:
a liquid pervious topsheet:
a liquid impervious backsheet associated with said
topsheet;
an absorbent core having side edges, said absorbent
core disposed between said topsh~eet and said backsheet:
an elastically contractible gasketing cuff disposed
adjacent each longitudinal edge of the absorbent article,
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each gasketing cuff comprising a flexible side flap
- extending from and along said side edge of said absorbent
core in at least the crotch region of the absorbent
article, and a flap elastic member secured to said side
flap in an elastically contractible condition, whereby paid
elastically contractible gasketing cuff forms an effective
barrier about a wearer's legs;
a barrier cuff disposed adjacent each of said
gasketing cuffs in at least the crotch region, each of said
barrier cuffs being integral with said topsheet and having
a proximal edge and a distal edge, said proximal edge
disposed in said side flap between said flap elastic member
and said side edge of said absorbent core, said distal edge
being free from attachment in at least the crotch region:
and
a spacing elastic member secured to said barrier cuff
for elasticizing said barrier cuff so that said distal edge
is spaced away from the top surface of said topsheet,
whereby a channel is formed.
said elastically contractible gasketing cuff and said
barrier cuffs presenting an effective means against the
soiling of a wearer's garments.
BRIEF DESCRIPTIQN ~F THE DRAWINGS
While the specification concludes with claims
particularly pointing out and distinctly claiming the
subject matter which is regarded as forming the present
invention, it is believed that the invention will be better
understood from the following descriptions which are taken
in conjunction with the accompanying drawings in which like
designations are used to designate substantially identical
elements, and in which;
Figure 1 is a plan view of a disposable diaper
embodiment of the present invention having portions cut
away to reveal underlying structure.
' 1 ~4~ 41 2
Figure 2 is a fragmentary sectional view taken along
section line 2-2 of Figure 1.
Figure 3 is a fragmentary sectional view taken along
section line 3-3 of Figure 1,
Figure 4 is a perspective view of the disposable
diaper embodiment of Figure 1.
Figure 5 is a fragmentary coronal view showing the
diaper of Figure 1 in place on a wearer,
Figure 6 is a fragmentary sectional view of an
alternative embodiment of the present invention.
Figure ~ is a fragmentary sectional view of a further
alternative embodiment of the present invention.
~F AT TLED DFS:~~ION OF TIi~ INVENTION
As used herein, the term '"integral disposable
absorbent article" refers to articles which absorb and
contain body exudates and more specifically refers to
articles which are placed against or in proximity to the
body of the wearer to absorb and contain the various
exudates discharged from the body, and which are intended
to be discarded after a single use (i.e., they are not
intended to be laundered or otherwise restored or reused),
and which are unitary in that they do not require separate
manipulative parts like a separate holder and liner. A
preferred embodiment of the integral disposable absorbent
. article of the present invention, diaper 20, is shown in
Figure 1. As used herein, the term "diaper" refers to a
garment generally worn by infants and incontinent persons
that is worn about the lower torso of the wearer. It
should be understood, however, that the present invention
is also applicable to other integral disposable articles
such as incontinent briefs and the like.
As used herein, a "waist containment pocket" is a
region of the absorbent article which extends between the
barrier cuffs and is defined by the channels associated
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with each barrier cuff.
Figure ~1 is a plan view of the diaper 20 of the
present invention in its flat-out, uncontracted state
(i.e., with all elastic induced contraction pulled out)
with portions of the structure being torn away to 'more
clearly show the construction of the diaper 20 and with -the
portion of the diaper 20 which contacts the wearer facing
the viewer. The diaper 20 is shown in Figure 1 to have a
front waist region 22, a back waist region 24, a crotch
region 26 and a periphery 28 which is defined by the outer
edges of the diaper in which the longitudinal edges are
designated 30 and the end edges ate designated 32. The
diaper 20 additionally has a lateral centerline which is
designated 34 and a longitudinal centerline which is
designated 36.
The diaper 20 comprises a liquid pervious topsheet 38,
the top surface of the topsheet 38 being designated 40; a
liquid impervious backsheet 42: an absorbent core 44 having
side edges 46 and comprising an absorbent layer 48 and
first and second tissue layers 50 and 52, respectively: a
pair of tape-tab fasteners 54: gasketing cuffs 56 each
comprising a side flap 58 and a flap elastic member 60:
barrier cuff6 62 each having a proximal edge 64, a distal
edge 66, an inboard surface 68, an outboard surface 70, a
first end 72 and a second end 74; and spacing means 76 such
as spacing elastic member 77 for spacing the distal edge 66
away from the topsheet top surface 40. The diaper 20
additionally comprises adhesive means 78 such as a glue
bead 79 for securing closed the first and stcond ends 72
~ and 74 of each barrier cuff 62. They areas in which the
adhesive means 7s are disposed are designated front closure
zone 80 and back closur~ zone 82. While the topsheet 38,
the absorbent core 44, the backsheet 42, and, the
elastically contractible gasketing cuffs 56 may be
1 341 41 2
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assembled in a variety of well known configurations, a
- preferred diaper configuration is described generally in
U.S. Patent 3,860,003 entitled "COntractable Side Portions
for Disposable Diaper", which issued to K.B. Buell on
January 14, 1975.
Figure 1 chows a preferred embodiment of the diaper 20
in which the topsheet 38 and the backsheet 42 are
coextensive and have length and width dimensions generally
larger than those of the absorbent care 44. The topsheet
38 is associated with and superposed on the backsheet 42 to
thereby form the periphery 28 of the diaper 20. The
periphery 28 defines the outer periphery or, in other
words, the edges of the diaper 20. The periphery 28
comprises the end edges 32 and the longitudinal edges 30.
The diaper 20 has front and back waist regions 22 and
24 extending, respectively, from the end edges 32 of the
diaper periphery 28 toward the lateral centerline 34 of the
diaper 20 a distance from about 1/4 to about 1/3 the length
of the diaper 20. The waist regions comprise those
portions of the diaper 20 which, when worn, encircle the
waist of the wearer. The crotch region 26 is that portion
of the diaper 20 between the waist regions 22 and 24, and
comprises that portion of the diaper 2o which, when worn,
is positioned between the legs of the wearer and covers the
lower torso of the wearer.
Figure 2 is a fragmentary sectional view taken along
line 2-2 of Figure 1 and depicts the diaper construction in
the front waist region 22 of the diaper 20. (It should be
understood that the diaper construction in the back waist
region 24 is identical to the construction in the front
waist region 22.) The absorbent core comprises the
absorbent layer 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
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1 X41412
and the backsheet 42: both the topsheet 38 and the
backsheet 42 extend beyond the longitudinal edge 46 of the
absorbent care 44 to define the side flap 58. The
juxtaposed areas of the topshset 38 and the backshset 42
are adhesively secured together by adhesive 88. In a
preferred embodiment, the flap elastic members 60 do not
extend into the front waist region 22 so that the gasketing
cuff 56 is not formed in this region. The barrier cuff 62
is shown as being a separate element secured to the
topsheet 38: the proximal edge 64 being formed by securing
the element to the topsheet 38 by adhesive 92. The inboard
surface 68 of the barrier cuff b2 is secured to the
topsheet top surface 40 by adhesive means 78. Therefore,
the distal edge 66 is closed (i.e., it is not spaced away
from the topsheet top surface 40) . It should be noted that
the spacing elastic member 77 is not disposed in this
region because the distal edge 66 is not designed to be
spaced away from the topsheet top surface 40, in the waist
regions. Therefore, the barrier cuff 62 is not open nor
ready to constrain the flow of body exudates in this
region.
Figure 3 is a fragmentary sectional view taken along
line 3-3 of Figure 1 and depicts the diaper construction in
the crotch region 26 of the diaper 20 as it is shaped
before being applied to the wearer (i.e., the diaper 20 is
subjected to elastic contraction). The absorbent core 44
comprises the absorbent layer 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 42: both the topshset 38 and
the backsheet 42 extend beyond the longitudinal edge 46 of
the absorbent core 44 to define the aide flap 58. The
juxtaposed areas of the topshset 38 and the backsheet 42
are adhesively secured together by adhesive 88. The
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_ topsheet 38 and the backsheet 42 al6o enclose the flap
elastic members 60 adjacent the longitudinal edge 30 in the
periphery 28. The flap elastic members 60 are secured in
the topsheet-backsheet formed side flap 58 by elastic
attachment means 90. The elastically contractible
gasketing cuff 56 is thereby formed by the side flap 58 and
the flap elastic members 60. The barrier cuff 62 is shown
as being formed by securing an element to the topsheet 38
between the flap elastic members 60 and the side edge 46 of
the absorbent core 44. The proximal edge 64 of the barrier
cuff 62 is formed by securing the barrier cuff element to
the topsheet 38 by adhesive 92. The spacing elastic
members 77 are enclosed in a tunnel that is formed when an
end of the barrier cuff element is folded back upon itself;
the spacing elastic members 77 being secured in the barrier
cuff 62 by elastic attachment means 94. The distal edge 66
of the barrier cuff is spaced away from the topsheet top
surface 40 by the elastic gathering action of the spacing
elastic members 77; a channel 96 thereby being formed by at
least the proximal edge 64, the distal edge 66 and the
inboard surface 68 of the barrier cuff 62. The channel 96
is shown as being ready to restrain, contain and hold body
exudates until the diaper 20 is removed from the wearer.
The topsheet 38 is compliant, soft feeling, and non
irritating to the wearer's skin. Further, the topsheet 38
is liquid pervious permitting fluids to readily penetrate
through its thickness. A suitable topsheet may be
manufactured from a wide range of materials, such as porous
foams, reticulated faams, apertured plastic films, natural
fibers (e. g., wood or cotton fibers), synthetic fibers
(e.g., polyester or polypropylene fibers) or from a
combination of natural and synthetic fibers. Preferably, it
is made of a hydrophobic material to isolate the wearer's
skin from fluids in the absorbent core 44.
1341412
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- A particularly preferred topsheet 38 comprises staple
- length polypropylene fibers having a denier of about 1.5,
such as Hercules' Type 151 polypropylene 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 topsheet 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 tensile 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 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, capable of absorbing and retaining fluids
and certain body exudates. A preferred absorbent core 44
has first and second opposed faces and comprises an
absorbent layer 48 and first and second tissue layers 50
and 52, respectively. The first and second tissue layers
50 and 52 overlay the mayor surfaces of the absorbent layer
48 to form the first and second opposed faces of the
absorbent core.
The absorbent layer 48 may be manufactured in a wide
variety of 6iaes and shapes (e. g., rectangular, hourglass,
etc.) and from a wide variety 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 cellulose wadding,
1 X41412
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- absorbent foams, absorbent sponges, super absorbent
polymers, or any eguivalent material 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 48 may be varied to accommodate wearers ranging from
infants through adults.
A preferred embodiment of the diaper 20 shown in
Figure 1 has an hourglass shaped absorbent layer 48 and is
intended to be worn by infants ranging in weight from about
5 kgs to about 12 kgs (about 12 pounds to about 26 pounds).
The airfelt used in the absorbent .layer 48 weighs from
about 30 grams to about 56 grams, has a generally uniform
caliper, and has an absorbent capacity of from about 8
grams to about 16 grams of water per gram of absorbent
material. 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
2o 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
superabsorbent materials). The absorbent layer is
. preferably, therefore, a butt of airfelt about 32 cm wide
(lateral dimension), about 45 cm long (longitudinal
dimension) and approximately 7 cm across the narrowest part
of the crotch region.
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
~~ X41 41 2
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exudates throughout the absorbent layer 48. While a number
of materials and manufacturing techniques may be used to
manufacture the first and 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 3000 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
(1/2 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 absorbent core 44 is superimposed on the backsheet
42 and is preferably attached thereto by attachment means
(not shown) such as those well known in the art. For
example, the absorbent core 44 may be secured to the
backsheet 42 by a uniform continuous layer of adhesive, a
patterned layer of adhesive, or an array of separate lines
or spots of adhesive. An adhesive which has been found to
be satisfactory is manufactured by Eastman Chemical
Products Company of Kingsport, Tennessee and marketed under
the tradename Eastobond~A~3.
The backsheet 42 is impervious to liquids and is
preferably manufactured from a thin plastic film, although
other flexible liquid impervious materials may also be
used. The backsheet 42 prevents the exudates absorbed and
contained in the absorbent core 44 from wetting articles
which contact the diaper 20 such as bedsheets and
undergarments. Preferably, the backsheet 42 is a
polyethylene film having a thickness of from about 0.012 mm
(0.5 mil) to about 0.051 cm (2.0 mils), although other
flexible, liquid impervious materials may be used. As used
herein, the term "flexible" refers to materials which are
~4~ ~+1 2
-14-
compliant and which will readily conform to the general
shape and cantours of the human body.
A suitable polyethylene film is manufactured by
Monsanto Chemical Corporation and marketed in the trade as
Film No. 8020. The backsheet 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 by the size
of absorbent core 44 and the exact d~.aper design selected.
In a preferred embodiment, the backsheet 42 has a modified
hourglass shape extending beyond the absorbent core 44 a
minimum distance of at least about 1.3 cm to about 2.5 cm
(about 0.5 to about 1.0 inch) around the entire diaper
periphery 28.
The topsheet 38 and the backsheet 42 are associated
together in any suitable manner. As used herein, the term
"associated" encompasses configurations 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. In a preferred embodiment, the topsheet 38
and the backsheet 42 are joined directly to each other in
the diaper periphery 28 by attachment means such as
adhesive 88 or any other attachment means as known in the
art. For example, a uniform continuous layer of adhesive,
a patterned layer of adhesive, or an array of separate
lines or spots of adhesive may be used.
Tape tab fasteners 54 are typically applied to the
back waist region 24 of the diaper 20 to provide a
fastening means to hold the diaper on the wearer. The tape
1 ~~+1412
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- tab fasteners 54 can be any of those well known in the art,
such as the fastening tape disclosed in U.S. Patent
3,848,594 issued to K. 8. Buell on November 19, 1974.
These tape tab fasteners 54 or other diaper fastening
means, such as pins, are typically applied near the top
edge of a diaper in its "'in-use" configuration.
The elastically contractible gask~ting cuffs 56 are
disposed adjacent the periphery 22 of the diaper 20,
preferably along each longitudinal sedge 30 so that the
l0 gasketing cuffs 56 tend to draw and hold the diaper 20
against the legs of the wearer. Alternatively, a gasketing
cuff 56 may be disposed adjacent either or both of the end
edges 32 of the diaper 20 to provide a waistcuff rather
than leg cuffs. While the gasketing cuffs 56 may comprise
any of several means as are well known in the,diaper art,
a particularly preferred gasketing cuff construction
comprises a flexible side flap 58 and a flap elastic member
60, as is described in detail in the hereinbefore
referenced U.S» Patent 3,860,003. In addition, a method
and apparatus suitable for manufacturing a disposable
diaper having elastically contractible gasketing cuffs 56
are described in U.S. Patent 4,081,301 entitled "Method and
Apparatus for Continuously Attaching Discrete, Stretched
Elastic Strands to Predetermined Isolated Portions of
Disposable Absorbent Articles" which issued to R. 8. Buell
on March 28, 1978.
The side flap 58 should be highly flexible and thus
contractible so that the flap elastic members 60 may gather
the side flap 58 to provide a gasketing cuff 56 about the
legs or waist of the wearer. The side flaps 58 are that
portion of the diaper 20 between the periphery 22 and the
longitudinal edges 46 of the absorbent core 44. Thus in a
preferred embodiment of the present invention as shown in
Figure 1, the side flaps 58 are formed from the extension
1 341 41 2
-is-
- of the backsheet 42 and the topsheet 38 from and along the
side edges 46 of the absorbent core 44 of the diaper 20 in
at least the crotch region 26.
The flap elastic members 60 are secured to the side
flaps 58 in an elastically contractible condition so 'that
in a normally unrestrained configuration, the flap elastic
members 60 effectively contract or gather the side flaps
58. The flap elastic members 60 can be secured to the side
flaps 58 in an elastically contractible condition in at
least two.ways. For example, the flap elastic members 60
may be stretched and secured to the side flaps 58 while the
side flaps 58 are in an uncontracted condition.
Alternatively, the side flaps 58 may be contracted, for
example by pleating, and the flap elastic members 60
secured to the contracted side flaps 58 while the flap
elastic members 60 are in their unrelaxed or unstretched
condition.
In the embodiment illustrated in Figure 1, the flap
elastic members 60 extend essentially the entire length of
the side flaps 58 in the crotch region 26 of the diaper 20.
Alternatively, the elastic members 60 may extend the entire
length of diaper 20, or any other length suitable to
provide an elastically contractible gasketing cuff. The
length of the flap elastic members 60 is dictated by the
diaper's design.
In the diaper 20 of Figure 3, the flap elastic members
60 are associated with the side flaps 58 by securing them
to the side flaps 58 with elastic attachment means 90. The
elastic attachment means 90 should be flexible and of
sufficient adhesiveness to hold the flap elastic member in
its stretched condition. The elastic attachment means 90
herein are preferably glue beads made of hot melt adhesives
such as marketed by Findley Adhesives Incorporated, Elm
Grove, Wisconsin as Findley Adhesives 581. A more detailed
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description of the manner in which the flap elastic members
6o may be positioned and secured to the diaper 20 can be
found in U.S. Patent 4,253,461 issued to Strickland and
Visscher on March 3, 1981, and U. S. Patent 4, 081, 301 issued
to Buell.
One flap elastic member 60 which has been found to be
suitable is an elastic strand having a cross section of
0.18 mm by 1.5 mm and made from natural rubber as available
from Easthampton Rubber Thread Company of Stewart,
Virginia, under the trademark L-1900 Rubber Compound.
Other suitable flap elastic members 60 can be made from
natural rubber, such as elastic tape sold under the
trademark Fulflex 9211 by Fulflex Company of Scotland,
North Carolina. The flap elastic member 60 may also
comprise any heat shrinkable elastic material as is well
known in the art. Other suitable flap elastic members 60
may comprise a wide variety of materials as are well known
in the art including elastomeric films, polyurethane films,
elastomeric foams, and formed elastic scrim.
In addition, the flap elastic members 60 may take a
multitude of configurations. For example, the width of the
flap elastic members 60 may be varied from about 0.25 mm
(0.01 inches) to about 25 mm (1.0 inch) or more: the flap
elastic members 60 may comprise a single strand of elastic
material or may comprise several parallel or non-parallel
strands of elastic material; or the flap elastic members 60
may be rectilinear or curvilinear. Still further, the flap
elastic members 60 may be affixed to the diaper 20 in any
of several ways which are well known in the art. For
example, the flap elastic members 60 may be ultrasonically
bonded, heat/pressure sealed into the diaper 20 using a
variety of bonding patterns or the elastic members 60 may
simply be glued to the diaper 20.
Each barrier cuff 62 is a flexible member having a
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- proximal edge 64, a distal edge 66, an inboard surface 68
and an outboard surface 70. As used herein, the term
flexible refers to materials which are compliant and will
readily conform to the general shape and ~ contours of the
body. In addition, if the spacing means 76 comprise
spacing elastic members 77, the barrier cuff 62 must be
contractible so that the distal edge 66 may be sufficiently
spaced away from the topsheet top surface 40 so that a
channel 96 is formed to restrain, contain and hold body
exudates within the article. The barrier cuff 62 may be
manufactured from a wide variety of materials such as
polypropylene, polyester, rayon, nylon, foams, plastic
films, formed films, and elastic foams. A number of
manufacturing techniques may be used to manufacture the
barrier cuff. For example, the barrier cuff 62 may be
woven, non-woven, spunbonded, carded, or the like. A
particularly preferred barrier cuff 62 comprises a
polypropylene material containing no finish or surfactant
to render it liquid impermeable. A particularly preferred
polypropylene material is manufactured by Crown Zellerbach
Company as Celestra~.
As shown in Figures 1 and 3, the barrier cuff 62, and
more particularly the proximal edge 64, is disposed inboard
of and preferably adjacent to the gasketing cuff 56. The
. term "inboard" is defined as the direction toward the
centerline (30 or 32, respectively] of the diaper that is
parallel to the respective edge of the diaper 20 along
which the particular gasketing cuff 56 is disposed. The
barrier cuff 62 is disposed inboard of the gasketing cuff
56 so that exudates, especially loose fecal material which
is not easily absorbed and tends to float along the
topsheet top surface 40, will contact the barrier cuff 62
before it can contact the gasketing cuff 56. The barrier
cuff 62 is disposed adjacent the gasketing cuff 56 to
1 X41412
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provide a more effective dual restraint against the flow of
body exudates. The barrier cuff 62 is preferably disposed
between the flap elastic member 60 of the gasketing cuff 56
and the longitudinal centerline 36 of the diaper 20. Most
preferably, the barrier cuff 62 is disposed between the
flap elastic member 60 and the side edge 46 of -the
absorbent core 44 in the crotch region 26 of the diaper 20.
The proximal ~dge 64 and the distal edge 66 are in
spaced relation to each other and define the width of the
barrier cuff 62. The proximal and distal edges 64 and 66,
respectively, may be in a parallel, nonpara11e1,
rectilinear or curvilinear relationship. In addition, the
barrier cuff 62 may have a variety of different cross
sectional areas including circular, square, rectangular or
any other shape such as shown in Figure 3. Preferably, the
proximal edge 64 is spaced from the distal edge 66 in a
parallel and rectilinear relationship to provide a barrier
cuff 62 having uniform widths. Each barrier cuff 62
preferably has a width of at least about 5 mm, and
preferably from about 1o mm to about 25 mm.
A preferred embodiment of the diaper 20 shown in
Figure 1 is provided with the barrier cuff 62 joined to the
topsheet 38. The term "joined" includes any, means for
affixing the barrier cuff 32 to the diaper 20, and includes
embodiments wherein the barrier cuff 62 is a separate
element having the proximal edge 64 directly or indirectly
attached to the topsheet 38 (i.e., integral) or embodiments
wherein the barrier cuff 62 is made from the same element
or material as the topsheet 38 so that the proximal edge 64
is a continuous and undivided element of the topsheet
(i.e., unitary). The barrier cuff b2 may alternatively be
joined to the side flap 58, the backsheet 42, the absorbent
core 44, the topsheet 38 or any combination of these or
other elements of the diaper 20. In a preferred diaper 20,
1 ~~1 41 2
-20-
- the barrier cuffs 62 are integral with the topsheet 38.
The integral barrier cuff 62 is preferably formed by a
single strip of material which is secured to the topsheet
by adhesive 92, the distal edge 66 being formed by folding
an end of the material back upon itself. '
The distal edge 66 is preferably disposed inboard of
the proximal edge 64 to present a more effective barrier
against the flow of exudates. The distal edges 66 are
maintained inboard of the proximal edges 64 by the adhesive
means 78 so as to obviate their inversion. While the
distal edges 66 may alternatively be disposed in other
positions in relation to the proximal edges 64, such
positions are not preferred.
The distal edge 66 is preferably not secured to any
other element in at least the crotch region 26 of the
diaper 20 so that it may be spaced away from the top
surface 40 of the topsheet 38. The distal edge 66 is
preferably spaced away from the top surface 40 of the
topsheet 38 so that the barrier cuff 62 may form a channel
96 to enhance the containment of the article. As used
herein, "spaced" includes embodiments wherein the distal
edges 66 may assume one or more positions relative to the
top surface 40 of the topsheet 38 including at some times
assuming a position adjacent the top surface 40 of the
topsheet 38. The distance between the distal edge 66 to
the top surface 40 of the topsheet 38 is measured along a
line drawn from the distal edge 66 to the closest part of
the topsheet 38 when the distal edge 66 is positioned so as
to be spaced away from the topsheet as far as possible.
(i.e., in the elastically contracted position).
Preferably, the distal edge 66 is spaced away from the
topsheet 38 by a height of at least about 2 mm, and more
preferably of from about 5 mm {about 1/4") to about .10 mm
(3~8n).
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The channel 96 is formed at least along the proximal
and distal edqes 64 and 66 and the inboard surface 68 of
the barrier cuff 62. The channel 96 forms a barrier to the
flow of exudates as they tend to move or float across the
topsheet 38. Thus the channel 96 holds and contains
exudates until the diaper 20 can be removed. .
The barrier cuffs 62 may additionally be provided with
absorbent means secured to or within the barrier cuff 62.
The absorbent means absorb and contain exudates which
contact the barrier cuff 62» The absorbent means may be
any means which is capable of absorbing and retaining
fluids and may have any size, shape, configuration or
absorbent capacity. The absorbent means may be positioned
to the barrier cuff 62 along the inboard surface 68 or
within the barrier cuff 62. Preferably, the absorbent
means is a layer of airfelt secured within the tunnel
formed by the integral barrier cuff and secured along the
entire length and width of the inboard surface 68 of the
barrier cuff 62.
In addition, the barrier cuff 62 may be rendered
liquid impermeable so as to prevent the strikethrough of
body exudates. A liquid impermeable barrier cuff 62
retards the movement of liquid through the barrier cuff 62,
thereby making it more leakage resistant. The barrier cuff
62 may be rendered liquid impermeable in any manner well
known in the art such as selectively treating the barrier
cuff, untreating the barrier cuff, or by securing a
separate material to the barrier cuff.
The spacing means 76 for spacing the distal edge 66
3o away from the topsheet to surface 40 is any member which
gathers, contracts, stiffens, shortens or otherwise acts on
the barrier cuff 62 so as to cause a channel 96 to be
formed along the barrier cuff 62 to provide a constraint
against the leakage of exudates.
1 X41 41 2
-22-
As shown in Figure 1, the spacing means 76 preferably
comprise spacing elastic member 77 secured adjacent the
distal edge 66 inside of the barrier cuff 62. The spacing
elastic member 77 is preferably s~ecurtd to the barrier cuff
62 in an elastically contractible condition so that~in a
normally unrestrained configuration, the spacing elastic
member 77 effectively contracts or gathers the barrier cuff
62. The spacing elastic member 77 can be secured to the
barrier cuff 62 in an elastically contractible condition in
at least two ways as is discussed in the above referenced
U.S. Patent 3,860,003 issued to K. H» Buell. In addition,
the length of the spacing elastic member 77 in general is
dictated by the diaper design. In the embodiment
illustrated in Figure 1, the spacing elastic member 77
extends essentially the entire length of the barrier cuff
36 in the crotch region 26, although other lengths are
cognizable.
As shown in Figure 3, the spacing elastic member 77 is
associated with the barrier cuff 62 by securing it within
the barrier cuff with elastic attachment means 94. While
the spacing elastic members 77 may be secured to the
barrier cuff 62 adjacent only the ends of the elastic
spacing member 77, it is preferable to secure the entire
length of the spacing elastic member 77 to the barrier cuff
62. The elastic attachment means 94 herein are preferably
glue beads made of hot melt adhesive such as marketed by
Findley Adhesives Incorporated, Elmgrove, Wisconsin, as
Findley Adhesives 581. A more detailed description of the
manner in which the spacing elastic members 77 may be
positioned and secured to the barrier cuff 62 can be found
in U.S. Patent 4,081,301, issued to Buell on March 28,
1978, and in U.S. Patent 4,253,461, issuad to Strickland
and Visscher on Match 3, 1981. It should also be noted
that one or more spacing elastic members 77 can be used to
~~i4~4~2
-23-
w elasticize each barrier cuff 62.
A spacing elastic member 77 which has been found
suitable is an elastic strand having a cross section of
0.18 mm by 1.5 mm and made from natural rubber as available
from Easthampton Rubber Company of stewart, Virginia, under
the trademark L-1900 Rubber Compou»d. Other suitable
spacing elastic members 77 can be made from natural rubber,
such as elastic tape sold under the trademark Fulflex 9211
by Fulflex Company of Scotland, North Carolina. The
to spacing elastic member 77 may also comprise any heat
shrinkable elastic material as is well known in the art.
Other suitable elastic materials may comprise a wide
variety of materials as are well known in the art including
elastomeric films, polyurethane films, elastomeric foams
and formed elastic scrim.
I» addition, the spacing elastic members 77 may take
a multitude of configurations. For example, the width of
the spacing elastic members 77 may be varied; the spacing
elastic members may comprise a single strand or several
2o parallel or non-parallel strands of elastic material; or
the spacing elastic members 7? may be rectilinear or
curvilinear. Still further, the spacing elastic members 77
may be affixed to the barrier cuff 62 in any of several
ways which are well known in the art. For example, the
spacing elastic members 77 may be ultrasonically bonded or
heat sealed into the barrier cuff 62 using a variety of
bonding patterns, or the spacing elastic members 77 may
simply be glued to the barrier cuffs 62.
The spacing means 76 for spacing the distal edge 66
away from the topsheet top surface 40 aay alternatively
comprise several other elements. For example, the barrier
cuff 62 may have stiffening means disposed in or on each
barrier cuff 62, The stiffening means must be sufficiently
stiff so that the distal edge 66 is spaced away from the
~ ~ 41 4 ~ 2
-24-
topsheet top surface 40. Suitable materials for the
stiffening means include foams, nonwoven fabrics, batting,
polyethylene film, formed films, spray glues, foamed
elastomerics, polyester, polyurethane, or a high loft
material as is manufactured by Carolina Formed Fabrics.
The spacing means 77 may also comprise means for
shortening the length of the distal edge 66 in comparison
to the length of the edges of the diaper 20. The distal
edge 66 can be shortened by making a fold or pleat in the
distal edge 66. This fold or pleat is secured by any of
the holding means well known to those of ordinary skill in
the art, such as adhesives or heat sealing. Alternatively,
a section may be cut out of the distal edge and the edges
brought together to form a butt or lapp joint. The distal
edge 66 may also be shortened by attaching a length of the
distal edge 66 to the topsheet 38 at a position different
from where the distal edge 66 would lie when the diaper 20
is in a flattened out condition. Other shortening
techniques as are known in the art may also be used.
The adhesive means 78 for securing end portions 72 and
74 of the barrier cuf f 62 closed are shown in Figures 1
and 2. The adhesive means ?8 provide a more comfortable
fit for the wearer and obviate inversion of the distal
edges 66 of the barrier cuff 62 during application and use.
~ Inversion is generally defined as the inboard disposed
distal edge 66 turning outwardly when the diaper 20 is
applied to the wearer. In a preferred embodiment as shown
in Figures 1 and 2, such adhesive means 78 are disposed in
the front waist region 22 and the back waist region 24 of
the diaper in the front closure zone 80 and the back
closure zone 82, respectively. The remaining portions of
the barrier cuff 62 are not secured closed so that the
distal edges 66 are left freely openable. In a preferred
embodiment, the front closure zone 80 extends through the
1 X41412
'-2 5-
entire front waist region 22, while the back closure zone
82 extends through only a portion of the back waist region
24. This construction is preferred so as to create a
channel 96 around the buttocks of the wearer to especially
prevent leakage of loose fecal material.
The adhesive means 78 are preferably glue beads' 79
consisting of hot melt adhesives such as marketed by
Findley Adhesives Incorporated, Elmgrove, Wisconsin, as
Findley Adhesives 581.
l0 Figure 4 is a sectional view of the diaper 20 in its
elastically contracted position prior to being placed on
the wearer. The topsheet 38 is chown as the body
contacting surface of the diaper 20, the backsheet 42 being
disposed away from the body of the wearer. The gasketing
cuffs 56 are shown to be gathered or contracted by the flap
elastic members (not shown in Figure 4). The diaper 20 is
shown as having two barrier cuffs 62 extending adjacent to
and inboard of the gasketing cuffs 56. The distal edges 66
are shown to be gathered and contracted by the spacing
elastic members (not shown) in the crotch region 26 so as
to provide a longitudinally extending channel 96 along the
diaper 20. In addition, the ends 72 and 74 of the barrier
cuff 62 are secured closed in the front and back closure
zones 80 and 82, respectively, so as to provide comfort for
the wearer, to obviate inversion of the barrier cuffs, and
for ease of application of the diaper.
The diaper 20 is applied to a wearer, by positioning
the back waist region 24 under the wearer's back, and
drawing the remainder of the diaper 20 between the wearer's
leg so that the front waist region 22 is positioned across
the front of the person. The ends of the tape-tab
fasteners 54 are then secured preferably to outwardly
facing areas of the diaper 20. In this manner, the barrier '
cuffs 62 should be disposed in the crotch region of the
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_26-
wearer and should provide the dispositions and functions
described hereinbefore. Once applied, the distal edges 66
of the barrier cuffs 62 extend through the groin areas and
diverge upwardly along both of the buttocks of the wearer.
Neither of the barrier cuffs 62 encircle the thighs of the
wearer. However, the gasketing cuffs 56 will encircle the
thighs and create a gasketing action against the thighs.
The ends of the barrier cuff 62 are secured to the topsheet
38 to obviate the inversion of the barrier cuffs, for
comfort for the wearer during application and use, and for
ease of application.
Figure 5 is a fragmentary coronal view showing a
section of the diaper 20 of Figure 1 in place on a wearer.
(A coronal view is a frontal plane that passes through the
long axis of the body.) As shown in Figure 5, the
gasketing cuffs 56 ride dawn on the legs and encircle the
thighs of the wearer. The barrier cuffs 62 ride up on the
legs and run through the crotch region and diverge upwardly
over both the buttocks of the wearer. The barrier cuffs 62
do not encircle the thighs of the wearer. The distal edges
66 are spaced away from the top surface 40 of the topsheet
38 and lie against the perineum of the wearer. The barrier
cuffs 62 are, therefore, pushed Bnuggly against the
perineum of the wearer in the crotch region 26 of the
diaper 20. The size of the channel 96 is enhanced by the
resiliency of the absorbent core 44 because the core tends
to push itself away from the perineum. This results in the
diaper 20 having channels 96 extending along the crotch
region of the wearer. Therefore, body exudates are
restrained from penetrating beyond the barrier cuffs 62
because the channels 96 form a barrier to the flow of
exudates.
Basically, without intending to limit the present
invention, the present invention is a diaper that is
~ ~4~4~2
-27-
especially useful and leakage resistant against loose fecal
material, the improved containment characteristics being
achieved in the following manner. As loose fecal material
is discharged onto the topsheet 38, the material flows or
floats on the top surface 40 of the topsheet 38.
(Hereinafter referred to a surface material). The surface
material moves from the point of discharge toward the
longitudinal edges 30. Surface material will contact the
barrier cuff 32 along the inboard surface 68. In normal
use, gravitational forces will tend to cause the surface
material to collect in the channel 96 formed by the
standing barrier cuf f 62 : the material being held in the
channels 96 until the diaper 20 can be removed. Improved
containment is achieved because surface material would have
to flow up the channel 96, which direction is substantially
directly against the force of gravity when the wearer is in
an upright position, in order to penetrate and flow over
the distal edges 66 of the barrier cuffs 62. However,
should such material flow beyond the barrier cuffs 62, it
is retarded from leaking out of the diaper 20 by the
gasketing effect achieved by the gasketing cuffs 56, as
they draw and gather the side flaps 58 about the legs of
the wearer, thereby providing a second and independent
effective barrier against leakage so as to further prevent
the soiling of adjacent garments.
Figure 6 is a sectional view of an alternative barrier
cuff 662 of the diaper 20 of the present invention. A
unitary barrier cuff 662 is formed by pleating the entire
diaper structure (i.e., the backsheet 42, the absorbent
core 44, and topsheet 38.) After pleating the structure,
the proximal edges 64 of the barrier cuff 662 are secured
together by adhesive 98. The barrier cuff 662 may
preferably have spacing means such as spacing elastic
members 77 secured within the barrier cuff 662 to
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-28-
elasticize the distal edges 6b of the barrier cuff 6b2 so
as to space the distal edges b6 away from the top surface
40 of the topsheet 38.
Figure 7 is another fragmentary sectional view of an
alternate embodiment of the present invention. A unitary
barrier cuff 762 is formed by U-folding or pleating the
topsheet spacing means such as barrier cuff 762 of the
diaper 20 of the present invention, The topsheet is folded
upon itself to form a distal edge 66: a spacing elastic
l0 member 77 secured within the tunnel formed in the distal
edge 66. The proximal edge 64 is secured by adhesive
attachment means 100 such as a glue bead made of hot melt
adhesives.
While particular embodiments of the present invention
have been illustrated and described, it would be obvious to
those skilled in the art that various other changes and
modifications can be made without departing from the spirit
and scope of the invention. It is therefore intended to
cover in the appended claims all such changes and
modifications that are within the scope of this invention.
