CA 02298108 2000-02-23
WO 96123469 PGTIUS96I00472
ABSORBENT ARTICLE HAVING FLAPS
WITH GATHERED ppRTIONS
The present invention relates to absorbent articles such as sanitary napkins,
panty liners, adult incontinence devican, and the like which have side flaps.
Morc
particularly, the prexnt invention concerns absorbent articles having side
flaps that
are provided with gathered portions that can expand to provide improved fit
and
coverage of the weards undergarment when the flaps are wrapped around the side
edges of a weareiJ's undergarzna~t.
All manner snd variety of absorbent articles configured for the absorption of
body fluids such as menses, urine, and feces are, of course, well known.
Absortxnt
articles, partiarlarly sanitary napkins, haring wings or Saps are disclosed in
the
literature and are available in the marketplace.
Gsr~eraUy, the flaps exttnd laterally from a caitral absorbent mans and are
i~avded to be folded around the edges of the wearers panties in the crotch
region.
Thus, the Saps are dispoxd between the edges of the wearers panties in the
crotch
region and the vveuer's thighs. Commonly, the flaps are provided with an
attachment
means for affixing the flaps to the underside of the wearer's panties.
The flaps serve at least two purposes. First, the flaps prevent exudates which
otherwix would soil the edges of the wearers panties from doing such. Second,
the
Saps help stabilize the napkin from shifting out of place, especisljy when the
gaps are
aced to the underside of the panties.
Sanitary napkins having flaps of the various types are disclosed in U.S.
Patent
4,687,478, entitled "Shaped Sanitary Napkin With Flaps", which issued to Van
T'~burg on August 18, 1987, U.S. Patent 4,608,047, entitled "Sanitary Napkin
CA 02298108 2000-02-23
WO 96113469 PCTIUS96100472
2
Attachment Means", which issued to Mattingiy on August 26, 1986, U.S. Patent
4,589,876, entitled "Sanitary Napkin", which issued to Van Tilburg on May Z0,
1986, U.S. Patent 4,285,343, entitled "Sanitary Napkin", which issued to
McNair on
August 25, 1981, U.S. Patent 3,397,697, entitled "Disposable Sanitary Shield
For
Undergarments", which issued to Rickard on August 20, 1968, and U. S. Patent
2,787,271, entitled "Sanitary Napkin", which issued to Clark on April 2, 1957.
While sanitary napkins having flaps are commonly viewed as providing better
protection against soiling as compared to sanitary napkins without flaps, the
flapped
napkins commonly experience problems that keep them from being optimally
effective. These problems generally result from the stresses exerted on the
flaps
when the sanitary napkins are worn.
When the flaps are folded down along the edga of the wearer's panties,
stresses are created in the flaps, particularly when the $sps are relatively
large in size.
The stresses are especially high along the fold line at the edges of the
wearels panties
where the flaps arc bent from the body side of the panty to the underside of
the
panty. These stresses are caused by fitting a flap around the curved edges of
a panty
crotch. The stresses are magnified when a wearer sits or crouches because the
edges
of the panties are pulled outward against the flaps thus uuxeasing the forces
against
this fold line. When the strasGS become too high, the Saps may become detached
from the patsy and some portion of the aforementioned benefits of the flaps
may be
lost. In addition, even if the stresses arc not cuff dent to detach the flaps,
they may
still be sufficient to cause the flaps to bunch longitudinally inward. This
effectively
reduces the size of the flaps and the area of the wearers undergarments that
the flaps
ate able to cover. Thus, there is a commercial need for a way of eliminating
or at
tart reducing the stresses that develop in the flaps when folded, so as to
prevent
them from becoming detached from the wearer's panties and losing ability to
cover a
given arcs of the panties.
A number of variations on the types of flaps described above have been
presented in an attempt to solve these problems. A sanitary napkin having
flaps with
stress relief means in the form of a notch or a slit is described in U.S.
Patent
4,917,697 which issued to Osborn, III, et al. on April 17, 1990. Absorbent
articles
having flaps and zones of differential extensibility for relieving the
stresses which
develop in the flaps are disclosed in U.S. Patent 5,344,416 issued to Nuhara
on
September 6, 1994, and U.S. Patent 5,354,400 issued to Lavash, et al. on
October
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w0 96i'.3469 PC'ffC596~OW:
3
1-1, 1994. Although these sanitary napkins work quite well, the search for
sanitary
napkins having improved flaps hu continued.
Therefore, it is an object of an aspect of the present invention to
provide an absorbent article, such as a sanitary napkin, having flaps that
provides the absorbent article with further improved means for relieving the
stresses that develop in the flaps when they are folded down along the edges
of
the crotch of the wearer's undergarments and affixed to the underside of the
undergarments. It is another object of an aspect of the present invention to
provide such an absorbent article with flaps that do not lose their ability to
cover a given area of the wearer's undergarments during wear.
These and other objects of aspects of the present invention will be
more readily apparent when considered in reference to the following
description and when taken in conjunction with the accompanying drawings.
The present invamon is dareaed to an absorber: artide, such as a sassitary
napian, having 8sps that are prohded with gsthaed portions that an ocpand to
rdirve the that develop is the 8sps when the Saps are folded down wound
the edges of the cotch of the w~nre:'s unde:ganteerts.
The abamide oomprisa s maia body portioa having two spsad apart
ioagtardioal edges and twro spaced apart transverse edge, and a pair of Saps
uaodsted witti said tiuia body portioa, oae ea~die~ la~tQavy outward beyond
each
Io1 edge of the ma'a body portion. The tnaia body portion comprises a
~d pQViow top:hea, a iaquid impa~ious bsckshedto the topshat, and an
absorbent coca positioned batvv~een the topshea and the b~ackshea. The main
body
portioa has s fast end rcgior~ a second end region, and a ~tral region
disposed
between the 5tst and second end regions. The absorbent article has a principal
longatdinal ~a~e and a pcinaipal tran:vcse c~i~e. The Saps have a
pr~al edge, a distal edge, and a Sap traa:vene centaiine that intersects the
prindpai loagi~aal ansaiine of the absorbent article.
The sbsorbeat article is provided with a gsthaed portion positioned between
the pritKipal longitudinal caualine artd the distil edge of the Saps. A
restraint.
which extatds along at lean part of the cawal region of the main body portion,
CA 02298108 2002-08-22
4
restrains portions of the gathered portion from unfolding while allowing the
ends of
the gathered portion to unfold at locations disposed longitudinally away from
said flap
transverse centerline. In particularly preferred embodiments, the sanitary
napkin also
comprises one or more zones of differential extensibility. The zones of
differential
extensibility comprise material that has a greater range of extensibility
outward than
the points on the flaps that are located along the flap transverse centerline.
The zones
of differential extensibility are preferably disposed laterally outward from
the
gathered portions and longitudinally away from the flap transverse centerline.
A novel
releasable wrapper is also provided for enclosing and protecting the sanitary
napkin
prior to use.
In accordance with one embodiment of the invention, a releasable wrapper for
a sanitary napkin, which sanitary napkin has a main body portion having a pair
of
longitudinal side edges, the main body portion comprising a liquid pervious
body-
facing side, a liquid impervious garment-facing side, an absorbent core
position
between the body-facing side and the garment facing side, and an adhesive
fastener on
the garment-facing side of the main body portion, the sanitary napkin further
comprising a pair of side flaps joined to the main body portion and extending
laterally
outward beyond the longitudinal side edges of the main body portion, the side
flaps
each having an adhesive fastener on their garment facing side, the releasable
wrapper
comprising:
a main wrapping sheet having an inside surface, an outside surface, and a
releasable material on the inside surface for releasably securing the main
wrapping
sheet to the adhesive fastener on the garment-facing side of the main body
portion;
and
at least one flap release element having an inside surface, an outside
surface,
and a releasable material on the inside surface for releasably securing the
flap release
element to one of the adhesive fasteners on the sanitary napkin side flaps,
the flap
release element being pivotably joined to the main wrapping sheet so that the
side flap
with the flap release element releasably attached thereto may be folded over
the body-
facing side of the sanitary napkin while the main wrapping sheet is in a
substantially
planar configuration.
CA 02298108 2000-02-23
4a
BRIEF DESCRIPTION OF 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 description which is taken in conjunction with the accompanying
drawings in which:
Fig. 1 is a top plan view of a preferred sanitary napkin of the present
invention.
Fig. 2 is a cross-sectional view taken along line 2-2 of Fig. 1 through the
portions of the flaps which can expand when the sanitary napkin is wrapped
around the edge of a wearer's panty.
Fig. 3 is a cross-sectional view taken along line 3-3 of Fig. 1 which passes
through the flip transverse centerline.
Fig. 3A is a perspective view of one particularly preferred releasable
wrapper prior to the placement of the same on the sanitary napkin.
Fig. 3B is an end view of the sanitary napkin shown in Figs 1-3, which
shows the folding of one of the flaps of the sanitary napkin into position
before
enclosing the same within the particularly preferred type of releasable
wrapper.
Fig. 4 is a bottom plan view of the sanitary napkin shown in Fig. 1, with
the releasable wrapper removed.
CA 02298108 2000-02-23
'8V0 96123469 PCT/US96/00472
Fig. 5 is a perspective view of the sanitary napkin shown in Figs. 1, 2, 3,
and
4 in an in-use configuration.
DETAILED DE~CI~IpTION OF THE 1N~~E ;~Or1
FIGS. 1-3 show one preferred embodiment of a disposable absorbent article of
the present invention, sanitary napkin, 20. As shown in Figure 1, the sanitary
napkin
20 basically comprises a main body portion 22 and two flaps 24. (In the
discussion
that follows, unless otherwise noted, the sanitary napkin described herein
will have
two flaps. While it is not ne~sary that the napkin have two flaps, two flaps
are
preferred over one flap. Also, while it is not necessary that the flaps be
mirror
images of one another, they preferably are. Thus, the description of one flap
will be a
description of the other, and, for clarity, discussion of the second flap may
be
omitted.)
The sanitary napkin 20 (and the main body portion thereof) has two surfaces, a
liquid pervious body-contacting au6ce or "body s<rrface" 20A thst is intended
to be
worn adjacent to the body of the wearer and a liquid impervious gannait
s<uface
20B. The sanitary napkin 20 is shown in FIG. 1 as viewod from its body surface
20A. The sanitary napkin 20 has two centerlines, s principal longitudinal
centerline L
and a principal transverse centerline T. The term "longitudinal", as used
herein,
refers to a line, axis or direction in the plane of the sanitary .napkin 20
that is
g~~ ~>~ ~ (~~8-. aPPro~ely paraDel to) a ver'cical plane which bisects a
standing wears into left and right body halves when the sanitary napkin 20 is
worn.
Tire tams "transverse" or "lateral" used herein, are interchangeable, and
refer to a
lice, axis or direction which 4es within the plane of the sanitary napkin 20
that is
ga~aalty perpendiculu to the longitudinal direction.
FIG. 1 shows that the main body portion 22 of the sanitary napkin 20
comprises the portion of the sanitary napkin without the Saps 24. The main
body
portion 22 has two spaced apart longitudinal edges 26, two spaced apart
transverse
or end edges (or "ends") 28, which together form the periphery 30 of the main
body
portion of the sanitary napkin 20. The main body portion 22 also has two end
regions, which are designated first end rtgion 32 and second end region 34. A
central region 36 is disposed between the end regions 32 and 34. The end
regions 32
and 34 extend outwardly from the edges of the central region 36 about 1/8 to
about
1/3 of the length of the main body portion. A detailed description of a
sanitary
CA 02298108 2000-02-23
WO 96lZ3i69 PCTIZ;596~OO.t'~
6
napkin having such a central region 36 and the rwo end regions 32 and 34 ~s
contained in U.S. Patent 4,690,680 issued to Higgins on September 1, 1987.
The main body portion of the sanitary napkin 20 can be of any thickness,
including relatively thid~ rdativdy thin, or even very thin. The embodiment of
the
sanitary napkin 20 shown in Figures 1-3 of the drawings is intended to be an
example
of a moderately thiclc sanitary napkin having a main body portion simile to
that
dacnbed in U.S. Patents 5.234,422 and 5,308,346 issued to Sndla, et al.
It should be understood
thst the sanitary napkin shown is mcdy one pcefrrred embodiment, and that the
praau invattion is not limited to absorbent uncles of the type or having the
specific
con5gurations shoam in the drawings. For example, the ausin body portion 22 of
the
sanitary napkin as alto be embossed with such as thox desatbed is the
SneUa patents.
FIG. 2 the individual contpoeamts of the main body portion 22 of the
y napiaa 20 of the pracat it~on. The maim body portaoa Z2 8a~a~aliy
coatprisa at least three primaryr coe~oneau. Tlrae mchrde s liquid pervious
top~ea 38, a frquid impervious 40, and as ab~ocbent core 42 poaaiooed
bavveai the top:heet 38 and the bsclohea 40. Suitable msta~als for tbex
components of the pry napioe 20 m dac~tbed err g~w detail in the pate~a
pubiicanioe~ ~ Tire tapahea, the
badnheet, sad the abeocbant cae may be auembled in a vuiay of configurations
lmown is the art ('mchrd~ so aged 'sandwich' prod<rw and 'tube' p~roduets).
S~recal p~5wred saedtaty napkin ~figsuatior~ are described gmaaliy is U.S.
Patent 4,3I1,9?r4, 'Honder~ed Disposable Abaorb~a>< Article' isnred to Ahr on
March
30; 19=2; U.S. Patent 4,4?.f,130, 'Compound Sarntary Napkin' isared to
De:Marais
net Js~r 10, 1984; U.S. Pataus 4,950,264 and 5,009,653, both ~d 'Thin,
F7~oble Sarotny Napidn' isaied to Osborn on August 21, 1990 sad Apn'1 Z3, 1991
rape~ivdy; the aforementioned patent app~atioot iswred to Snella, et aL;
Canadian application 2140767 filed February 22, 1993,
~rc-r Pubu~ion rro. wo 9orozo96, published
Fehruir5r 3, 1994); and Canadian application 2170492 filed
October 12, 1994.
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wo 96 x.3~169 PCT~TS96~OO.i'.
7
The main body portion 22 of the sanitary napkin may
also be comprised of one or more extensible components such as thox sanitary
napkins, and the like described in Canadian a~nlication 2192199
f i led July 2 3 , 19 9 2 , (PCT fubhcation
Nos. WO 93/01785 and 93/01786, both pub4shed February 4, 1993 ,
The sanitary napkin 20, as shown in FIG. 2, is ssxmbled in a sandwich
conscuction in which the topsheet 38 and the backshea 40 have length and width
dima~ions ga~aliy large: than those of the ab~cb~ core 42. The top:heet 38 and
the bscksheet 44 extend beyond the edgy of the absocban core 42 and arc joined
together along a seam to form at least portions of the periphery 30 of the
main body
portion. The seam an be formed by any aims ply used in the art for this
purpose, such as gluing, aimpirtg, or fusiag. It a to be understood thu the
embodiment illustrated is only one pou~bie embodin~at, albeit a preferred one.
Other possible anbodiments ~e one in which as absor~t core 44 is nsq:t~iy
campltsdy wrapped with topsbea before it is placed on a badcshee:. The maia
body
portion 2Z caa also wise an absorbatt core which ponasa su~dmt iateg:ity
to stand alone and is Gquid pwious on oae strr6x wh0e the other stu5ae has
been
traced to rends it liquid itetpavious.
The santnry naplaa 20 of the praerrt invention cxxnpri:a a pair of Saps 24
joined to the main body portion Z'1. The gaps Z4 esund tom their proximal
edges
44 lnaagy outerard beyond the longitudinal side edgy 26 of the main body
portion
a to their duta! edges 46. '/he term ~joioed~, as used herder, ancontpasses
~usatioos in which an dement is ~recdy warred to another danatt by ~g
tb. de~c dareatr to the «~er d~ ~m w~ the den>ent is
m,~t,xtlyr seaaod to the other danmt by aging the dement to intamediue
m~be(s) wl~ in turn are axed to the otlKr dema~ and configuruions in which
one dement is integral writh another dement, i.e., one dm>mt is part of
the other dement.
'The Saps 24 of the one preferred anboditmrt shown in Fgures 1-3 are
integral with the maim body portion 22 of the sanitary ruplon. Ia such a tax,
the
topsheet 38 may form the body-5cing of both the Saps Z4 and the main body
porooa 22, and the baclcshea 40 may form the 8artnast~~'8 ~ of the same.
It is posa'ble for the sb:orbent material of the s:nitary napidn 20 to extend
into the
Saps 24 to form a gap absorbent core, as described in gr~ata desyl in U.S.
Puent
CA 02298108 2000-02-23
WO 96123469 PCT/US9GI00472
8
4,917,697 (although the embodiment shown in Figs. 1-3 does not utilize such a
construction). In alternative embodiments, the flaps 24 may be comprised of
separate pieces of material or elements which are attached to the main body
portion
22. When the flaps comprix xparate elements, they can be joined to the main
body
portion 22 by any techniques known to thox skilled in the art. Such techniques
include, but are not limited to adhesives, heat and/or pressure, ultrasonics,
etc.
The flaps 24, whether they are integral with the main body portion or separate
elements attached thereto, are each associated with main body portion 22 along
a
juncture. This is typically a longitudinally-oriented (or "longitudinal")
juncture, such
as line of juncture 48. As uxd herein, the terms "juncture" (or "line of
juncture")
refer to regions where the flaps 24 extend from or are joined to the main body
portion 22. The junctures can be arty of various curved or straight tines, but
they are
not limited to lines. Thus, the juncaues cut comprix regions, flanges, strips,
intermittent lines, and the like. In the sanitary napkin 20 illustrated in
Figure 1, lime
of juncture 48 is a generally longitudinally oriented region that can range
from being
relatively straight to slightly concave. When the flaps 24 are integral with
the main
body portion 22, the lines of junctiue 30 may represent lines of derturcation
bdwaxt
the main body portion 22 and the flaps 24, although it is not necessary that
there be a
precise line of demarcation. Thus, it is also possible to either consider the
line
designated 48' in 1 ig. 1 as a line of juncarre stn which csse the flaps 24
arc indirectly
joined to the main body portion through folded regions 50), or for the line of
juncture
to be considered to be located betwxn lines 48 and 48'.
It is also not necessary that the flaps 24 extend from (or be joined along)
the
longitudinal edges 26 of the main body portion 22. The flaps 24 race, for
instance, be
joined to the maim body portion 22 arty distance inward (or "inboard") from
the
longitudinal edges 26 toward the principal longitudinal centerline L. From the
foregoing, it is apparent that the Saps 24 can each be joined to the main body
portion
22 along the longitudinal edges 26 of the main body portion 22, or along the
principal longitudinal centerline L, or at arty place betvvxrt the principal
longitudinal
centerline L and the longitudinal edges 26 of the main body portion 22.
The flaps 24 have a proximal edge 44 at or adjacent the line of juncture 48. A
distal edge (or "free end") 46 is remote from the tine of juncture 48. As
shown in
Figure 1, each flap 24 is divided into a front half 50, and a back half 52 by
a flap
transverse centerline T 1. The flap transverx centerline T 1 may coincide with
the
principal transverse centerline T of the sanitary napkin, but this is not
absolutely
CA 02298108 2000-02-23
WO 96113469 PCT/US96I00472
9
required. In other embodiments, the flap transverse centerline T 1 may be
offset
either to the front or to the rear of the principal transverse centerline T.
The flap
transverse centerline Tl extends through the principal longitudinal centerline
I to
divide the sanitary napkin into four quarters A, B, C, and D.
Figures I-3 show that the flaps 24 preferably each have at feast one gathered
portion 54. The term "gathered portion" refers to a portion of the sanitary
napkin
which is gathered inward, preferably toward the principal longitudinal
centerline L of
the sanitary napkin. The gathered portion also preferably remains in a
gathered
condition during the time the sanitary napkin is worn. The gathered portion 54
can
be formed entirely in the flaps 24, entirely in the main body portion 22, or
partially in
the flaps 24 and partially in the main body portion 22. Preferably, the
sanitary napkin
20 has two gathered portions 54, one adjacent each flap 24.
The gathered portions 54, as shown in Figs. I-3, are preferably located in the
regions surrounding and including the junct<rra 48 of the flaps 24 with the
main body
portion 22. Fig. 1 shows that the flaps 24 also have portions which are not
gathered
inward to the same extent as the gathered portions 54. The portions of the
flaps 24
that are disposed longitudinally away from the gathered portions are referred
to
herein as "expar>daWe portions" 55. The expandable portions 56 should be
capable
of expanding (preferably generally in the transverse direction (as shown by
the
arrows in Figure I)) when the flaps 24 are folded around the edges of the
wearer's
parries.
The gstlwxed portions 54 and the expandable portions 56 can be formed in arty
suitable manner. In the preferred embodiment shown in Figs. I-3, the gathered
portions 54 are foamed by pleating or folding the flaps 24 with generally
Ioagrtudintlly-oriented fold tines 58 to form folded or pleated sections (or
"pleats")
60. The fold lines 58 can run along andlor inboard or outboard of the juncture
48 of
the flaps and the main body portion 22: The folded sections 60 of the flaps 24
are
preferably folded and arranged side-by-side. The folding of the Saps 24
creates an
enclosed tube or casing which is left open at its ends. In alternative
embodiments in
which it is not desired to have the folded sections stead up, the folded
sections 60
may be folded on top of each other (that is, stacked perpendicular to the
plane of the
sanitary napkin). The folded sections 60 preferably run the length of the
juncture 48.
The folded sections 60 are gathered in and restrained from opening by a
restraint,
such as a fold or pleat restraint 66 that preferably extends the length of the
entire
central region 36 of the main body portion 22, but does not extend into the
end
CA 02298108 2000-02-23
WO 96123469 PCTJUS96I00472
10
regions 32 and 34. This provides the sanitary napkin 20, and particularly the
flaps
24, with expandable end portions 56 which are generally extensible in the
transverse
direction and with center portions (along the central region 36 of the main
body
portion 22) which are not transversely extensible.
In such a folded embodiment, the folded sections 60 of the sanitary napkin can
be provided with any number of fold lines. For instance, in the most basic
form of
the folded embodiment, the $sps 24 can simply be folded inward toward the
principal
longitudinal centerline L at a single line along the juncture 48 and tacked to
the main
body portion 22 in the region of the junctwe 48. Typically, however, as shown
in
Figwes 1-3, the sanitary napkin will have st least three fold lines 58, which
are
designated 58A, 58B, and 58C. Fold lines 58A and 58C will be referred to as
the
outer fold lines, and fold line S8B is referred to as the center fold line.
The folded
portions 60 of the sanitary napkin are preferably arranged so that the center
fold line
58B is approximately evenly spaced between the outer fold lines 58A and 58C.
The
folded portions 60 of the saniwy napkin are preferably restrained so that the
outer
fold lines 58A and 58C sre both joined to the side of the main body portion 22
as
shown in Fig. 3 in approximatdy the same plane as the bottom of the backsheet
of
the sanitary napkin. The fold lines 58 are preferably spaced so that the
folded
portions 60 between the outer fold lines 58A and 58C and the center fold line
58B
extend vertically upward above the plane defined by the topsheet of the
sanitary
napkin to foam s pair of double wall barriers (or "barrier leg w$s") 68 along
the
longitudinal edges 26 of the main body portion 22 of the sanitary nspkin. The
restraint 66 should preferably extend subs<antia>!y the entire length of the
central
portion 36 of the main body portion in order to foam these barriers 68.
The restraint 66 can be any suitable type of dement that is capable of keeping
a
portion of the folded rnataiaf fi~om unfolding. Suitable restraints 66
include, but are
not limited to adhesives, ultrasonic bonds, heat and/or pre~we bonds, tapes,
etc.
These different types of restraints can be in an unlimited number of
configurations.
Such configurations can include spots, lines, patches, err. The ends 66A and
66B of
the restraint 66 are preferably spaced equal distance away from the flap
transverse
centerline Tl. This creates flaps with expandable portions 56 which are able
to open
up an equal amount in both the front and back halves 50 and 52. In alternative
embodiments, however, it may be desirable for the restraint 66 to be offset
more
toward one end of the sanitary napkin than the other to adapt the sanitary
napkin to
fit various types of panties.
CA 02298108 2000-02-23
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The sanitary napkin can have two restraints 66, one for each flap, or it can
have a single restraint that spans from one flap to the other. In alternative
embodiments, the sanitary napkin could have more than one restraint 66 for
each flap
24. In the preferred embodiment shown in Figs. 1-3, the sanitary napkin has
one
restraint 66 for each flap. The restraint 66 shown in Figures 1-3 is an
"interior"
restraint (i.e., it is located in between two folded sections 60 of the flaps
24). In
alternative embodiments, the restraint 66 can be of a type which secures the
folded
sections 60 of the flaps 24 from the outside (or exterior) of the folded
sections 60.
The restraint 66 may be of any size provided it is no larger than the length
of the
juncture 48. This allows the expandable portions 56 of the flaps 24 to open
properly.
This is the case since the expandable portions 56 of the flaps 24 will
typically open
from the ends 48A and 48B of the lines of juncture 48 to the ends 66A and 66B
of
the restraint 66.
The sanitary napkin 20 can also be provided with an optional means for
elastically contracting the double-wall barrier 68, such as elastic strand 67
inside each
of the folded portions 60. The elastic strands 67 car, be used to assist the
stand-up
barriers in staying upright so that they form a tight seal against the
wearer's body to
prevent leakage of exudates. One suitable cocuxruction for an elasticized
stand-up
barrier is described in U.S. Patent 4,909,803 issued to Aziz on March 20,
1990.
The sanitary napkin 20 preferably also has st least one zone of differential
extensibility (or "zone of aaensibility") 70. The tam "zone of differential
extensibility", as used herd refers to a portion of the sanitary napkin 20
which is
capable of exta~ding s differing amount (preferably a greater amount), than
surrounding portions of the sanitary napkin 20. Preferably, as shown in Figure
l, the
sarritsty napkin 20 has four zones of differential rxtau~ility 70, one in each
quarter
of the unitary napkin 20. The zones of di$a~auial extensibility 70 act to
further
relieve the straaes which develop in the flaps 24 when they are folded around
the
sides of the wearers panty crotch.
The zones of diffenerttial extensibility 70 are preferably primarily
extensible in a
greater amount generally outward in the transverx direction. This is generally
in the
direction of the arrows shown in Figure 1. As used herein, the phrase
"generally in
the transverse direction" means that the extensibility has a transverse
component. All
of the extension, however, need not be exactly parallel to the principal
transverse
centerline, T, of the sanitary napkin. For example, in the embodiment shown in
Fig.
l, the zones of differential extensibility 70 are extensible in a direction
between the
CA 02298108 2000-02-23
R~O 96P23~69 PCTIC596~OO.t'.:
12
longitudinal and transverse directions. The extensibility of the zones of
differential
extensibility 70, however, is preferably oriented more in the transverse
direction than
in the longitudinal direction so that it is still generally in the transverse
direction.
Although, it is also possible that in other mtbodiments, the extensibility of
the zones
of differential extensibility can be oriented more in the longitudinal diradon
than the
transverx diraiion, or even amrety in the longitudinal dirxvon.
The zone(:) of diffaen:>s1 exteruability 70 can comprise any structure capable
of eaaending s grater amourrt in the transvax direcxion than the surrounding
portions of the sanitary napkin. Suitable structures for the zones of
differential
extensibility 70 include, but tie not limited to zones of rastaial that tie
mechanicaUv
strained, conugsted, "rind rolled'. folded, 'SELFed' as described in
C~1 apple. 2170492 filed October 12, 1994, I pleated, or joined along
a auvad juncture. These s:nrcaues (alttvough shown is Ftgs 1-3 as only being
P~
of the 8sps 24), an comprise portions of the maser body portion ZZ, portions
of the
Saps Z4, or both Examples of sanitary tnplcn: with ~ of diffaarbal cctam'bdity
are &rrthc dex~ed is the afocanentiooed U.S. Pst~ 5,354,400 sawed to Lavasl~
a al. oa October 11, 1994, and U.S. Patmt 5,3E9,094 to be i:wud to Lvsul~ a
al.
on February 14, 1995.
The Duty napmt ZO shoarn in F>gura 1-3 has Saps with ~ regions 62
that hsv~e been provided arith diffaentW a~'brTity by ring rolling the corns
'f bs otaar room are ring roiled is aarocdanoe with methods described in
U.s. Pateot 4,107,364 i:ved to S'tssoa oa August 15, 19?E, U.s. Patmt
4,834,741
istwd to Sabee on May 30, 1919, U.S. Patent 5,143,6T9 isrued to Gerald M Webs,
at aL on Septaimbar 1, 1992, U.S. Patent 5,156,793 issued to Kameth B. Buell,
et al.
oa October m, 1992, and U.S. Pataat 5,167,x97 isrued to Gerald M Webs, et al.
on December 1, 1992. The ring roiling (or pr~acon~u~ should be applied so that
dc fold litres 72 in the comrgatior~~ are oriented ganaally is the
long'rtudirul
darec:ioa. The phrase 'gmaa>ty in the longiardina! datectioo' (acrd similar
Phr~s).
a used hae4 ~ ~m ~ the longinrdinal diauauion than in the
trsnsvax ion. Thos, the fold lines 72 may angle away from the Principal
longitudinal caualine L. Ia the preferred embodira~att shown in Figs. 1-3, the
fold
lines 72 form an angle of between about 40' - 45' with the principal
longitudinal
ceraaline L This wdl provide the desired transverse direction extensibility. -
CA 02298108 2000-02-23
WO 96/23469 PCTNS96100472
13
The zones of differential extensibility 70 are generally located laterally
outboard of the gathered portions 54 and expandable portions 56 of the
sanitary
napkin in the embodiment shown in Figs. 1-3. The zones of differential
extensibility
70 are also preferably located in the corner regions 62 of the sanitary napkin
20. The
sanitary napkin 20 has four corner regions 62 (two corner regions either in
and/or by
each flap, and one in each quarter). The team "corner regions" 62, as used
hereic~
refers to portions of the sanitary napkin 20 that are generally located along
or
adjacent a portion of the juncture 48 of the flaps 24 with the main, body
portion 22.
The corner regions 62 for each flap 24 are located in two areas in the regions
of the
ends 48A and 488 (or 48A' and 48B~ of each juncture 48 (or 48~. One corner
region 62 is located adjacent the longitudinal juncture 48 in the front half
50 of the
flap 24. The other is adjacent the longitudinal juncture 48 in the back half
52 of the
flap 24. The corner regions 62 are preferably at least partially disposed
longitudinally
away from the flap transverse centerline T 1 in each direction. (Thus, the
corner
regions 62 may be described ss being longitudinally "remote" from the flap
transverse
centerline T1.)
In the most preferred case (as will be subsequently described in greater
detail),
the zones of differential extensibility 70 are located along a porrion of the
fold line
where the flaps 24 are folded around the wearers panty notch. The fold line
will
typically be located along or adjacent the longitudinal juncture 48 of each
flap 24.
Since the terms "portions", "zones", and "regions", as used herein, refer to
general
areas, the zones of differerttia! extensibility 70 and the corner regions 62
are, thus,
not limited to points- which lie precisely on the lines of juncture 48.
Typically, they
will inchide both those points which Ge on the lines of juncture 48 as well as
the
surrounding areas of the sanitary napkin 20 (which include the aforementioned
fold
lines). The longitudinal junctures, thus, may merely serve as approximations
for the
location of the zones of differential extensibility 70.
In alternative embodiments, the zones of differential extensibility 70 need
not
be located laterally outboard of the gathered portions 54 and the expandable
portions
56. It is also possible for the zones of differential extensibility 70 to be
at least
located laterally inward of the expandable portions 56, or even at least
partially
within the boundaries of the expandable portions 56. The location of a zones
of
differential extensibility 70, or a portions thereof, within the boundaries of
the
expandable portions 56 can be advantageously used to further increase the
amount of
extension provided by the zone of differential extensibility. Any of these
types of
CA 02298108 2000-02-23
WO 96/Z3469 PCT.T596~04i':
14
arrangements can be beneficial provided the operation of each of the differem
types
of structures do not unduly interfere with the other.
The sanitary napkin 20 preferably also has fastener: that are adapted to
secure
the sanitary napkin 20 to the crotch region of an undergarment. Figwes 2, 3,
and 4
show one preferred type of faaa~a, adhesive attachment means, such as central
pad
' adhesive 74 and fisp adhesive 76. The fasteners used with the sanitary
nspkin of the
presort invention are, howewc, not limited to adhesive attschment means. Any
type
of 5.stata used in the art ties be used for such use. For example, the saniury
napkin 20 could be secured to the vwearears urtderganttart by mechanical
fasteners, or
a combination of adhesive and mechanical fasteners. For simplicity, however,
the
fish will be dacnbed in tams of sttachment means and are prcferabiy
P~'e sassitive adhesive fastmas. Suitable prelude sensitive adtk,9ve isnaesz
are dearn'bed in grates detar~ err U.S. Patent 4,917,697.
The adhesive f>srmQS ties be estranged in any suitabk con5guratioa Ia the
preferred embodiment :irovvn, the oantral pad adhmv~e 74 aid Sap adhesive 76
form
one continuous adhesive patch that ~ is the shape of a croes. The coal psd
adhesive 74 pro~idas an att:c~t means for seauiug main body portion
Z2 in the crotch portion of a peaty. 'The Sap adhnive 76 portion of the
adhesive
pa:tan is used to s~ in maiettaiainS the Saps 24 is potion after they are
wrapped
around the adSes of the c~otdt portion of the panty. The gaps 24 cra be
maintained
in position by the 8apa Z4 to the undergaenent, or to the opposing Sap.
'fhe fact that tHere are no ape betw~em the omaal pad adhaiv~e 74 and the Sap
adbnive 76 bas the e~eCx of holdi~ the ~ napion in plane better and reducing
nay teod~cy Sot the nasia body portion 2Z to buxh t:ansvQady inarard and make
tbs >3apa I4 come unattached from the w~nre:'s peaty.
'Ib omdral pad adhesive 74 and the Sap adhesives 76 may each be covered by
aepacate removabk rdmse !laws to keep the adhesives from :ticjdng to
actraneous
sutssoa prig to tree. Prefaabiy, howevc, the adhe:rve atuchmeat means are both
covered by a sinSle tdease litrat (or 'edeasabla wrsppd') 7E. Evm more
prefaabty,
the rdmae liner 7E also scves as as individual pckage for the sanitary napkin.
Suitable rdease liners that also save a an individual pacinge for a sanitary
napkin
are dacnbed is U.S. Patent 4,556,146 iuued to Swanson, et al. (which dixloses
a
~'~Y ~P~ ~ ~'sPPa) arid U. S . Patent 5 , 569 , 22 8 .
CA 02298108 2000-02-23
WO 96113469 PCTNS96100472
Fig. 3A shows an especially preferred version of a releasable wrapper 78 for
use with the sanitary napkin 20 of the present invention. As shown in Fig. 3A,
the
releasable wrapper, generally designated by reference number 78 comprises
several
components. These include: a ruin wrapping sheet 78A; an optional release
component, such as a release paper or release coating 788; and, a pair of flap
release
dements 78C.
The main wrapping shett 78A can comprise any material known in the art as
being suitable for use as s releasable wrapper material. It may have a release
coating
thereon (that is, on its inside surface) so that it can be releasably attached
to the
central pad adhesive 74. Alternatively, the main wrapping sheet 78A may have a
release paper adhered to its inside surface as shown in Fig. 3A, and the
central pad
adhesive 74 is adhered to the release paper rather than directly to the main
wrapping
sheet 78A The flap release dements 78C are joined to the main wrapping sheet
78A
such as by flap release demem seau~ement means 79. The flap release dements
78C
are positioned so that they will underlie the flap adhesives 76 when the main
body
portion 22 is placed on the main wrapping sheet 78A It should be understood
that,
although the flap release dements 78C are shown a9 comprising two separate
dements, it is also possrble that the flap release dements 78C can comprise a
single
element or strip of material that has two portions, one at each of its ends
which
comprise the flap release denunts. The flap release dements 78C are preferably
pivotally connected to the main wrapping sheet 78A
The key to the furtcxioning of this pr~eferTed releasable wrapper 78 is that
the
end portions comprising the release dements 78C cover the flap adhesive 76 and
are
abk to pivot relative to the main wrapping sheet 78A as shown in Fig. 4A The
pivoting enables the flaps 24 to be folded over the body surface 20A of the
sanitary
r~aplaa. This allows the flaps 24A to be foldod so that the resrrliing package
is
smalia and more corrveniertt for the user to carry than if the releasable
wrapper were
folded around the sanitary napkin with the flaps extended as shown in Fig. 1.
The sanitary napkin 20 is prepared for packaging when the sanitary napkin and
its flaps 24 are placed flat on the releasable wrapper 78 a shown in Fig. 1.
The flaps
24 and the releasably attached flap release elements ?8C covering the flap
adhesives
76 are folded over the body siuface 20A of the sanitary napkin. The flaps 24
can be
retained in this body surface-facing relationship (or topshett-facing
relationship) in a
number of di$arent ways. One way to maintain the flaps 24 folded over the
topshcct
is by placing a spot of adhesive between the flaps 24 and the body surface 20A
of the
CA 02298108 2000-02-23
WO 96123469 PCTNS96100472
16
sanitary napkin. Preferably, however, the flaps 24 are temporarily maintained
in a
topsheet-facing relationship by placing a folding bar on top of the flaps
during the
packaging process, and then tri-folding the main body portion 22 of the
sanitary
napkin 20 and wrapper 78 about transverse axes with the flaps 24 folded so
that the
tri-folding of the main body portion 22 around the flaps 24 holds the flaps in
place.
In such a configuration, the advantage of the releasable wrapper 78 is that
when the
rdeasable wrapper 78 is unfolded from a tri-folded configuration, the sanitary
napkin
20 can be conveniently removed Gom the rdeassble wrapper 78 in a one-piece
motion. The user can, for example, hold one end of the releasable wrapper 78
with
one hand and then grasp the end of the sar>itary napkin 20 which is adjacent
thereto
with the other hand, and simply peel the sanitary napkin 20 from the wrapptr
78.
While a preferred sanitary napkin embodimatt has been described, numerous
other sanitary napkin embodiments having flaps are available and are disclosed
in the
literature. Thex could be provided with the gsthaed portions of the present
irrvention. In particular, sanitary napkins having flaps are dixlosed in U.S.
Patent
5,346,486 entitled "Sanitary Napkin Having Latently Extenstible Means for
Attachment to the Undergarment of the Wearer", issued Septanba 13, 1994, in
the
name of Osborn, et al., U.S. Patents 5,009,653 and 4,950,264, both entitled
"Thin,
Flexible Sanitary Napkin" which issued to Osborn on April Z3, 1991 and August
21,
1990, rvely. U.S. Patent 4,917,697 entitled "Sanitary Napkin Having Flaps and
Stress Relief Mesas" which issued to Osborn, III, et al. on April 17, 1990, U.
S.
Patent 4,687,478, entitled "Shaped Sanitary Napkin With Flaps", which issued
to
Van T'ilburg on August 18, 1987, U.S. Patent 4,608,047, emitted "Sanitary
Napkin
Atta~chntent Meaat", which issued to Mattingly on August 26, 1986, U.S. Patent
4,589,876, entitled "Sanitary Napkin", which issued to Van Tilburg on May 20,
1986, U.S. Patent 4,285,343, entitled "Sanitary Napkin", which issued to
McNair on
Aunt 25, 1981, U.S. Patent 3,397,697, entitled "Disposable Sanituy Shield For
Undergarntatts", which issued to Rickard on August 20, 1968, and U.S. Patent
2,787,241, entitled "Sanitary Napkin", which issued to Clark on April 2, 1957.
Suitable absorbent articles in the form of pantiliners that could be provided
with such
flaps are dixlosed in U.S. Patent 4,738,676 entitled "Pantiliner" issued to
Osborn on
April 19, 1988. Suitable absorbent articles, at least some of which are in the
form of
adult incontinence products, are described in U.S. Patents 5,300,054 issued to
Feint,
et al. on April 5, 1994, and 5,304,161 issued to Nod, et al. on April 19,
1994.
In addition, in one particularly preferred version of the sanitary napkin of
the
present imrention, the flaps 24 can be provided with two doublo-wall barriers
along
CA 02298108 2000-02-23
WO 96/23469 PCT/US96I00472
17
each side of the napkin. One of these double-wall barriers (preferably the
interior
barrier) is constructed as described herein, and the other double-wall barrier
is
provided as described in U.S. Patent 4,589,876 issued to Van Tilburg. Having
now
described some sanitary napkins that can be provided with gathered portions,
the
sanitary napkin of the present invention will now be described in greater
detail with
relation to the function of the same in the wearer's undergarments.
Figure 5 is a depiction of the sanitary napkin 20 of the present invention in
place in an undergarment of the type commonly worn by many women and well
known as a panty 10. The configuration of the sanitary napkin 20 shown in Fig.
5 is
presented primarily for purposes of discussion, rather than to limit the
possible
configurations the sanitary napkin may take in ux. It should be understood
that the
sanitary napkin of the present invention may also take other configurations in
use.
The panty 10 comprises a crotch portion 12, a front section 14, and s back
section 16. The crotch portion I2 joins the front and back sections and
comprises
two elasticized side edges 18. The salutary napkin 20 is utilized by removing
the
releasable wrapper 78 and placing the sanitary napkin 20 in the panty 10 as
shown in
Figure 5. The center of main body portion 22 is placed in the crotch portion
12 of
the panty 10 with the backsheet 40 in contact with the inner surface of crotch
portion
12 of the panty and one end of main body portion 22 extending towards the
front
section 14 of the panty and the other end towards the back section 16. Central
pad
adhesive 74 maintains main body portion 22 in position. The distal portions 46
of
flaps 24 are folded around the elasticized side edges 18 of the panty. The
flap
adhesive portions 76 secure the flaps 24 to the underside of the panty.
The sanitary napkin of the present imrention is believed to provide a number
of
ba>~ts over prior sanitary napkins. In prior sanitary napkins, when the flaps
are
folded down around the arrved edges 18 of the crotch portion 12 of the panty,
stt~a developed in the flaps, Particularly in the corner regions of the same.
These
straws are rnagnified when the flaps are attached to the pants underside. The
stresses are further magnified when the panty is pulled up into position and
the
elastics in the partly edgy 18 force the folded portions of the flaps into the
uppermost part of the wearer's crotch and thigh. The straw are most highly
concentrated along the fold 19 where the flap 24 change from being disposed on
the
body side of the panty to being located on the underside of the panty. In
other
words, the stress are concentrated at the edges 18 of the crotch portion 12 of
the
panty 10. The stresses in the flaps 24 generally follow the arc formed by the
edges
CA 02298108 2000-02-23
WO 96123469 PCTIUS96100472
18
18 of the crotch portion 12. These stresses may cause the corner regions of
the flaps
24 to bunch longitudinally inward. This reduces the area of the wearer's
undergarments the flaps are able to cover. If the stresxs are great enough,
the flaps
24 can become detached from the panty and the flaps 24 will be less than
optimally
effective.
In order to eliminate, or at least reduce these stresses, the sanitary napkin
20 is
provided with the expandable portions 56 and zones of differential
extensibility 70.
The expandable portions 56 and zones of differential extensibility 70
preferably
reduce the stresses siong the fold 19 to such a degree that the flaps 24 will
remain
attached to the underside of the panty and will not lox their ability to cover
a given
area of the wearers undergarments.
The sanitary napkin of the present invention provides a number of advantages
ova a sanitary napkin provided with a single type of zone of differaitial
extensibility,
such as either ring rolled regions or pleated regions. The gath«ing .inward of
portions of the sanitary napkin, as noted above, ailowa the sanitary napkin to
additionally expand transversely to ft around the elasticized side edges of
the
wearers panty crotch to further reduce stresses on the 8sps 24.
Providing the sanitary napkin with expandable portions 56 eau also be used to
overcome potential design limitations that can occur when attempting to
achieve
optional amounts of exterwbility using only ring rolled zones of diff~er~tial
extensibility. In order to provide the optirtul fit around the wearer's
panties, it has
been found to be neoawy to build a rdativdy large amount of extensibility into
such ring rolled regions (preferably about 26 mm in each zone of differential
exteatrbility). The extenstbitity is particwlarly important in the region
betwxn the
narrowest part of the panty crotch and the pLce where the elasticized edges 18
of the
vveare~s panties cross the distal edges 46 of the flaps. The flaps 24 need to
expand
transverxly an amount equal to the distance D in Fig. 5 in order to fit
smoothly
around the curved side edges 18 of the wearers panties.
There are potentially inherent limitations on the amount of extensibility that
can be added to a material by ring rolling the material. These limitations are
due to
the properties of the material as well as the ring rolling process. The
materials
generally used in sanitary napkin flaps typically have to be rdat'rvely low
cost and
readily available. Thus, the materials have to be cost-effective for ux on
disposable
absorbent articles. When thex materials are ring rolled, any attempt to deform
the
CA 02298108 2000-02-23
WO 96123469 PCT/US96/00472
19
material in order to impart greater amounts of extensibility to such materials
may run
the risk of rupturing or creating holes in the material.
One way previously used to achieve the necessary amount of extensibility was
to form the flaps 24 as separate elements and then to attach the flaps 24 to
the main
body portion 22 laterally ittward of the longitudinal edges 26 of the main
body
portion 22. This way allowed the ring rolled regions to start underneath the
absorbent core 42. Starting the ring rolling underneath the absorbent core 42
is
necessary because it is generally di~cult to achieve the desired extensibility
by ring
rolling the main body portioa 22 of the sanitary napkin through the topsheet,
backshxt, and core. Forming the flaps 24 from separate elements also allowed
greater flexibility in the types of materials that could be used for the flaps
(i.e., the
flaps would not be limited to the material used in the topsheet 38 and
backsheet 40).
However, attaching separate Sap elements to the main body portion had the
disadvantage that it complicated the process of making the sanitary napkin
because of
the need to make, handle, and attach separate pieces of material to the main
body
portion of the sanitary napkin.
The structure of the presatt invention, however, solves these problems, and
allows a sanitaryr napkin having integrally-formed flaps to be made with an
optimal
amount of extensibility. The structure described herein also allows the
optimal
amount of extensibility to be achieved with a broader range of materials
without
aicountering the aforane~ioned cnataial and processing limitations. The
gathering
of tfte flaps of the praatt invattion further effecdvdy doubles the amount of
flap
material that can be ring rolled, if desired, for additional extensibility.
The ring
r~oUittg is shown, for instance, as extending into the expandable portion 56
of the flap
(ao that the zone of differ~dal extensibility and expandable rtion ov
po erlap), in the
iaw~a right hand comer of Figure 1. In addition, since the structure of the
sanitary
napkin of the present invention does allow the flaps to be provided with such
greater
amounts of extensibility, it is possible to. effectively make flaps which are
even longer
(measured in the longitudinal direction). This allows the flaps to cover a
larger
portion of the wearer's panty elastics, and to preferably cover a length of
the panty
elastics that nuts substantially the entire length of the main body portion.
The present invention also provides the sanitary napkin with a flap structure
which has advantages over a flap which is pleated and retrained only in the
area of
the flap transverse centerline T1. One advantage over such a structure is that
the
restraining of the flaps ova a larger distance reduces the tendency of the
flaps to
CA 02298108 2000-02-23
WO 9611.3169 PCTlL;S96i00.1'.:
become sloppy and unwieldy where they are not restrained. Thus, more efficient
ux
is made of the flap material. In addition, the unrestrained flap rtuurial can
be
positione=d more closely along the weareras parry elastics where it is needed
to cover
and protect the same from soiling.
The gsthaed portions can, as described above, also provide double-wall
barriers to the Sow of bodily exudsta in the transvexx dirxrion across the:
body
sutfux 20A of the sanitary napkin 20. In addition, the underside of the double-
walleai barrios 68 can form tuned-Nice struc:iua that can fit over the dastics
on the
edges l8 of the wards paatid to aid in holding the s;nitary napkin 20 in
props position during weir. This is eAspeaaUy tare for the expandable portions
56 a
the ends of the Saps 24.
The :aoitary napkin of the pr~a~t invatdon is also capable of being made
comrestiexttly on s mararfiuxuring voe. One non.timitmg way of malting s<rcb a
sanitary napkin is to 5rst ais~biy the compoomts for the :~itary aapkin into a
pre-
formed :arritary napkia that looks vexy much liioe the sudtary rapids shown is
fig. 1
woedd look with the rat:~s 66 punad out and the $~ 24 aixmded. The ring
rolling is than added to the ~ region 62 of the :amta:y napkin to provide the
mne: of diffa~ial oaexnnbilrty 70. FoOowing the ring rol>mg step, the
pre'formeed
sa~tar~r napkin a pasted through a mans, such a folding boards to form the
folded aectioas 60. '11e raa~raints 66 are th~ added to bold the folded
sections in
place, the adhesive s are apptied~, and that the rdexnbk 78 is placed
oa top of tb adhaaive mss.
Wl~e partiaalar eanbodimatts of the pre: Lion have bexa dlustnted
sad deaatbed, it arould be obvious to those skt'lled in the art that vuiexrs
othex
doings and modi8extions catr be made: without departing from the spirit and
scope
of the imrenvoa
