Patent Application
20150351978
This invention relates to absorbent articles such as catamenial devices and light incontinence products. In particular, this invention relates to catamenial devices such as sanitary napkins having improved comfort and body fit.
Sanitary napkins and related disposable absorbent articles that provide for the collection of menses and other bodily discharges are well known in the art. Some commercially available sanitary napkins have pressure sensitive adhesive on their backsheets for affixing the sanitary napkin to the undergarment of the wearer which can help maintain the sanitary napkin in the proper position to intercept the discharged bodily fluid. Additionally, some commercially available sanitary napkins include side flaps which can adhere to the undergarments of the wearer via adhesive and further help to maintain the sanitary napkin in the proper position.
Typically, such sanitary napkins are provided with two separate release liners—one covering the pressure sensitive adhesive of the backsheet and the other covering the pressure sensitive adhesive of the side flaps. Typically, the user removes the first release liner from the backsheet and attaches the sanitary napkin to the undergarment. Subsequently, the user removes the second release liner from the side flaps and then folds the side flaps over the undergarment thereby sandwiching the undergarment between the side flaps and the backsheet. Because the pressure sensitive adhesive of the backsheet and the side flaps can readily adhere to many different surfaces, the attachment of the sanitary napkin to an undergarment is often times not a trivial exercise.
Additionally, side flaps are often subjected to stresses during use. For example, the movement of the wearer, e.g. standing, sitting, running, etc., can cause the pressure sensitive adhesive to release from the undergarment and cause discomfort for the wearer. Unfortunately, often times the design of the sanitary napkin further contributes to the stresses applied to the side flaps during use further compromising the fit/comfort of the sanitary napkin.
Accordingly, there is a need for a sanitary napkin having side flaps configured to facilitate the adherence of the sanitary napkin to the undergarment of the user. Additionally, there is a need for a sanitary napkin having side flaps which improves the fit/comfort to the wearer while reducing stresses on the side flaps during use.
Absorbent articles constructed in accordance with the present invention can facilitate the application of the absorbent article to an undergarment of a user as described herein. In one embodiment, an absorbent article has a longitudinal axis, a lateral axis extending generally perpendicular to the longitudinal axis, and a vertical axis extending generally perpendicular to the longitudinal axis and the lateral axis. The absorbent article further comprises a chassis, a pair of side flaps and a release liner. The chassis comprises a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The chassis has a body-facing surface and an outer-facing surface.
Each of the pair of side flaps have a first surface and a second surface which is opposite the first surface. Each side flap comprises an attached area and a free end. The attached area of each side flap is attached to the chassis such that a portion of the first surface of each side flap is attached to the outer-facing surface of the chassis. An adhesive is disposed on a portion of the first surface of each of the side flaps adjacent the free end. The release liner covers at least a portion of the adhesive on the first surface of each of the side flaps, the release liner and the free ends of each of the side flaps being disposed superjacent to the chassis when the absorbent article is in an unfolded state and oriented where the topsheet is positioned superjacent to the absorbent core.
In another embodiment, an absorbent article has a longitudinal axis, a lateral axis extending generally perpendicular to the longitudinal axis, and a vertical axis extending generally perpendicular to the longitudinal axis and the lateral axis. The absorbent article further comprises a chassis, a pair of side flaps, and a release liner. The chassis comprises a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The backsheet has an outer-facing surface.
The pair of side flaps each has a first surface and a second surface opposite the first surface and each further comprises an attached area and a free end. The attached area of each side flap is attached to the backsheet such that a portion of the first surface of each side flap is attached to the outer-facing surface of the backsheet, and an adhesive is disposed on a portion of the first surface of each of the side flaps adjacent the free end. The release liner covers at least a portion of the adhesive on the first surface of each of the side flaps. The release liner and the free ends of each of the side flaps is disposed superjacent to the chassis when the absorbent article is in an unfolded state and oriented where the topsheet is positioned superjacent to the absorbent core.
In another embodiment, an absorbent article, has a longitudinal axis, a lateral axis extending generally perpendicular to the longitudinal axis, and a vertical axis extending generally perpendicular to the longitudinal axis and the lateral axis. The absorbent article further comprises a chassis, a pair of side flaps, a pair of flange seams, and a release liner. The chassis comprises a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The chassis has a first longitudinal edge and a second longitudinal edge, wherein each of the first longitudinal edge and the second longitudinal edge is curvilinear. The backsheet has an outer-facing surface.
The pair of side flaps each has a first surface and a second surface opposite the first surface and each side flap further comprises a side flap end adjacent an attached area and a free end. The attached area of each side flap is attached to the backsheet such that a portion of the first surface of each side flap is attached to the outer-facing surface of the backsheet. An adhesive is disposed on a portion of the first surface of each of the side flaps adjacent the free end. Each of the side flap ends is coterminous with the first longitudinal edge and the second longitudinal edge.
One of the pair of flange seams comprises the first longitudinal edge and the attached area of one of the pair of side flaps, and the other of the pair of flange seams comprises the second longitudinal edge and the attached area of the other of the pair of side flaps. Each of the pair of flange seams are disposed laterally outboard of the absorbent core thereby forming guides.
The release liner covers at least a portion of the adhesive on the first surface of each of the side flaps. The release liner and the free ends of each of the side flaps are disposed superjacent to the chassis when the absorbent article is in an unfolded state and oriented where the topsheet is positioned superjacent to the absorbent core.
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the present invention, it is believed that the invention can be more readily understood from the following description taken in connection with the accompanying drawings, in which:
The present invention may be utilized in a sanitary napkin and many different absorbent articles as provided below. As used herein, the phrase “absorbent article” refers to devices which absorb and contain body liquids, and more specifically refers to devices which may be placed against or near the skin to absorb and contain the various liquids, such as those discharged from the body. In typical use the absorbent articles are not intended to be laundered or otherwise restored or reused after a single use. Examples of absorbent articles include, but are not limited to: personal care absorbent products, such as: feminine hygiene products, for example feminine sanitary napkins, pantiliners, tampons, interlabial devices and the like and adult incontinence products.
Absorbent articles, and their individual components, such as a liquid pervious topsheet, a substantially liquid impervious backsheet joined to the topsheet, and an absorbent core positioned and held between the topsheet and the backsheet, have a body-facing surface and an outer-facing surface. As used herein, “body-facing surface” means that surface of the article or component which is intended to be disposed toward or placed adjacent to the body of the wearer during ordinary use, while the “outer-facing surface” is on the opposite side, and is intended to be disposed to face away from the wearer's body during ordinary use. The outer-facing surface may be arranged to face toward or placed adjacent to the wearer's undergarments or outer garments when the absorbent article is worn.
The term “nonwoven” or “nonwoven material” refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. Nonwovens do not have a woven or knitted filament pattern.
As used herein, the term “nonwoven web” means a manufactured sheet, web, or batt of directionally or randomly orientated fibers, bonded by friction, and/or cohesion, and/or adhesion, excluding paper and products which are woven, knitted, tufted, stitch-bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibers may be of natural or man-made origin and may be staple or continuous filaments or be formed in situ. Commercially available fibers may have diameters ranging from less than about 0.001 mm to more than about 0.2 mm and may come in several different forms such as short fibers (known as staple, or chopped), continuous single fibers (filaments or monofilaments), untwisted bundles of continuous filaments (tow), and twisted bundles of continuous filaments (yam). Nonwoven webs may be formed by many processes such as meltblowing, spunbonding, solvent spinning, electrospinning, carding, and airlaying. The basis weight of nonwoven webs is usually expressed in grams per square meter (g/m2 or gsm).
As used herein, the terms “joined”, “bonded”, or “attached” encompasses configurations whereby an element is directly secured to another element by affixing the element directly to the other element, and configurations whereby an element is indirectly secured to another element by affixing the element to intermediate member(s) which in turn are affixed to the other element.
As used herein, the term “hydrophilic”, refers to a material having a contact angle less than or equal to 90° according to The American Chemical Society Publication “Contact Angle, Wettability, and Adhesion,” edited by Robert F. Gould and copyrighted in 1964.
As used herein, the term “hydrophobic”, refers to a material or layer having a contact angle greater than or equal to 90° according to The American Chemical Society Publication “Contact Angle, Wettability, and Adhesion,” edited by Robert F. Gould and copyrighted in 1964.
The absorbent articles of the present invention comprise a chassis having a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet. The absorbent articles further comprise a pair of side flaps attached to the chassis. In some embodiments as discussed with regard to
The absorbent articles of the present invention can facilitate the application of the absorbent article to an undergarment of the wearer as described herein. For example, the attachment of the side flaps to the chassis can create a fold axis which can more closely follow the contour of the user's undergarment than side flaps on commercially available absorbent articles. This can improve the comfort and fit that the user experiences during use. Additionally, the attachment of the side flaps to the chassis of the absorbent article can provide guides to the consumers with regard to centering the absorbent article on the undergarment. Last, the orientation of the absorbent article either in its package or once removed from its package, can visually signal to the consumer the benefit of enhanced protection. Flange seams, described hereafter, can communicate a benefit of additional protection to the consumer.
For ease of reference, as shown in
Referring to
The absorbent article 10, constructed in accordance with the present invention, is shown in an unfolded state. The absorbent article 10 may comprise a chassis 20 which further comprises a topsheet 220, a backsheet 230, and an absorbent core 250 between the topsheet 220 and the backsheet 230. The chassis 20 may define the periphery 30 comprising the first longitudinal edge 30A and the second longitudinal edge 30B. As shown, in some embodiments, each of the first and second longitudinal edges 30A and 30B may include curvature to provide a comfortable wearing experience for the user.
As shown in
The side flaps 40A and 40B may be positioned along the periphery 30 of the chassis 20 in any suitable location. In some embodiments, the side flaps 40A and 40B may be positioned near a first end 50 of the chassis 20. In some embodiments, the side flaps 40A and 40B may be positioned near a second end 60 of the chassis 20. Still in other embodiments, the side flaps 40A and 40B may be positioned near the lateral axis 91. Still in other embodiments, the side flaps 40A and 40B may be positioned on the lateral axis 91. Still in other embodiments, more than one pair of side flaps may be utilized as discussed hereafter with regard to
Referring to
The side flaps 40A and 40B comprise an attached area 41 and 47, respectively, and free ends 43 and 49, respectively. The attached areas 41 and 47 are joined to the chassis 20 and form a portion of the flange seams 245A and 245B, respectively. The free ends 43 and 49 are typically positioned subjacent to the undergarment of the user during use. For example, the side flap 40A comprises the first surface 61 and side flap 40B comprises the first surface 65 and each side flap 40A and 40B comprises a second surface 63 and 67, respectively. The first surface 61 of the side flap 40A may comprise an adhesive for adherence to the undergarment of the user. Additionally, the first surface 65 of the side flap 40B may also comprise adhesive for adherence to the undergarment of the user.
During the application of the absorbent article 10, the side flaps 40A and 40B can fold about an axis which is immediately adjacent to their respective attached areas 41 and 47. The fold axis is created via the flange seams 245A and 245B and/or the attached areas 41 and 47. The fold axis can further facilitate the application of the side flaps 40A and 40B to the undergarment of the wearer. Unlike the side flaps on conventional absorbent articles which have no predefined fold axis, the user is often left guessing or forming, on an ad hoc basis, a fold axis which can introduce stresses into the side flap. For the embodiments of the present invention, the fold axis is created via the flange seams 245A and 245B and attached areas 41 and 47. And, in some embodiments, the attached areas 41 and 47 and can be configured to closely follow the contour of the undergarment of the wearer as discussed hereafter.
When initially removed from its outer packaging, the absorbent article 10 may be folded in half, in thirds or more. Additionally, a first release layer may be provided covering adhesive on the backsheet 230, and a second release layer may be provided covering adhesive on the side flaps 40A and 40B. For ease of viewing, neither the first release layer nor the second release layer is shown. However, the release layers will be discussed hereafter with regard to
With regard to
As shown, the flange seam 245A may comprise a portion of the first longitudinal edge 30A and the attached area 41 of side flap 40A. Similarly, flange seam 245B may comprise a portion of the second longitudinal edge 30B (shown in
In some embodiments, the attached area 41 of side flap 40A may extend from the side flap end 51 laterally inboard by about 5 mm to about 10 mm. In some embodiments, the attached area maybe less than 5 mm. However, in some embodiments, the attached area 41 may begin laterally inboard from the side flap end 51 by about 2 mm to about 5 mm. Similarly, the attached area 47 of side flap 40B may be similarly configured as the attached area 41.
During processing, after creation of the chassis 20, the chassis 20 may be cut to provide the curved first and second longitudinal edges 30A and 30B (shown in
Additional embodiments are contemplated where each of the side flaps 40A and 40B is attached to the chassis 20 such that the side flaps 40A and 40B extend laterally outboard of the first and second longitudinal edges 30A and 30B (shown in
The side flaps 40A and 40B may further comprise adhesive which is disposed on the first surface 61 of the side flap 40A and the first surface 65 of the side flap 40B. The adhesive can help adhere the side flaps 40A and 40B to the undergarment of the wearer during use. Suitable adhesives are discussed hereafter.
Referring to
In order to prevent premature attachment of the side flaps 40A and 40B to the skin of the wearer or some unintended surface, a release liner 275 may be provided which covers the adhesive on the first surface 61 of side flap 40A and adhesive on the first surface 65 of side flap 40B until the user is ready to adhere the side flaps 40A and 40B to their undergarment. The release liner 275 can facilitate the application of the absorbent article 10 to the undergarment of the wearer by allowing the user to first adhere the absorbent article 10 to their undergarment via the adhesive on the backsheet 230 while the side flaps 40A and 40B are conveniently held out of the way via the release liner 275. As shown, the free ends 43 and 49 may be positioned vertically superjacent a body-facing surface 35 of the chassis 20 prior to the removal of the release liner 275 and/or prior to use. Once the absorbent article 10 is adhered to the undergarment, the user can then remove the release liner 275 and adhere the side flaps 40A and 40B to their undergarment.
Additionally, prior to use as shown, the flange seams 245A and 245B or a portion thereof may be positioned vertically superjacent to the body-facing surface 35 of the chassis 20. In such embodiments, although the guides 263A and 263B (shown in
Additional embodiments are contemplated where the application of the absorbent article 10 to the undergarment of the user via the guides 263A and 263B (each shown in
Side flaps of the present invention may be attached to the chassis in a number of different configurations—some examples of which are discussed hereafter. Each of the embodiments described can facilitate the application of an absorbent article to a user's undergarments via guides formed by flange seams created by the attachment between side flaps and the chassis and/or via the fold axis created by the flange seams and attached areas. Additionally, each of the embodiments described below may utilize side flaps formed from discrete elements and be attached to a chassis as heretofore described regarding side flaps comprising discrete elements. Embodiments are contemplated where the side flaps may comprise an integral construction, e.g. formed from a portion of the topsheet, backsheet, or laminates/combinations thereof.
As shown in
Alternatively, in some embodiments, as shown in
In another embodiment, as shown in
The cuff 655 may be disposed on the body-facing surface 620A of the topsheet 620. Similarly, a side flap end 651 may form a cuff/barrier as well. Depending on the material utilized for the side flap 640A, the side flap end 651 and the cuff 655 can be made to be substantially hydrophobic thereby making the cuff 655 and the side flap end 651 substantially liquid impermeable.
Regarding
In some embodiments, as shown in
In another embodiment, as shown in
The cuff 955 may be disposed on the body-facing surface 920A of the backsheet 930. Similarly, a side flap end 951 may form a cuff/barrier as well. Depending on the material utilized for the side flap 940A, the side flap end 951 and the cuff 955 can be made to be substantially hydrophobic thereby making the cuff 955 and the side flap end 951 substantially liquid impermeable.
The configuration provided for side flaps 440A, 540A, 640A, 740A, 840A, and 940A may be applied to additional side flaps of an absorbent article. Similarly, the configurations described with regard to side flaps 440A, 540A, 640A, 740A, 840A, and 940A may be applied to the side flaps 40A and 40B discussed previously with regard to
Referring to
The absorbent article 1000 may comprise a chassis 1020 defining a periphery 1030 having a first longitudinal edge 1030A and a second longitudinal edge 1030B. As shown, each of the side flaps 1040A, 1040B, 1040C, and 1040D extend generally laterally outward from the periphery 1030 of the chassis 1020. Additionally, side flaps 1040A, 1040B, 1040C, and 1040D may be positioned any suitable location along the curved periphery 1030 of the absorbent article 1000 and held in place by a first release layer (not shown).
The side flaps 1040A, 1040B, 1040C, and 1040D may be positioned along the periphery 1030 of the chassis 1020 in any suitable location. In some embodiments, at least one pair of the side flaps 1040A, 1040B, 1040C, and 1040D may be positioned near a first end 1050 of the chassis 1020. In some embodiments, at least one pair of the side flaps 1040A, 1040B, 1040C, and 1040D may be positioned near a second end 1060 of the chassis 1020. Still in other embodiments, at least one pair of the side flaps 1040A, 1040B, 1040C, and 1040D may be positioned near the lateral axis 1091. Still in other embodiments, at least one pair of the side flaps 1040A, 1040B, 1040C, and 1040D may be positioned on the lateral axis 1091. Each of the side flaps 1040A, 1040B, 1040C and 1040D may be configured similarly to the side flaps described herein.
As stated previously, absorbent articles in accordance with the present invention can provide at least one of many benefits to consumers. However, processing of absorbent articles in accordance with the present invention can present some unique challenges. Side flaps on conventional sanitary napkins are unbiased. As such, processes for folding the side flaps above their respective topsheets are relatively established. In contrast, the wings of the absorbent articles of the present invention are biased against being held superjacent to their respective topsheets. As such, conventional processing may not accomplish the desired absorbent article for packaging.
Any suitable material may be utilized for the side flaps disclosed herein. Some examples include but are not limited to, nonwovens, nonwoven laminates, film-nonwoven laminates, elastomeric films laminate, elastomeric nonwovens laminate, elastomeric film-nonwoven laminates, differentially extensible substrates or laminates thereof, textile or woven materials such as cotton fabrics, elastic materials, stretchable materials, and/or combinations thereof. Embodiments are contemplated where at least one of the side flaps comprises an antibacterial and/or antimicrobial additive/composition or bacterial/microbial growth inhibitors. An example of such a composition is described in U.S. Pat. No. 7,790,947. For example, silver ions may be added to the material of at least one of the side flaps. In some embodiments, at least one of the side flaps may be breathable allowing air/vapor to permeate therethrough but not allowing liquid to pass therethrough. In some embodiments, at least one of the side flaps may be transparent or translucent or may have portions which are transparent and portions which are translucent. In some embodiments, at least one of the side flaps may comprise a friction reducing composition and/or a lotion and/or a sensate. In some embodiments, the lotion may provide the function of the friction reducing composition in addition to other benefits. Suitable lotions and sensates are disclosed in U.S. Patent Application Publication No. 2012/089110; U.S. Patent Application Publication No. 2011/070277; and U.S. Pat. No. 8,357,445. Examples of additional lotions and/or sensates are described in U.S. Pat. No. 6,570,054 and U.S. patent application Ser. No. 12/974,674. In some embodiments, the side flaps may comprise materials which comprise compositions which enhance its hydrophobicity. Some examples include hydrophobic additive formulations. Hydrophobic additive formulations and methods for incorporating them in nonwoven webs are described by Catalan in US applications publication Nos. 2006/0189956 filed on Feb. 18, 2005, and 2005/0177123 filed on Feb. 10, 2005, and in U.S. application Ser. No. 12/691,929 filed on Jan. 22, 2010, and U.S. application Ser. No. 12/691,934 filed on Jan. 22, 2010 both to J J Tee et al. that are all assigned to The Procter and Gamble Company. Some suitable, but not limiting, hydrophobic materials used as hydrophobic surface coatings and/or hydrophobic melt additives may comprise one or more silicone polymers that are also substantially free of aminosilicones. Suitable silicone polymers are selected from the group of silicone MQ resins, polydimethysiloxanes, crosslinked silicones, silicone liquid elastomers, and combinations thereof. Typically, the molecular weight of such silicone polymers should be at least 4000 MW. However, the molecular weight of such silicone polymers may be at least 10,000 MW, at least 15,000 MW, at least 20,000 MW, or at least 25,000 MW. Suitable polydimethylsilosxanes are selected from the group consisting of vinyl-terminated polydimethysiloxanes, methyl hydrogen di methylsiloxanes, hydroxyl-terminated polydimethysiloxanes, organo-modified polydimethylsiloxanes, and combinations thereof. Alternatively, fluorinated polymers may also be used as the hydrophobic surface coatings and/or the hydrophobic melt additives. Suitable fluorinated polymers are selected from the group of telomers and polymers containing tetrafluoroethylene and/or perfluorinated alkyl chains. For instance, fluorinated surfactants, which are commercially available from Dupont under the tradename Zonyl®, are suitable for use herein.
In some embodiments, the side flaps may comprise “capillary channel fibers.” Such fibers can be solid or hollow, and they can be tri-lobal, delta-shaped, and are preferably fibers having capillary channels on their outer surfaces. The capillary channels can be of various cross-sectional shapes such as “U-shaped”, “H-shaped”, “C-shaped” and “V-shaped”. One suitable example of a capillary channel fiber is T-401, designated as 4DG fiber available from Fiber innovation Technologies, Johnson City, Tenn. T-401 fiber is a polyethylene terephthalate (PET polyester).
In some embodiments, the side flaps may comprise microfibers. Meltblown fibers are microfibers which may be continuous or discontinuous and are generally smaller than 10 microns in average diameter. In some embodiments, the side flaps may comprise Coolmax® fibers.
Any suitable adhesive may be utilized on backsheets and/or side flaps disclosed herein. The adhesive can be hot-melt adhesive material capable of establishing a temporary bond with the undergarment material. A suitable adhesive is the composition designated HL-1491 XZP commercially available from H. B. Fuller, Toronto, Ontario, Canada, a composition designated as H2031 available from Bostik, a composition designated as NS34-2823 as manufactured by National Starch and Chemical of Bridgewater, N.J.
The adhesive can be applied to the backsheet at levels between about 9 gsm to about 20 gsm, in some embodiments. The adhesive applied to the backsheet may be applied in discrete strips or may cover a substantial portion of the backsheet. Regarding the adhesive for the side flaps, the adhesive above may be suitable and an additional adhesive which is suitable is designated as LA203 available from Savare Specialty Adhesives or the composition designated as 1461 available from H. B. Fuller. The adhesive for the side flaps may be applied at levels of between about 13 gsm to about 38 gsm.
Any suitable release liners can be used in conjunction with the present invention. Some examples of suitable release liners include those disclosed in U.S. Pat. No. 4,556,146, and U.S. Patent Application Publication No. 2011/0202029. The releasable cover may be a silicone coated release liner, a plastic film or any other easily removable cover. The releasable cover may be in a single piece or in a multitude of pieces, e.g. to cover the individual adhesive areas. It also can perform other functions such as providing individualized packaging for the article or provide a disposal function. Any commercially available release liner or film may be used. Some suitable examples include BL 30 MG-A SILOX EI/O, BL 30 MCI-A SILOX 4 P/O available from Akrosil Corporation, and M&W films available from Gronau in Germany, under the code X-5432.
The methods of the invention can be used with any suitable feminine hygiene article. Suitable absorbent articles include any type of structures, from a single absorbent layer to more complex multi layer structures. Certain absorbent articles typically include a fluid pervious topsheet, a backsheet, which may be fluid impervious and/or may be water vapour and/or gas pervious, and an absorbent element often called “core” comprised there between.
In general the topsheet is operatively permeable to the liquids that are intended to be held or stored by the absorbent article, and the backsheet may be substantially impermeable or otherwise operatively impermeable to the intended liquids. The absorbent article may also include other components, such as a secondary topsheet, liquid wicking layers, liquid distribution layers, barrier layers, and the like, as well as combinations thereof. Suitable topsheets, backsheets, side flaps and absorbent core materials for use in conjunction with the present invention are discussed hereafter. Additionally, suitable joining methods for topsheets, backsheets, side flaps, and optionally the absorbent core are also discussed hereafter.
The topsheet may be manufactured from a wide range of materials such as woven and nonwoven materials; polymeric materials such as apertured formed thermoplastic films, apertured plastic films, and hydroformed thermoplastic films; porous foams; reticulated foams; reticulated thermoplastic films; and thermoplastic scrims. Suitable woven and nonwoven materials can be included of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polymeric fibers such as polyester, polypropylene, or polyethylene fibers) or from a combination of natural and synthetic fibers. In one embodiment, the topsheet may be made of a hydrophobic material to isolate the wearer's skin from liquids which have passed through the topsheet. If the topsheet is made of a hydrophobic material, at least the upper surface of the topsheet is treated to be hydrophilic so that liquids will transfer through the topsheet more rapidly. This diminishes the likelihood that body exudates will flow off the topsheet rather than being drawn through the topsheet and being absorbed by the absorbent core. In one embodiment, the topsheet can be rendered hydrophilic by treating it with a surfactant. Suitable methods for treating the topsheet with a surfactant include spraying the topsheet material with the surfactant and immersing the material into the surfactant.
The topsheet can include an apertured formed film. Apertured formed films can be used for the topsheet because they are pervious to body exudates and yet non-absorbent and have a reduced tendency to allow liquids to pass back through and rewet the wearer's skin. Thus, the surface of the formed film which is in contact with the body remains dry, thereby reducing body soiling and creating a more comfortable feel for the wearer. Suitable formed films are described in U.S. Pat. No. 3,929,135, entitled “Absorptive Structures Having Tapered Capillaries”, issued to Thompson on Dec. 30, 1975; U.S. Pat. No. 4,324,246 entitled “Disposable Absorbent Article Having A Stain Resistant Topsheet”, issued to Mullane, et al. on Apr. 13, 1982; U.S. Pat. No. 4,342,314 entitled “Resilient Plastic Web Exhibiting Fiber-Like Properties”, issued to Radel, et al. on Aug. 3, 1982; U.S. Pat. No. 4,463,045 entitled “Macroscopically Expanded Three-Dimensional Plastic Web Exhibiting Non-Glossy Visible Surface and Cloth-Like Tactile Impression”, issued to Ahr, et al. on Jul. 31, 1984; and U.S. Pat. No. 5,006,394 “Multilayer Polymeric Film” issued to Baird on Apr. 9, 1991.
The absorbent core can be any absorbent member which is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining body fluids. The absorbent core may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, hourglass, “T”-shaped, asymmetric, etc.) and from a wide variety of liquid-absorbent materials commonly used in disposable pull-on garments and other absorbent articles such as commuted wood pulp which is generally referred to as airfelt. Examples of other suitable absorbent materials include creped cellulose wadding; meltblown polymers including coform; chemically stiffened, modified or cross-linked cellulosic fibers; tissue including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers; absorbent gelling materials; or any equivalent material or combinations of materials.
The configuration and construction of the absorbent core may vary (e.g., the absorbent core may have varying caliper zones, a hydrophilic gradient, a superabsorbent gradient, or lower average density and lower average basis weight acquisition zones; or may include one or more layers or structures). Further, the size and absorbent capacity of the absorbent core may also be varied to accommodate wearers ranging from infants through adults. However, the total absorbent capacity of the absorbent core should be compatible with the design loading and the intended use of the absorbent article.
The absorbent core may include other optional components. One such optional component is the core wrap, i.e., a material, typically but not always a nonwoven material, which either partially or totally surrounds the core. Suitable core wrap materials include, but are not limited to, cellulose, hydrophilically modified nonwoven materials, perforated films and combinations thereof.
The backsheet can comprise a liquid impervious film. The backsheet can be impervious to liquids (e.g., body fluids) and can be typically manufactured from a thin plastic film. However, typically the backsheet can permit vapours to escape from the disposable article. In an embodiment, a microporous polyethylene film can be used for the backsheet. A suitable microporous polyethylene film is manufactured by Mitsui Toatsu Chemicals, Inc., Nagoya, Japan and marketed in the trade as PG-P.
One suitable material for the backsheet can be a liquid impervious thermoplastic film having a thickness of from about 0.012 mm (0.50 mil) to about 0.051 mm (2.0 mils), for example including polyethylene or polypropylene. Typically, the backsheet can have a basis weight of from about 5 g/m2 to about 35 g/m2. However, it should be noted that other flexible liquid impervious materials may be used as the backsheet. Herein, “flexible” refers to materials which are compliant and which will readily conform to the general shape and contours of the wearer's body.
The backsheet can be typically positioned adjacent a outer-facing surface of the absorbent core and can be joined thereto by any suitable attachment device known in the art. For example, the backsheet may be secured to the absorbent core by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive. Illustrative, but non-limiting adhesives, include adhesives manufactured by H. B. Fuller Company of St. Paul, Minn., U.S.A., and marketed as HL-1358J. An example of a suitable attachment device including an open pattern network of filaments of adhesive is disclosed in U.S. Pat. No. 4,573,986 entitled “Disposable Waste-Containment Garment”, which issued to Minetola et al. on Mar. 4, 1986. Another suitable attachment device including several lines of adhesive filaments swirled into a spiral pattern is illustrated by the apparatus and methods shown in U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on Oct. 7, 1975; U.S. Pat. No. 4,785,996 issued to Ziecker, et al. on Nov. 22, 1978; and U.S. Pat. No. 4,842,666 issued to Werenicz on Jun. 27, 1989. Alternatively, the attachment device may include heat bonds, thermal fusion bonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitable attachment device or combinations of these attachment devices. The backsheet may be additionally secured to the topsheet by any of the above-cited attachment devices/methods.
The absorbent article may also include such other suitable features as are known in the art including, but not limited to, re-closable fastening system, lotion, acquisition layers, distribution layers, wetness indicators, sensors, elasticized waist bands and other similar additional elastic elements and the like, belts and the like, waist cap features, containment and aesthetic characteristics and combinations thereof.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
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.
