The present invention relates generally to absorbent garments and, more particularly, to diapers having an apertured zone in the surface facing the wearer for enhanced absorbency and bowel movement (BM) containment.
Absorbent products, such as baby diapers, training pants, adult incontinence briefs and underwear, all of which may be made in disposable forms. “Disposable” refers to articles that are designed to be discarded after a limited use rather than being laundered or otherwise restored for reuse. Disposable absorbent products have met with widespread acceptance in the marketplace for a variety of applications, including infant and adult incontinence care, in view of the manner in which such products can provide effective and convenient liquid absorption and retention while maintaining the comfort of the wearer. Such disposable absorbent articles often include a topsheet that is configured to be closest to the wearer during use, a liquid-impermeable backsheet or outer cover, and an absorbent core between the topsheet and the backsheet. Conventional absorbent cores often include superabsorbent polymer or “SAP,” such as hydrogel-forming polymer material. The inclusion of SAP in an absorbent core typically also increases the ability of the absorbent core, relative to a similarly sized absorbent core of fluff pulp alone, to retain absorbed liquid against pressure, thus providing lower rewet and better skin dryness. In some instances, such disposable absorbent articles also include an acquisition-distribution layer (ADL) disposed between the topsheet and the absorbent core.
Typical topsheet materials are coated with a surfactant to make them hydrophilic. Such materials are largely adequate in allowing urine to pass through to the absorbent core. However, these material do little to help bowel movement (BM) containment. Particularly, a runny BM, which includes a fluid-solid mixture that does not easily pass through the topsheet and, thus, will have the tendency to run across the surface of the topsheet. Further, the fluid-solid mixture may be unable to be absorbed by the article and may find its way outside of the product, referred to as a leak or “blowout.” There are two approaches commonly used by absorbent products to increase BM containment and decrease chances of a blowout.
The first approach involves providing an apertured topsheet to increase the ability of the fluid-solid mixture associated with a runny BM to pass through the topsheet and be absorbed by the core, or simply creating a 3-dimensional surface that makes it more difficult for fluid to travel across the surface. Current articles have topsheets that are fully-apertured such that the apertures cover an entire surface of the topsheet. While this is helpful in BM containment, there are also disadvantages of having an apertured topsheet. Namely, the topsheet also functions to keep the SAP in the core from escaping up through the topsheet and getting on the wearer. Thus, while apertured topsheets enable passage of fluid-solid mixture to the core, these topsheets also enable passage of SAP from the core through the topsheet. Accordingly, if the topsheet is apertured then the design must account for another way to contain the SAP in the core.
The second approach is to include a BM containment feature such as a pocket, pouch, voids, or other feces containment portion in the back of the article to contain the BM and stop fluid-solid mixture flow. While such features increase BM containment, they also increase design complexity which results in increased manufacturing time and price. Additionally, these features are inadequate at containing excess fluid associated with runny BMs from leaking across the topsheet into a front portion of the absorbent product.
The present absorbent garments provide improved BM containment with a target apertured topsheet. Some of the present absorbent garments include a chassis having opposing front and rear waist portions, a crotch portion extending longitudinally between the front and rear waist portions, a topsheet defining a plurality of apertures, and a backsheet. Such garments may include an absorbent core disposed between the topsheet and the backsheet, at least a portion of the absorbent core positioned in the crotch portion and an acquisition-distribution layer (ADL) disposed between the topsheet and the absorbent core, the ADL including a plurality of external edges that cooperate to define an ADL boundary. In some aspects, substantially all of the plurality of apertures are defined within an apertured region that is disposed vertically above the ADL and is enclosed within the ADL boundary when the chassis is in a flat configuration. For example, at least 75%, such as 80, 85, 90, 95, 98, or 100%, of the plurality of apertures defined by the topsheet are positioned within the apertured region. The present topsheet may include a topsheet that is only apertured within a targeted region to increase fluid absorption for BM containment as well as prevent SAP leakage. Accordingly, the absorbent garments described herein can help with BM containment in an area that it is most needed and there is no longer a need for an alternative methods of SAP containment.
In some garments, the apertured region overlies at least a majority of the ADL. Alternatively, in other garments, the apertured region overlies an entirety of the ADL. In some of the forgoing garments, a width and a length of the apertured region are substantially equal to a width and a length, respectively, of the ADL. In some configurations, the external edges of the ADL includes two widthwise edges extending in a first direction; and two lengthwise edges extending in a second direction perpendicular to the first direction
In some garments, the chassis includes a first end and a second end opposite the first end. The front waist portion extending from the first end and the rear waist portion extending from the second end. In some such configurations, the apertured region is positioned closer to the first end than the second end. In some configurations, at least a majority of the apertured region is disposed in a front half of the chassis.
In some of the foregoing configurations, the topsheet includes the apertured region and a non-apertured region. In some configurations, the apertured region includes a percentage of open area greater than or equal to 5% (e.g., between 5 and 40%) and the non-apertured region includes a percentage of open area less than 2% (e.g., less than 1%). Each aperture in the apertured region may include a maximum transverse dimension that is between 0.25 and 5.0 millimeters (mm). In some configurations, the non-apertured region spans at least a majority of the topsheet. The topsheet may include only a single apertured region. In some aspects, the topsheet includes a liquid-permeable nonwoven and the backsheet includes a liquid impermeable material.
Some of the present absorbent garments include a topsheet and a backsheet, the topsheet defining a plurality of apertures and having an apertured region and a non-apertured region. Some such garments include an absorbent core disposed between the topsheet and the backsheet and an acquisition-distribution layer (ADL) disposed between the topsheet and the absorbent core, the ADL including a plurality of external edges that cooperate to define an ADL boundary. The apertured region may overlie the ADL and be enclosed within the ADL boundary. In some configurations, an area of the ADL is less than or equal to an area of the absorbent core. Additionally, or alternatively, an area of the apertured region may be between 25% and 95% of the area of the ADL. In some configurations, an area of the non-apertured region is greater than the area of the ADL. In some garments, the chassis includes a first end and an opposing second end, a front portion extending from the first end, and a rear portion extending from the second end. In some such configurations, at least a majority of the apertured region is disposed within the front portion of the chassis. In some configurations, an entirety of the apertured region is disposed within the front portion of the chassis.
As used herein, various terminology is for the purpose of describing particular implementations only and is not intended to be limiting of implementations. For example, as used herein, an ordinal term (e.g., “first,” “second,” “third,” etc.) used to modify an element, such as a structure, a component, an operation, etc., does not by itself indicate any priority or order of the element with respect to another element, but rather merely distinguishes the element from another element having a same name (but for use of the ordinal term). The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified — and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel—as understood by a person of ordinary skill in the art. In any disclosed embodiment, the term “substantially” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent. The phrase “and/or” means and or or. To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, “and/or” operates as an inclusive or. Unless stated otherwise, the term “or,” as used herein, refers to an inclusive or and is interchangeable with the term “and/or.”
The terms “comprise” and any form thereof such as “comprises” and “comprising,” “have” and any form thereof such as “has” and “having,” and “include” and any form thereof such as “includes” and “including” are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” or “includes” one or more elements possesses those one or more elements, but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” or “includes” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.
Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/include/have—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.
Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described. The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments. Some details associated with the embodiments described above and others are described below.
The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. Views in the figures are drawn to scale, unless otherwise noted, meaning the sizes of the depicted elements are accurate relative to each other for at least the embodiment in the view.
Referring to
As shown in
Chassis 104 includes a front waist portion 124, an opposing rear waist portion 128, and a crotch portion 132 extending longitudinally between the front and rear waist portions. Front waist portion 124 includes a portion of chassis 104 extending from a first end 116 that is associated with a front end (e.g., edge) of article 100 when worn by a user. In some configurations, front waist portion 124 includes only first end 116, while, in other configurations, the front waist portion includes the first end and a portion of the chassis extending from the first end. In some configurations, front waist portion 124 may have a length that is less than, equal to, or between any two of: 25, 20, 15, 12, 10, 8, 6, 5, 4, 3, 2, or 1 percent of length 122 (e.g., the overall length) of chassis 104. Rear waist portion 128 includes a portion of chassis 104 extending from a second end 120 that is associated with a rear end (e.g., edge) of article 100 when worn by a user. Rear waist portion 128 includes second end 120 and/or a portion of the chassis extending from the second end. In some configurations, rear waist portion 128 may have a length that is less than, equal to, or between any two of: 25, 20, 15, 12, 10, 8, 6, 5, 4, 3, 2, or 1 percent of length 122 of chassis 104. In some configurations, crotch portion 132 includes a portion of chassis 104 extending directly between front waist portion 124 and rear waist portion 128.
As shown in
In some configurations, article 100 includes an absorbent core 140 disposed between topsheet 108 and backsheet 112. Core 140 is configured to absorb liquid in the absorbent article and may include materials suitable for absorbing liquids, such as, for example, a mixture of conventional fluff (e.g., cellulosic fibers) and superabsorbent polymer (SAP) particles. “Superabsorbent” or “superabsorbent material” or “SAP” refers to a water-swellable, water-insoluble organic or inorganic material capable, under the most favorable conditions, of absorbing at least about 15 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride and, more desirably, at least about 30 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride and, even more desirably, at least about 50 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride.
Article 100 also includes an acquisition-distribution layer (ADL) 150 disposed between the topsheet and the absorbent core. “Layer” when used in the singular can be a single element or a plurality of elements. For example, a plurality of sheets may together define a single layer, such as, for example, a layer with a particular function to which the sheets of the layer contribute. ADL 150 functions to acquire the liquid as rapidly as it is added to the product (to prevent uncontrolled surface runoff) and then spreads or distributes the acquired liquid over a larger surface area of absorbent core 140 at a rate that the core can absorb the liquid without undesired internal runoff and leakage. The core 140, in turn, wicks the liquid into the core to reduce wetness in ADL 150, to present a relatively dry ADL surface to the wearer and partially restoring the ADL to its initial state to acquire subsequent insults of liquid.
ADL 150 can be sized and have a construction to help mitigate liquid trapping in topsheet 108 and thereby promote dryness at the topsheet. For example, ADL 150 can include one or more longitudinal edges 152 and one or more lateral edges 154 that cooperate to define an ADL boundary 156. Longitudinal edges 152 include edges of ADL 150 which extend further in longitudinal direction D1 than lateral direction D2 and lateral edges 154 include edges of the ADL which extend further in the lateral direction than the longitudinal direction D1. As shown in
In some configurations, an area of ADL 150 (e.g., surface of ADL enclosed by ADL boundary 156) might be smaller than absorbent core 140; in this manner, the larger absorbent core can have a relatively large absorption capacity and the smaller ADL can require fewer materials for its construction (e.g., to reduce costs) while being positioned at or near the location on chassis 104 likely to received liquid insults (e.g., closer to front waist portion 124 than to rear waist portion 128) such that it adequately promotes topsheet dryness. In the illustrative example shown in
Article 100 further includes one or more apertured regions 164 in which topsheet 108 defines a plurality of apertures 168 and one or more non-apertured regions 180. In some configurations, apertured region 164 includes a portion of topsheet 108 having an aperture density (e.g., as determined by dividing the total number of apertures 168 by an area of the topsheet) is greater than or equal to any one of, or between any two of: 1.0, 1.5, 2.0, 2.5, 3.0, 3.5 4.0, 4.5, 5.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, or 15.0 (e.g., between 5 and 12) apertures 168 per square centimeter of topsheet 108. Additionally, or alternatively, apertured region 164 includes a portion of topsheet 108 having a percentage of open area (e.g., as determined by dividing a total area of apertures 168 by an area of the topsheet) that is greater than or equal to any one of, or between any two of: 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 percent (%) (e.g., between 10 and 30% or between 15 and 25%. As depicted, substantially all of (e.g., at least 75% of, and preferably at least 80, 90, 95, 98, or 100% of) the plurality of apertures 168 defined by topsheet 108 are disposed within apertured region 164 Apertures 168 can be arranged in any suitable manner, such as, for example, in a plurality of rows and columns that may be aligned (e.g., a grid as shown in
Each of apertures 168 can have any suitable shape and size; as shown in
Apertures 168 can be arranged in two or more rows, each of the rows including two or more of the apertures aligned in lateral direction D2. Additionally, or alternatively, Apertures 168 can be arranged in two or more columns, each of the columns including two or more of the apertures aligned in longitudinal direction D1. In some configurations, apertures 168 may, but need not, be equally spaced. In some such configurations, each aperture 168 can be spaced apart from at least one other of the protrusions by a distance 172, measured between the centers of the apertures, that is greater than or equal to any one of, or between any two of, 1.0, 1.5, 2.0, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0 or 10.0 mm (e.g., between 1.0-6.0 mm).
Apertured region 164 overlies at least a portion of ADL 150. In some configurations, apertured region 164 is contained to portions of topsheet 108 that overlie ADL 150. For example, as shown in
In some configurations, apertured region 164 may be at least partially disposed within front waist portion 124 or crotch portion 132 to limit fluid (e.g., from a runny BM) flow across topsheet 108 toward the front waist portion. In some such configurations, apertured region 164 may be disposed nearer to front waist portion 124 (e.g., first end 116) than to rear waist portion 128 (e.g., second end 120). In some configurations, apertured region 164 is not positioned within rear waist portion 128. In other configurations, an area of apertured region 164 positioned within front waist portion 124 is greater than an area of the apertured region positioned within rear waist portion 128.
Non-apertured region 180 includes a portion of topsheet 108 having an aperture density less than 2.0 apertures 168 (e.g., less than 1.5, 1.0, 0.5, or 0.25 apertures) per square centimeter of topsheet 108, a percentage of open area that is less than 30% (e.g., less than 25, 20, 15, 10, 5, 3 or 1%), or both. Accordingly, non-apertured region 180 may not enable a fluid (or a fluid-solid mixture) to easily pass through topsheet 108. In some configurations, as shown in
Non-apertured region 180 may make up at least a majority of topsheet 108. For example, non-apertured region 180 may have an area that is between 50% and 90% (e.g., between any two of 50, 55, 60, 65, 70, 75, 80, 85, or 90%) of an area of topsheet 108. Non-apertured region 180 may abut a portion of apertured region 164 and, in some configurations, the non-apertured region and the apertured region cooperate to form an entirety of topsheet 108. In some such configurations, non-apertured region 180 may surround apertured region 164. As described herein, non-apertured region 180 may limit the amount to fluid that passes through topsheet 108. This may allow chassis 104 to (1) direct fluid flowing on topsheet to certain portions of the topsheet (e.g., apertured region 164) where the fluid may be better absorbed into ADL 150 and/or core 140, (2) limit fluid from escaping from the core up through the topsheet, or both.
Referring additionally to
As shown in
Unexpectedly, apertured region 164a may promote sufficient BM containment despite being positioned further away from rear portion 216, which is nearest the anus of a wearer when article 100a is worn. For runny BMs, the fluid-solid mixture will travel along topsheet 108a and be readily absorbed in ADL 150a via apertures (e.g., 168) and mitigate the risk of the fluid-solid mixture from leaking outside of article 100a. In some configurations, apertured region 164a is positioned near rear portion 216 (e.g., portion of front portion 212 nearest the rear portion) to absorb the fluid-solid mixture before the mixture travels further into the front portion. In this way, apertured region 164a may limit contamination of the mixture to the wearer's anus and avoid contamination of skin nearer the wearer's genitals. Additionally, as apertured region 164a does not overlie an entirety of core 140, topsheet 108a (via non-apertured region 180a) also functions to keep material (e.g., SAP) in the core from escaping up through the topsheet and getting on the wearer. Accordingly, apertured region 164a provides adequate BM containment without the additional need for an alternative SAP containment.
Referring now to
Referring now to
In yet other configurations, as illustrated in
The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.
The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.
This application claims priority to and the benefit of U.S. Provisional Application No. 63/270,441, filed Oct. 21, 2021, the contents of which are incorporated into the present application by reference in its entirety.
Number | Date | Country | |
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63270441 | Oct 2021 | US |