JPH0532063B2 - - Google Patents

Description

BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to disposable diapers, incontinence briefs, and the like.

BACKGROUND OF THE INVENTION Disposable diapers are garments worn primarily by infants around the lower torso and intended to receive urine, feces and other body fluids. Disposable diapers function to contain exudates and separate them from the wearer's body and the wearer's surroundings.

Previously, diapers were formed from a piece of cloth that was pinned around the lower part of the wearer's torso and was intended to be washed and reused. Recently, disposable diapers have become popular, thereby relieving mothers (and others caring for infants) from the unpleasant task of collecting and laundering dirty cloth diapers. In addition to the logistical benefits afforded by disposable diapers, modern embodiments provide a drier surface for the wearer's body more effectively and efficiently than cloth diapers even when enclosed in rubber or plastic pants. They often work in a manner superior to that of cloth diapers, as they tend to contribute to the wearer's outer clothing and other surrounding surfaces without soiling them.

Disposable diapers, incontinence pads, etc. typically consist of three elements: a liquid-permeable top sheet that is placed next to the wearer's skin; a liquid-impermeable back sheet that forms the outer surface of the diaper, incontinence pad, etc. during use; and an absorbent element interposed between the top sheet and the back sheet.

The topsheet is often a hydrophobic nonwoven fabric. The topsheet is fluid permeable so that urine passes freely through it to the absorbent element. Its hydrophobic nature tends to keep its upper surface (i.e. the surface away from the absorbent core and adjacent to the wearer's skin in use) dry and therefore protected from fluids absorbed within the absorbent element. .

The absorbent element, as its name suggests, is adapted to receive and retain liquid passing through the topsheet. The absorbent element is
It consists of a layer of batt, usually paper cotton, and more usually air-formed pulp fibers.

The backsheet functions to contain fluids within the absorbent element and to keep the wearer's outer clothing and other surfaces from becoming soiled by these fluids. Typically, the backsheet consists of a liquid-impermeable vapor-impermeable material, such as polyethylene film.

Backsheets of impermeable material function to contain liquid within the absorbent core and keep the wearer's outer garments from soiling, but are sometimes perceived as making the diaper hot and uncomfortable. Furthermore, their impermeability prevents self-drying of the diaper, which would occur due to evaporation of the liquid contained therein.

Backsheets that are impermeable to liquids but permeable to vapors are known and described in the art as breathable backsheets. A breathable backsheet provides a cooler garment and allows some self-drying of the diaper when worn. As mentioned above, these breathable backsheets seek to allow the passage of vapor therethrough while retarding the passage of liquid. For example, US Pat. No. 3,156,242 teaches the use of microporous films as breathable backsheets. U.S. Patent No. 3,881,489
A breathable backsheet is taught that is comprised of a combination of two layers: a low void volume porous thermoplastic film and a porous high void volume hydrophobic tissue. U.S. Pat. No. 3,989,867 teaches a breathable backsheet with tapered hollow bosses that allow vapor to pass easily while preventing the passage of liquid.

In general, the last two cited patents provide breathability over substantially the entire outer surface of the diaper. U.S. Pat. No. 4,341,216 describes and claims a slightly different example of a breathable backsheet. One practical effect of this invention is that it tends to limit the vapor permeability of breathable backsheets in the crotch region compared to the vapor permeability of the backsheet in the lumbar region.

While breathable backsheets offer further improvements over conventional impermeable backsheets, and those described in the last three patents have particular value, developments are still being sought that will provide diapers that are more comfortable and more useful. ing.

SUMMARY OF THE INVENTION The present invention relates to disposable diapers comprising breathable cuffs, i.e. cuffs that allow the passage of steam through them.

Disposable diaper cuffs (or leg bands)
is the portion of the diaper that, in use, wraps around or contacts the wearer's legs, usually in the thigh region of the wearer. The cuff is usually, but not necessarily, a portion or extension of the backseat. The cuff can be a portion or extension of the topsheet, or even a separate element connected to or affixed to the diaper. A breathable cuff is one that allows some degree of free passage of vapor (including air and water vapor) therethrough while resisting the passage of liquid to some degree. Disposable diapers usually have two cuffs.

Cuffs can be breathable over their entire area (or surface), or they can be breathable over only a portion of their area.

DETAILED DESCRIPTION OF THE INVENTION While this specification concludes the claims which particularly point out and distinctly claim the subject matter regarded as the invention, a better understanding of the invention may be obtained from a study of the accompanying drawings and the following examples. This is believed to be achieved by a careful reading of the following detailed description of the invention.

The present invention relates to a distinct improvement in disposable diapers, incontinence briefs, etc.

Disposable diapers have conventionally been presented in various specific examples. The present invention is intended to be used in conjunction with various known embodiments. In particular, U.S. patents
Re 26151 describes and claims a disposable diaper that has achieved wide acceptance and commercial success. U.S. Pat. No. 3,860,003 also describes and claims a significantly improved disposable diaper that has achieved wide acceptance and commercial success. The diaper taught by U.S. Pat. No. 3,860,003 differs in many ways from that taught by U.S. Pat. , a U.S. patent having retractable leg openings with lateral flaps that improve liquid containment by having sufficient width and flexibility to provide continuous non-slip contact with the wearer's body. No. 3860003 specifies that there are no provisions regarding diapers. In terminology herein, the diaper of US Pat. No. 3,860,003 is said to have elastic cuffs.

Another different embodiment of a disposable diaper is described and claimed in European Patent Application No. 82200801.7, filed June 29, 1982. The diaper of this European patent application also differs from the diaper of U.S. Patent Re 26151 in a number of ways, including that the diaper of U.S. Pat. There is no provision for a plurality of flaps having a fixed end fitted to the outer cover layer and connected to the outer cover layer and a resiliently operating end spaced apart from the fixed end. As with the diaper of U.S. Pat. No. 3,860,003, the terminology used herein refers to
The diaper of specification 82200801.7 is said to have shrinkable or elastic cuffs.

Disposable diapers (sometimes called incontinence briefs)
and intended to be worn by adults)
Another shape of is shown in US Pat. No. 4,253,461.

For convenience of explanation, the present invention is disclosed in European Patent Application No.
The case where it is applied to the diaper of Specification No. 82200801.7 is described. However, it should be understood that the present invention can be used and is recommended for use with other disposable diaper embodiments, particularly those described by U.S. Pat. No. 3,860,003. .

FIG. 1 shows a disposable diaper 10 (European patent application no.
82200801.7) is a perspective view.
Generally, the crotch portion 13 of the diaper 10 is placed between the wearer's legs, and the front waist portion 11 and back waist portion 12 are placed adjacent the wearer's front and back waist regions, respectively. The front waist section 11 and the rear waist section 12 are joined by a bonding adhesive tape 14 to surround the wearer's waist and hold the diaper 10 in place.

Diaper 10 is generally symmetrical with a lateral centerline 17 running laterally across its width. It is also symmetrical with a longitudinal centerline 18 running longitudinally along its length. In a symmetrical disposable diaper, the front waist part 11 and the rear waist part 1
The designation "front" and "rear" in relation to 2 is implied by the position of the bonding adhesive tape 14.

The cuff of disposable diaper 10 has reference number 15.
It is shown by. In FIG. 1, a cuff 15 is shown as a general representative of a cuff, one embodiment of which is breathable and will be described in detail below. The cuffs 15 can substantially be referred to as, and are sometimes referred to as, leg bands or side flaps. Cufflinks 1
5 are their respective outer edges (outboard
edges) have longitudinal side edges 16 on top.

As described in the background section of this specification, disposable diapers are comprised of three main elements:
That is, it comprises a top sheet, a back sheet and an absorbent element. The disposable diaper 10 shown in FIG. 1 is no exception. disposable diaper 1
0 comprises the three basic elements of a disposable diaper, although it contains additional elements as described below.

In FIG. 2, as in other figures showing cross-sectional views, the thickness of certain materials are exaggerated for clarity. Furthermore, in all the figures, reference numbers are used consistently to identify the same or similar elements.

FIG. 2 is a cross-sectional view of the disposable diaper 10 taken along line 2--2 at the front waist portion 11.

It shows one aspect of the structure of the diaper 10.

The main elements of the disposable diaper 10 are a top sheet 26, an absorbent element 24, and a back sheet 25. Top envelope tissue 22 and back envelope tissue 2
3 is placed adjacent to and surrounds the absorbent core 21 to contain the constituent materials of the absorbent core and provide tensile strength. Top envelope tissue 2
2. The combination of absorbent core 21 and back envelope tissue 23 is considered to be an absorbent element as indicated by reference numeral 24. That is, the three components generally function as a single absorbent element.

In certain embodiments of the disposable diaper 10, the absorbent core 21 is a generally flat, generally rectangular absorbent body. Top envelope tissue 22 and back envelope tissue 23
are essentially coextensive with the absorbent core 21 and are placed adjacent opposite sides thereof. As shown in FIG. 2, the back envelope tissue 23 is folded over and folded around the lateral distal edge 28 of the absorbent core 21 in the waist region of the disposable diaper 10, and is folded over by means not shown. The envelope tissue 22 is secured to the envelope tissue 22 (e.g., as shown in FIG. 3, the envelope tissue 22 and 23 do not overlap the absorbent longitudinal side edges 39). The construction of the diaper 10 in the rear waist region 12 is similar to that shown in FIG. The size of each of envelope tissues 22 and 23 is determined by the size of absorbent core 21.

Envelope tissues 22 and 23 may be manufactured from any permeable material known to those skilled in the art. Preferably the material has wet strength properties.
Envelope tissues 22 and 23 weigh approximately 16
g/m ² and approximately 12.7 mmH ₂ O with a pressure differential of approximately
Particularly satisfactory results are obtained when produced from sheets of wet strength tissue paper having an air permeability of 30.5 m ³ /min/m ² tissue.

In connection with disposable diapers, envelope tissues, such as top envelope tissue 22 and back envelope tissue 23, are optional elements. Although not required, their presence is preferred.

Envelope tissues 22 and 23 may optionally be secured to respective sides of absorbent core 21 by convenient means (not shown) well known to those skilled in the art.

Absorbent core 21 is generally compressible, conformable, non-irritating to the wearer's skin, and can be any member capable of absorbing and retaining liquid.

In the illustrated embodiment, the absorbent core 21 is rectangular in shape. Its lateral and longitudinal dimensions are selected depending on the size of the infant selected to wear the disposable diaper. When the disposable diaper 10 is selected for use by infants weighing between about 5 kg and about 10 kg, the absorbent core 21 is
Width (horizontal dimension) approximately 31.8cm x length (vertical dimension)
It is approximately 40.6cm. Other sizes for larger or smaller infants can be readily selected by those skilled in the art.

Absorbent core 21 can be manufactured from a variety of materials commonly used in disposable absorbent articles. The materials are also described in the patent. Examples of suitable absorbent materials are paper cotton, absorbent foams, absorbent sponges, superabsorbent polymers, and preferably ground air-formed pulp, commonly referred to as absorbent fluff. In the specific example of the size described above, when the absorbent core 21 is made of absorbent fluff, the absorbent core 21 has a diameter of approximately 30 mm.
to about 56 grams and has an absorbent capacity of about 8 to about 16 grams of water per gram of absorbent fluff. It has a density of about 0.10 to about 0.175 g/ ^cm3 .

As illustrated in FIG.
The second main element of 0 is the top sheet 26
It is. The top sheet 26 is secured to the back envelope tissue 23 and the back sheet 25 by securing means 27, respectively. Fixing means 2
7 can be by means well known to those skilled in the art, such as adhesive bonding. A suitable adhesive is a hot melt adhesive sold under the trademark Eastobond A-3 by Eastman Chemical Products Company of Kingsport, Tennessee.

Topsheet 26 can be any conformable, soft-touch, non-irritating (to the wearer's skin), liquid-permeable flat material. It can be manufactured from porous paper made from natural fibers, synthetic fibers or mixtures thereof, non-woven fabric made from natural fibers, synthetic fibers or mixtures thereof, apertured plastic film, porous foam, etc. Examples of suitable topsheets are e.g.
Re et al. 26151 and US Pat. No. 3,860,003.

The top sheet of the diaper is in contact with the wearer's skin, receives liquid exudates, rapidly passes the exudates therethrough to the absorbent core, and separates the wearer's skin from the liquid in the absorbent core. Function. To facilitate effective performance of the last function, the topsheet is preferably hydrophobic.

A preferred topsheet is a spunbond polyester nonwoven fabric made from fibers having a denier of about 2.2 to about 2.5 and a basis weight of about 17 g/m ² . Another preferred topsheet material is about 65% staple length, 1.5 denier polyester fibers (e.g., Kodel type 411 polyester fibers sold by Tennessee Eastman Corporation of Kingsport, Tennessee). 1.5 denier rayon fiber with crimped staple length approx.
15% and an acrylic copolymer binder [e.g.
Celanese in Siallot, North Carolina
Celanese (CPE8335) sold by the Corporation consists of approximately 20%. "Staple length" means fibers having a length of at least about 15 mm.

Suitable topsheets may also be made from apertured plastic films, such as those described in U.S. Pat. No. 4,342,314. Another apertured thermoplastic film useful as a topsheet is detailed in U.S. Pat. No. 4,341,217. Still yet another suitable topsheet is disclosed in U.S. Pat.
It may be formed from a liquid impermeable material with tapered capillaries as described in US Pat. No. 3,929,135.

Another preferred topsheet is made from polypropylene fibers that are carded and thermally bonded in a spaced pattern. Length approx. 3.8cm and approx. 1.5~approx.
3.0 denier fibers are preferred. A preferred sheet has a basis weight of about 22 g/m ² .

The size of the top sheet 26 is determined by the size of the absorbent core 21.

Disposable diapers usually and preferably have a top sheet. However, it is not unknown for disposable diapers to be manufactured without a topsheet (eg, when the surface of the absorbent element serves the function of the topsheet). The present invention will function and is intended for use in this type of structure.

As mentioned above, one function of the backsheet 25 is to
The objective is to prevent liquid from escaping the disposable diaper 10 and soiling the wearer's outer clothing or other surfaces that come into contact with the disposable diaper. Any conformable, non-irritating, flat material that is impermeable to bodily fluid exudates may be used as the backsheet 25. Suitable materials are detailed, for example, in the aforementioned US Pat. No. Re 26151 and US Pat. No. 3,860,003.

Preferred backsheets have a thickness of about 0.012 to about
Made from polyethylene film with a diameter of 0.051mm.

Breathable backsheets useful in the present invention are described in the aforementioned US Pat. No. 3,156,242, US Pat. No. 3,881,489, US Pat. No. 3,989,867 and US Pat.

The size of the backsheet 25 is determined by the size of the absorbent core and the exact diaper design chosen.

As detailed below, the present invention includes breathable cuffs on disposable diapers. In certain preferred embodiments of the invention, the breathable cuffs may be manufactured from a portion of the backsheet 25. This requires that certain modifications be made to the longitudinal edges of the backsheet 25. Thus, the discussion of backsheets (including backsheet 25) up to this point in this specification refers appropriately to the portion of backsheet 25 that forms the outer portion of the disposable diaper (including disposable diaper 10). It is thought that there are. That is, the portion of the back seat that extends longitudinally from the front waist portion 11 to the rear waist portion 12 (including both) and extends horizontally between the cuffs 15 is as follows:
This is considered to be the original back seat for disposable diapers.

In FIG. 1, cufflinks 15 as shown
is a typical cuff part. They are,
Defined in further detail by referring to a cross-section of the cuff 15 taken along line 3--3.

FIG. 3 is an enlarged cross-sectional view of cuff 15 taken along line 3--3 of FIG. 1 and shows a conventional elasticized cuff.

Top envelope tissue 22, back envelope tissue 23 and top sheet 26
are essentially coextensive with the longitudinal side edges 39 of the absorbent core 21 . The top sheet 26 is preferably secured to a top envelope tissue 22 which may optionally be secured to the absorbent core 21 by means of securing means 37.
The fixing means 37 may be any means known to those skilled in the art,
For example, it can be an adhesive bond. The backsheet 25 is folded around the longitudinal side edges 39 of the absorbent core 21 as shown and secured to the topsheet 26 by fastening means 37. Optionally, the backsheet 25 and pack envelope tissue 23 may be secured to the absorbent core 21 by means well known to those skilled in the art, such as by securing means 38, which can be an adhesive bond.

When the back sheet 25 is connected to the top sheet 26 by the fixing means 37, the fixed ends 36 for the cuffs 15
give. From the fixed end 36 to the distal end 3 of the cuff 15
The extension of the backsheet 25 through 5 to the free end 34 serves to form the cuff 15.

In the conventional embodiment shown in FIG. 3, elastic element 31 is operatively associated with cuff 15 by securing it to cuff 15 by elastic coupling means, not shown. The elastic coupling means should be flexible and should have sufficient adhesive properties to hold the elastic element 31 in a substantially infinitely stretched state. A preferred means is a hot melt adhesive, such as the trademark Findley Adhesives manufactured by Findley Adhesives, Inc. of Elm Grove, Uruk.
691-336. A more detailed description of how the elastic element 31 should be positioned and secured to the disposable diaper 10 is given in the aforementioned US Pat. No. 3,860,003. It should also be noted that one or several elastic elements can be used in the elastic cuff of a disposable diaper.

The elastic element 31 is affixed to the cuff 15 in an elastically contractible condition such that the elastic element 31 effectively contracts or gathers the cuff material adjacent the elastic element 31 in a normally unconstrained configuration. The elastic element 31 is
It can be attached to the cuff 15 in an elastically contractible state in at least two ways. For example, elastic element 31 may be stretched to a tensioned state and secured to cuff 15 while cuff 15 is in an unshrunk state. Alternatively, the cuff 15 can be contracted, for example by pleating, and the elastic element 31 can be secured to the contracted cuff 15 while the elastic element 31 is in its relaxed or unstretched state.

Preferably, the elastic element 31 develops a skin contact pressure of about 0.007 to about 0.17 Kg/cm ² in use.
In order to provide suitable skin contact pressure, the elastic element 31 preferably has a thickness of about 10
It will have a contraction force of ~200g. The elastic element 31 should provide a retraction force of this kind, and thus from its relaxed state approximately 50 to
Establish the state of elongation at approximately 400% elongation.
One elastic element that has been found to be suitable is a natural elastic element such as that having a cross section of 0.18 mm x 1.5 mm and available under the trademark L-1900 rubber compound from East Hampton Rubber Company of Stuart, Virginia. It is an elastic tape made from rubber. Other suitable elastic elements may be manufactured from natural rubber elastic tape sold under the trademark Fulfex 9211 by Fulfex Company of Scotland, North Carolina. The length of the elastic element 31 is generally determined by the diaper design. In the embodiment shown in FIG. 1, the elastic element extends essentially the entire length of the cuff 15. In the embodiment shown in FIG.

Cuff 15 is manufactured from a flexible material. The overall width of cuff 15 can be considered to be the distance from fixed end 36 to distal end 35 when cuff 15 is fully extended. Because the cuff 15 is flexible, the actual distance in use between the disposable diaper, as typically represented by the outer surface of the topsheet 26 and the distal end 35, can vary.

Typically, the width of cuff 15 is greater than about 6.3 mm. Preferably, this width is at least about 13
mm, more preferably at least about 19 mm. The maximum width of cuff 15 will be determined by diaper size and practical considerations of material cost.

The dimensions of the cuff 15 from the distal end 15 to the free end 34 will vary according to the size and design of the diaper.

Length of cuff 15 (i.e. disposable diaper 10
(its dimensions along the longitudinal edges) will vary according to the size and design of the diaper.
In the specific example shown in FIG.
extends essentially the entire length of the diaper 10.

As mentioned above, the present invention is a significant improvement in disposable diapers. The foregoing discussion herein is primarily about conventional diapers, and it was necessary to fully describe the context in which the present invention is used. Attention will now be directed to the invention in more detail.

As shown in the conventional embodiment illustrated in FIG. 3, cuff 15 is comprised of an impermeable material. Even if the main part of the backsheet 25 is a breathable backsheet, the cuffs (or longitudinal edges) of the diaper
The portion of the backsheet that forms the backsheet is impermeable (ie, impermeable to both liquids and vapors). In the present invention, the cuff 15 is permeable to vapor over at least a portion of its surface or area (as used herein, "breathable" refers to a material or element that is "permeable to vapor"). (The two terms can and are used interchangeably).

Referring to FIG. 4, imaginary boundary line 46 represents the transition point between the breathable (vapor permeable) and impermeable zones of cuff 15. Referring to FIG. Reference numeral 47 generally indicates the impermeable portion of cuff 15, while reference numeral 4
5 generally indicates the breathable portion of the cuff 15. The exact location of the imaginary boundary line 46 is not fixed, but rather is selected by the diaper designer to provide the desired performance. If the imaginary border 46 is established adjacent the fixed end 36, essentially all of the cuff 15 will be breathable. However, if imaginary border 46 is established adjacent distal end 35, cuff 15 will be effectively impermeable and functionally equivalent to a conventional cuff.

As shown by the difference in the method of drawing in Figure 4,
The breathable portion 45 of the cuff 15 has the characteristics of the cuff 1
This is different from the impermeable portion 47 of No. 5. In the simplest case, the impermeable portion 47 is impermeable to both liquids and vapors (virtually all sheet materials are impermeable to vapors and, under some pressure, to liquids). It is recognized that some materials have a somewhat finite (sometimes small) permeability. As used herein, "impermeable" (whether referring to vapor or liquid) means that the material in question is substantially impermeable to the passage of vapor or liquid in the practical sense relevant to disposable diapers. means resistant. Similarly, "permeable" is sometimes used to describe a material that allows the easily measurable passage of liquid or vapor under conditions normally encountered during use of disposable diapers. The breathable part 45 is, in the simplest case, freely permeable to both vapor and liquid.

In more complex practical cases, the opaque portion 47
is as before impermeable to both liquids and vapors, while the breathable portion 45 is relatively permeable to vapors but relatively impermeable to liquids. .

In even more complex cases, such as when the backsheet 25 of the disposable diaper 10 is a breathable backsheet, the impermeable portion 47 may be relatively impermeable to liquids and permeable to vapors. , while the breathable portion 45 will be relatively more permeable to vapor per unit area than the impermeable portion 47 or the backsheet 25.

The overall breathability of cuff 15 (i.e., the amount of air and water vapor that can be transported through breathable portion 45 under given conditions and for a given length of time) can be varied and controlled by adjusting a number of factors. obtain. Among these are the inherent permeability of the material used to make the breathable portion 45, the physical length and width of the breathable portion 45, and the relative size of the breathable portion 45 and impermeable portion 47. Imaginary boundary line 46 showing
There is a position.

Cuff 15 when breathable portion 45 is maximum and impermeable portion 47 is minimum (i.e., absent), all other conditions being constant.
The breathability would be maximum. In practice, it is not necessarily desirable to make the cuff 15 completely breathable.

Generally, if the breathable portion 45 is made of a material that allows the free passage of vapor, it will also allow some somewhat finite passage of liquid.
It is desirable to keep this passage of liquid (referred to in the art as "leakage") to some minimum value determined by consumer tolerance. It has surprisingly been discovered that a desirable balance between breathability and leakage can be maintained if the impermeable portion 47 has some finite value. Although the inventor does not wish to be limited by theory of operation, it appears that this balance is achieved by the gasketing function achieved by the impermeable portion 47.

Since the cuff 15 is flexible, the absorbent core 2
can exhibit an indeterminate number of orientations with respect to 1.
When cuff 15 is considered to be oriented with respect to absorbent pad 21 as shown in FIG. 4, cuff 15 is said to have an inner surface 48 and an outer surface 48. The inner surface 48 of the cuff 15 will be the surface that is generally oriented toward the body of the diaper and the absorbent pad 21. The outer surface 49 is the outer surface 4
This is the surface of cuff 15 opposite to 8. When using
The diaper 10 generally has a crotch portion 1 within the infant's crotch area.
3 applied to the infant's body, and the front waist part 11
and when the rear waist portion 12 is placed around the infant's waist, the cuffs 15 are placed adjacent the inside and outside of the infant's thighs. The cuff 15 tends to rotate at some angle in the direction of the outer surface 49;
This brings the inner surface 48 into contact with the infant's skin. The main part of the contact between the cuff 15 and the infant's skin is caused by the elastic element 31;
and within the area of the elastic element 31, other parts of the inner surface 48 of the cuff 15 will tend to be brought into contact with the infant's skin. This includes the inner surface of the impermeable region 47. Liquid leaking from the original diaper, such as from the absorbent core 21, is directed from the direction of the original diaper to the inner surface 48 of the cuff 15.
must be approached. When the inner surface 48 of the impermeable portion 47 is adjacent to the infant's thighs (either in contact relationship or simply in close proximity), a significant portion of the liquid that tends to leak from the diaper is transferred to the impermeable portion 47. will be contacted and generally redirected through top sheet 26 and top envelope tissue 22 to absorbent pad 21. Thus, having an impermeable portion 47 in addition to the breathable portion 45 tends to limit leakage.

Providing at least the inner surface 48 of the breathable portion 45 with properties that retard the passage of liquids without unduly impeding the passage of vapors, in the same way that the impermeable portions 47 serve, allows liquids to pass through the absorbent wick 21. There will be a tendency to redirect. Physical properties that tend to retard the passage of liquid are, for example, the hydrophobic nature of the inner surface 48 of the breathable band 45 as well as the physical structure of the breathable band 45, such as providing "one-way openings." One-way openings are detailed in the aforementioned US Pat. No. 3,929,135, US Pat. No. 4,341,217 and US Pat. No. 4,342,314. Diameter approx.
Thermoplastic films formed with openings having less than 0.13 mm, preferably less than about 0.02 mm, also tend to allow the passage of vapor while retarding the passage of liquid.

Preferably, transparent portion 45 comprises about 5% to about 75% of the width of cuff 15.

Preferably, the breathable portion 45 extends the entire longitudinal length of the cuff 15, but in certain embodiments
It may be restricted to the portion of the cuff 15 that falls within the crotch portion 13. In practice, the breathable part 45 is the cuff 1
Even if they extend the entire length of cufflinks 15
and the infant's thigh. In some diaper designs, the ventilated portion 45 on the outside of the crotch portion 13
This area will tend to be blocked by the back seat 25 when the diaper 10 is secured to the infant.

Breathable portion 45 and impermeable portion 47 of cuff 15 may be manufactured by any suitable method.

For example, in FIG. 4, cuff 15 is shown to be formed as an integral extension of backsheet 25. That is, the cuffs 15 and the back sheet 25 are formed unitarily. The breathable portion 45 is, for example, the back sheet 25.
It is obtained by opening the thermoplastic film used to form the film in predetermined areas. If the backsheet 25 is formed from a rectangular section of thermoplastic film having a transverse width and a longitudinal length, the areas selected for aperture are adjacent to and at the longitudinal edges of the sheet. This will be the area along which you will be traveling. For example, back sheet 2
5 is manufactured from a polyethylene film having a transverse width of approximately 40 cm, a band adjacent each longitudinal edge extends transversely from each longitudinal edge toward the imaginary longitudinal centerline by a distance of approximately 7.6 cm. It can be opened inside. FIG. 8 is a partial enlarged view of a cross-section of the cuff 15 in the area of the imaginary boundary line 46 and shows the manufacturing method just described. An impermeable portion 47 is shown on one side of the imaginary border 46 and a breathable portion 45 is shown on the other side of the border. A general opening 88 is shown extending through the material comprising the breathable portion 45.

Alternatively, the backsheet 25 can completely enclose the outer surface of the disposable diaper 10 and provide sufficient excess material integral with the backsheet 25 to define the portion of the cuff 15 along the imaginary border line 4 as shown in the drawings.
It can be manufactured by such a method as to make up to 6. Then,
A breathable cuff sub-element, which can be an apertured film or another breathable material.
element) is affixed to the backsheet 25 in the area of the imaginary border 46 in such a way as to form the breathable portion 45 of the cuff 15. FIG. 9 illustrates this manufacturing method in a partially enlarged view of a cross-section of the cuff 15 in the area of the imaginary boundary line 46. FIG. In FIG. 9, the breathable cuff sub-element 96 has a general opening 8.
8 are formed and the impermeable portion 47 of the cuff 15 (formed from the backsheet 25 (such as) is shown attached. It should be emphasized that although the breathable cuff sub-element 96 is depicted as an apertured film in FIG. 9, it can be any suitable breathable material, such as a topsheet material.

Impermeable portion 47 and breathable portion 45 are essentially an extension of backsheet 25 when either manufacturing method (such as that shown in FIGS. 8 and 9) is used. Thus, FIG. 8 shows a cuff and backsheet formed from a one-piece material, while FIG. 9 shows a cuff and backsheet formed from a composite material that acts as a one-piece material.

In all embodiments of the invention presented herein, the impermeable portion 47 is
Formed from 5 integral parts. Although this method of manufacture is preferred, embodiments in which the impermeable portions of the backsheet and cuffs are manufactured from separate elements (and possibly from different materials) are included within the scope of the invention.

Methods of opening the material to provide breathable portions 45 can be readily selected by those skilled in the art from techniques and designs known in the art. for example,
The back sheet 25 is made of thermoplastic film (for example,
If it is a regular polyethylene film),
The following formula R=D(OA)/C [where D is the average diameter of the apertures in the film (cm), OA is the total aperture area of the apertured film expressed in %, and C is the The permeable zone 45 can be apertured to an extent that can be described by a dimensionless R-value defined as the average caliper (or length or height) of the aperture (cm). Typically, when an opening is formed in the elastic film, it takes the shape of a somewhat irregular cone that is open at both the distal and proximal ends. The average diameter is
This is the arithmetic mean of the diameters of the two types of openings formed in this way. Of course, if the aperture is cut uniformly from the film without the usual formation of a cone, the caliper will be film thick. R value about 2 to about 40,
Apertured films, preferably from about 5 to about 25, generally have vapor transfer rates suitable for use in the present invention. Said US Pat. No. 3,989,867;
Specification No. 4341217, Specification No. 3929135 and No.
The apertured film described in 3881489 can also be used.

If the elastic element 31 is coupled to the cuff 15 by ultrasonic welding, an opening may conveniently be formed in the breathable portion 45 by ultrasonic means simultaneously with the welding. Naturally, the openings may be formed in the venting portion 45 by spaced apart ultrasonic means apart from welding. In the drawings, the elastic element is shown to be in the form of a band. These elements can also consist of thin elastic films that can occupy most of the cuff area. In this design it is often advantageous to form perforations or openings in the elastic film. The use of ultrasound energy is also useful in this regard.

Another example of cufflinks 15 is shown in FIG. Figure 5, like Figures 3 and 4,
3-3 is a cross-sectional view of the typical cuff 15 of the disposable diaper 10 of FIG. 1 taken along line 3--3. In this embodiment, the backsheet 25 surrounds the longitudinal edges 39 of the absorbent core 21 and the securing means 3
7 indirectly fixed to the top sheet 26. The backsheet 25 terminates adjacent the fastening means 37 at a backsheet longitudinal end 55. Fifth
As shown, the ventilation element 54 is
Fastening means 3 adjacent to backsheet longitudinal end 55
7 by top sheet 26 and back sheet 25
(In the embodiment shown in FIG. 5, a breathable element 54 is coupled between the top sheet 26 and the back sheet 25.
In another less preferred embodiment, the breathable element 54 may be indirectly attached to the top sheet 26 using a back sheet 25 interposed between the breathable element 54 and the top sheet 26). . Cuff 15 is then manufactured from breathable element 54 in a manner similar to that in the previous embodiment, including bonding to elastic element 31. In this embodiment, the breathable element 54 constitutes the entire breathable portion. The imaginary boundary line 46 in this example corresponds to the longitudinal edge 55 of the backsheet.

Breathable element 54 can be an apertured film as described in connection with other embodiments, but is preferably a nonwoven fabric, such as that used to make topsheet 26. Manufacturing the cuff 15 essentially entirely from nonwoven fabric, as shown in this embodiment, provides two benefits: breathability and comfort. Breathability aspects have been detailed previously. The comfort aspect results from interposing, in use, a breathable element 54 (made from a non-woven fabric) between the backsheet 25 (usually made from plastic film) and the wearer's skin. in this way,
Direct contact between plastic and skin is excluded.

Another specific example of the cufflinks 15 is shown in FIG. FIG. 6 is a cross-sectional view of the typical cuff 15 of the disposable diaper 10 of FIG. 1 taken along line 3--3, as in FIGS. 3, 4, and 5. In this embodiment, the cuff 15 is manufactured to the distal end 35 essentially like the embodiment shown in FIG. That is, the backsheet 25 and cuffs 15 (up to the distal end 35) are fabricated from an essentially one-piece material or a composite material that acts as one piece. The transition point between the opaque portion 47 and the transparent portion 45 is indicated by an imaginary boundary line 46. Beyond the imaginary boundary line 46, the cuff 15 is manufactured from an apertured film as described above. The apertured film extends from the imaginary boundary line 46 to the distal end 35 and is folded around the elastic element 31 and the second elastic element 64 (in this embodiment two elastic elements, namely the elastic element 31 and A second elastic element 64 is shown (the optional second elastic element 64 is similar in construction to elastic element 31). In the embodiment described, the elastic element preferably extends within the entire longitudinal length of the diaper cuff 15 essentially from the front waist section 11 to the rear section 12. In this particular example, elastic element 31 and second elastic element 64 are
Preferably, the cuff 15 extends over a major portion of its length, but at one end at a point between the front waist portion 11 and the lateral centerline 17 and at the other end between the rear waist portion 12 and the lateral centerline. It ends at some point between line 17. Preferably, the two elastic elements extend from the lateral centerline 17 toward each waist region a distance of about 50% to about 80% of the total distance between the lateral centerline 17 and the respective waist region. do.

From the distal end 35, the apertured film is folded around the elastic element 31 and the second elastic element 64 and secured thereto by means not shown but well known to those skilled in the art. The apertured film is then secured to the topsheet 26 between the topsheet 26 and the impermeable portion 47 at the inner bond points 63. The back sheet 25 is indirectly secured to the top sheet 26 by a securing means 37.

In this specific example, the apertured material and the non-apertured material constituting the cuff 15 are
and an inner surface portion 62.
The outer surface portion 61 and the inner surface portion 62 have essentially no bond with each other over their entire length from the inner surface connection point 63 to the connection point around the second elastic element 64 . Liquid that would otherwise tend to leak through the vented portion 45 tends to become trapped within the space between the outer surface portion 61 and the inner surface portion 62.

Another specific example of the cufflinks 15 is shown in FIG. Figure 7 shows the 3-3
Disposable diaper 10 in Figure 1 taken along the line
FIG. 2 is a sectional view of a typical cuff 15 of FIG. This embodiment differs in that the portion of the apertured film forming the inner surface portion 62 of the cuff 15 is bonded to the topsheet 26 at an inner bond point by means known to those skilled in the art, such as adhesive bonding. This is different from that shown in Figure 6. Inner bonding point 73 is spaced some finite distance inwardly from longitudinal side edge 39 of absorbent core 21 (eg, about 3 to about 25 mm). Inner surface portion 62 terminates in a free end 74 . Depending on the case,
The inner surface portion may be secured to the topsheet 26 over essentially the entire distance from the inner surface bonding point 73 to the free end 74 by means known to those skilled in the art. Furthermore, the backsheet 25 and the cuffs 15 essentially have a connection to other parts of the disposable diaper (other than the elastic elements) over the distance from the optional fastening means 38 to the internal connection point 73. Not yet. Inner surface portion 62 and outer surface portion 61
Similarly, they essentially have no connections with each other over the same area.

In the embodiments described above, the cuffs were formed either by separate elements or by extensions of the backsheet. Cuffs may be formed by extensions of the topsheet in a manner similar to that shown. Embodiments of this kind are not disclaimed.

As mentioned above, the present invention is disclosed in European Patent Application No.
82200801/No. 7 describes in detail the case where it is applied to diapers. The present invention also finds utility in other disposable diaper embodiments, such as those described in US Pat. No. 3,860,003.
Figures 10 and 11 are from U.S. Patent No. 3860003.
Application is generally shown in diapers having contoured shapes within the diaper, such as those described in the present specification.

In Figure 10, 100 disposable diapers
is shown expanded in plan view. The drawings have been slightly simplified for clarity. For example, certain details to the left of longitudinal centerline 18 have been omitted. FIG. 11 is a cross-sectional view of a portion of disposable diaper 100 taken along line 11--11 in FIG. 10. The relative thickness of some elements is
Exaggerated for clarity.

The disposable diaper 100 generally has a contour shape. It is symmetrical about the longitudinal centerline 18. The lateral centerline 17' is displaced from the rear waist section 12 toward the front waist section 11 for improved fit. Cufflinks 15 are imaginary boundaries 46
It consists of a breathable part 45 and an impermeable part 47 separated by. 10 and 11, the imaginary boundary line 46 within each cuff corresponds to the longitudinal edge of the backsheet 25. In FIGS.

Disposable diaper 100 consists of an absorbent core 21, a back sheet 25 and a top sheet 26 (in FIG. 10, top sheet 26, breathable cuff sub-element 96 and upper breathable cuff sub-element 96' are partially shown for clarity). (shown cropped). In the particular embodiment shown, the disposable diaper 100 has an elastic element 31 and a second elastic element 64 within each cuff 15. The elastic elements are affixed to the disposable diaper 100 in such a manner that they tend to elastically contract the disposable diaper when the disposable diaper is in contact with the legs of the infant to whom it is applied. The absorbent core 21 is associated with a top envelope tissue 22 and a back envelope tissue 23, which are not shown in FIG.
The top sheet 26, top envelope tissue 22, absorbent core 21 and back envelope tissue 23 are secured together by fastening means 37 and optionally used fastening means 38. Bonding adhesive tape 14 is secured to disposable diaper 100 by adhesive means, not shown.

Cuffs 15 of disposable diaper 100 are generally formed as shown in FIG. That is, the breathable cuff sub-element 9 has an opening 88 formed therein.
6 are affixed to the backsheet 25 in an overlapping relationship by means of fixing means 91. The breathable cuff sub-element 96 is attached to the elastic element 31 and the second elastic element 64 by adhesive fixing means (not shown). Cufflinks 15 as shown
consists of a breathable cuff sub-element 96 and an upper breathable cuff sub-element 96'. The fact that the breathable portion of the cuff 15 consists of two elements in the illustrated embodiment is an artifact of construction. The most efficient method of manufacturing disposable diaper 100 is to use a single apertured film that is folded over and secured to elastic elements 31 and 64 during manufacture. Then, in the manufacturing process, the side edges of the folded apertured film are cut along the longitudinal sides of the disposable diaper to form a contour shape, thereby dividing the apertured film into two parts. namely, a breathable cuff sub-element 96 and an upper breathable cuff sub-element 96'. The upper breathable cuff sub-element 96', in which the opening 88' is formed, is attached to the elastic element 3 by means of adhesive fastening means (not shown).
1 and the second elastic element 64 (and thus to the breathable cuff sub-element 96) and to the top sheet 26 by means of the fastening means 37.

Disposable diaper 100 includes a rear waist extension 101 and a front waist extension 102 that are breathable (permeable to vapor) outside of imaginary boundary line 46 in the illustrated embodiment. The breathable portions of the waist side extensions 101 and 102 occupy essentially the entire area of the waist side extensions 101 and 102. In some cases, the disposable diaper 100 includes:
It is possible and preferred that the absorbent core be provided with a shape similar to the overall shape of the diaper rather than the rectangular shape shown in Figure 10. In this type of case, the total breathable area of the waist side extensions 101 and 102 will be reduced by the intrusion of the waist side extensions of the absorbent core in the shape described above.

In the above discussion of the invention, it is assumed that the absorbent product involved is a diaper intended for use by an infant. It is within the inventor's intention that the present invention may be used in a similar manner for diapers or briefs intended for use by incontinent individuals other than infants, such as incontinent adults. Additionally, the invention is described in terms of a disposable diaper having elasticized cuffs and a generally rectangular absorbent core. It is the inventor's understanding that the present invention will find utility in cases such as disposable diapers with de-elasticized cuffs (where this type of use is not preferred) and in the case of absorbent cores having shapes other than rectangular. It is within the intended range. Still further, although specific construction details and techniques are shown, it is anticipated that other construction details and techniques may be used without departing from the spirit and scope of the invention.

Preferred uses of the invention are disposable absorbent products,
Although for example disposable diapers, the teachings of the present invention may also be applied to disposable briefs, such as disposable panties.

In order to better illustrate (but not limit) the invention, the following examples are presented.

EXAMPLE A disposable diaper utilizing the present invention was manufactured in accordance with the teachings herein. Upon completion, the disposable diaper was as shown in FIG. The details of the structure in the anterior and posterior lumbar regions were as shown in FIG. Cufflinks were manufactured as shown in FIG. The breathable and impermeable parts of the cuff were obtained by bonding an apertured thermoplastic film to a non-apertured thermoplastic film in the manner shown in FIG.

The absorbent core 21 of each disposable diaper was an air-formed batt of ground wood pulp fibers. The butt was about 25.4 cm wide and about 40.0 cm long. It is about 0.3cm thick and about 46 to about 54g
It was hot.

The envelope tissue was tissue paper made using polyacrylamide wet strength resin having a basis weight of approximately 19.5 g/m ² . Top envelope tissue 22 is approximately 45cm long (before assembly)
and a width of about 25.4 cm, while the back envelope tissue 23 had a length (before assembly) of about 44 cm and a width of about 25.4 cm. The envelope tissue was assembled around the absorbent core as shown in FIGS. 2 and 7.

In the disposable diaper of this example, top sheet 26 was the polypropylene nonwoven fabric described above and was approximately 45 cm x 25.4 cm prior to assembly. It was also assembled around an absorbent core as shown in FIGS. 2 and 7.

The backsheet 25 and the impermeable portion 47 of the cuff 15 were made from a matte finish closed polyethylene film having a thickness of 0.025 cm. The breathable portion 45 of each cuff was fabricated from apertured polyethylene and bonded to closed polyethylene as shown in FIG. 2 pieces of apertured polyethylene strips 45cm long x approx. 6cm wide.
x 26 cm wide rectangular non-apertured polyethylene sheets were bonded together along their longitudinal edges to form a composite backsheet that functioned as an integral backsheet.
Adhesive bonding with NS34-2857 adhesive manufactured by National Starch End Chemical Company, Plainfield, New Jersey, was used.

The apertured polyethylene film is 0.025cm thick.
formed from a film of Apertures were selectively formed in the film in a hexagonal array with an aperture in each corner and one additional aperture located in the center of each hexagon. Approximately 90 ^{per cm2}
The openings were warm. Each opening is approximately 0.40 in height
mm, approximated the shape of a truncated cone with an average apical opening diameter of 0.38 mm and an average proximal opening diameter of 0.56 mm. Spacing between individual openings is approximately 1.14 center to center
It varied from mm to approximately 1.91 mm. The apertured film had an open area of about 7%. The truncated cone was oriented so that the tip was inside the loop forming the cuff. Additionally, the entire surface of the apertured film was textured to reduce surface gloss and film stiffness.

Elastic elements 31 and 64 are 0.24cm wide x
It is a full flex 9211 band with a thickness of 0.02 cm,
Each was approximately 22.2 cm long before joining. They are,
While the band was in tension, it was bonded to the cuff by hot melt adhesive.

In each cuff, a second elastic element 64
is affixed to the composite backsheet such that the centerline of the second elastic element is approximately 1.6 cm from the longitudinal side edges 390 of the absorbent core when in the plane of the outer surface (posterior surface) of the absorbent core. . Elastic element 3
1, the center line of the two types of elastic elements is approximately 0.95cm
They were fixed to the composite backsheet so as to be spaced apart.
In this construction, the unopened portion of the backsheet extended within approximately 0.6 cm of the centerline of the second elastic element. The junction between the apertured and non-apertured portions thus fell between the second elastic element and the longitudinal side edges of the absorbent core. This junction corresponded to the imaginary boundary line 46.

The backsheet (and back envelope tissue) runs essentially the entire lengthwise length of the absorbent core and is spaced approximately 0.95 cm from the longitudinal side edges thereof.
It was bonded to the absorbent core by an optional fastening means 38 consisting of beads of NS34-2857 adhesive.

The open interior surface 62 of the cuff was bonded to the top sheet (and to the top envelope tissue and absorbent core) at an interior bond point 73 by a bead of NS34-2857 adhesive running essentially the entire longitudinal length of the disposable diaper. indirectly combined)
[In the front waist portion 11 and the rear waist portion 12, the apertured film was directly bonded to the non-apertured film]. The adhesive beads were spaced approximately 0.6 cm from the longitudinal side edges of the absorbent core. The inner surface portion 62 is
It terminated at a free end 74 spaced approximately 0.6 cm from the inner surface bonding point and closer to the longitudinal centerline of the diaper.

The total width of the cuff from the longitudinal edge of the absorbent core to the distal end 35 of the cuff (the cuff and the absorbent pad are the same as the length of the cuff and the absorbent pad when the absorbent pad is essentially flat and the cuff is essentially in the plane of the outer or rear surface of the absorbent core). when oriented inward) was approximately 2.9 cm, and the outer approximately 1.9 cm constituted the breathable portion.

When worn by an infant, the disposable diaper of this example is comfortable, absorbs and contains exuded fluids, protects the infant's skin and surroundings from exuded fluids, and is superior to similar disposable diapers not using the present invention. It would have been much cooler and self-drying.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a disposable diaper in a Z-fold configuration to be placed on an infant, and represents a disposable diaper that can be advantageously used with the present invention. Figure 2 shows
FIG. 2 is a cross-sectional view of the diaper of FIG. 1 taken along line 2-2 and showing structural aspects thereof. Figure 3 shows
3 is a cross-sectional view of the diaper of FIG. 1 taken along line 3-3, and shows a conventional diaper cuff structure; FIG. FIG. 4 is a cross-sectional view of an embodiment of the invention taken along a line corresponding to line 3--3 of FIG. FIG. 5 is a cross-sectional view of another embodiment of the invention taken along a line corresponding to line 3--3 of FIG. FIG. 6 is a cross-sectional view of another embodiment of the invention taken along a line corresponding to line 3--3 of FIG. FIG. 7 is a cross-sectional view of another embodiment of the invention taken along a line corresponding to line 3--3 of FIG. FIG. 8 is an enlarged partial view of one embodiment of the present invention.
FIG. 9 is an enlarged partial view of another embodiment of the invention. FIG. 10 is a plan view of a disposable diaper in an expanded configuration using the present invention. Figure 11 shows 1
10 is a cross-sectional view of the diaper of FIG. 10 taken along line 1-11. FIG. 10...disposable diaper, 15...cufflinks, 2
4...absorbency, element, 25...back sheet, 26...top sheet, 35...distal end, 4
5... Breathable part, 47... Impermeable part, 8
8,88'...opening, 100...disposable diaper.

Claims (1)

[Scope of Claims] 1. A liquid-impermeable backsheet, a liquid-permeable topsheet fixed to the backsheet, an absorbent element interposed between the topsheet and the backsheet, and a pair of vertically extending and rising vents. sex cuffs, each of the cuffs having a fixed end and a distal end spaced apart from the fixed end, each cuff having the fixed end attached to the diaper, the distal end being attached to at least one portion of the diaper; said cuffs, each of said cuffs being permeable to vapor over at least a portion of its extent; and operatively associated with said distal end of each of said cuffs; an elastic element secured to the cuff under elastically contractible conditions to enable the distal end of the cuff to elastically contract, the elastic element causing cuff material adjacent to the elastic element to A disposable diaper comprising an elastic element that is contracted or geared to displace the distal end inwardly from the absorbent element and the fixed end. 2. The disposable diaper according to claim 1, wherein each of said fixed ends is attached to said top sheet. 3. The disposable diaper according to claim 2, wherein each of the cuffs is formed integrally with the top sheet. 4. The disposable diaper according to claim 2, wherein said cuffs are each formed by separate elements fixed to said top sheet. 5. The disposable diaper of claim 1, wherein the cuff is vapor and liquid permeable. 6. The disposable diaper of claim 1, wherein said cuffs are vapor permeable but liquid impermeable, said cuffs being more vapor permeable than said backsheet. 7. The disposable diaper of claim 1, wherein the cuff includes a vapor permeable portion and a vapor impermeable portion. 8. Said vapor permeable portion is located proximate said distal end portion, and said vapor impermeable portion is located intermediate said vapor permeable portion and said fixed end. Disposable diapers as described. 9. Said vapor permeable portion is approximately 5% of said cuff.
9. The disposable diaper of claim 8 comprising ˜75%. 10. The disposable diaper of claim 1, wherein the absorbent element has longitudinal side edges, and the cuffs are secured to the diaper inwardly from the longitudinal side edges of the absorbent element. 11. The diaper of claim 10, wherein the absorbent element has a generally hourglass shape.