CA1182603A - Breathable backsheet for disposable diaper - Google Patents

Breathable backsheet for disposable diaper

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Publication number
CA1182603A
CA1182603A CA000397104A CA397104A CA1182603A CA 1182603 A CA1182603 A CA 1182603A CA 000397104 A CA000397104 A CA 000397104A CA 397104 A CA397104 A CA 397104A CA 1182603 A CA1182603 A CA 1182603A
Authority
CA
Canada
Prior art keywords
absorbent core
diaper
inner panel
region
outer sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000397104A
Other languages
French (fr)
Inventor
Mary C. Obenour
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Co
Original Assignee
Procter and Gamble Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
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Classifications

    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/514Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51474Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure
    • A61F13/51478Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its structure being a laminate, e.g. multi-layered or with several layers

Abstract

BREATHABLE BACKSHEET
FOR DISPOSABLE DIAPERS
Mary C. Obenour ABSTRACT

Disposable diapers provided with a two-element breathable backsheet. The two elements are a vapor pervious, relatively liquid impervious outer sheet and a liquid impervious inner panel.
An absorbent core is the third necessary element of the disposable diaper. The inner panel is placed between the outer sheet and the absorbent core in the crotch region of the disposable diaper. There is no requirement that the inner panel be affixed to the outer sheet in any manner other than to insure the maintenance of their relative orientations during use. The disposable diaper can be provided with an optional topsheet disposed on the absorbent core on the side oppo-site the breathable backsheet.

Description

;26~

~, ~ {~.

B~E~THABLE ~3ACICS~:LEET
FOR I)ISPOS~BLE DIAPERS
Mary C. Obenour BACK~OUND OF THE I~ENr~ION
.. ... .
Field _ ~_the Inven~ on This inven-~ion concerns gener~lly a~sorptive devices such as disposahle diapers and, more 10 particularly, a baclcing for such devices whi.ch retards the passage of liquids e~hile ~ermi~ing th~ passage o:E v~pors.

Background ~-L` t Absorptive de~ices such as diap~rs are ~ell known for their use ill absorbing and ret:aining liquid discharges ~rom the human body~ Diapers can be either of the mor~ or less permanent ~:ype which are itltended to be cleaned and reuse~ a 20 number o~ times or of the clisposable ~ype ~7hich are intended to be used onl.y once and i:hen dis carded. It is known that the e~terior o~ diaper.s, particularly of disposable cliapers, can be covered with a flexible, impe.~eable sheet to prevent any 25 absorbed liqui-l from passi.ng ~hrough the diaper and soiling ~Jacent artic].es s~ch as clothing~
bedding, and the like. These cc.vering sheets are kno~n as backsheets and ar~ generall.y constructed from a waterproof plastic such .?.S polyethylene.
30 The backsheets do pxevent licluid from passing therethrough and do hel.p con~ain liquid wi~hirl ~he diaper. Unfortunately, ~hey also somet-ilnes make the diaper :E~el hot and uncomfortable to wear beccause of t:heir to~al impermeabi].ity. Xn addi-3~ tion, their impermeabili~y precludes sel~-drying of the diapel which would o~herwise occur ~hrough evaporation of the liquid contained ~herein.

", . . .
.'``'''~ ~ '~

Backsheets which are pervious to vapor are known as breathable backsheets and have been described in the art. These brea~hable backsheets provide a cooler garment and permit some drying of 5 the diaper while it is being worn. In general, these breathable backsheets are intended to allow the passage of vapor through them while retarding the passage of liquid.

For example, U.S. Patent 3,156,242 issued to Crowe, Jr. on November 10, 1964 teaches the use of a microporous film as a breathable backsheet.
U.S. Patent 3,881,489, issued to Hartwell on May 6 9 1975, teaches a breathable backsheet comprising 15 in combination two layers, the first of which is a low void volume perforated thermoplastic film and the second of which is a porous high void volume hydrophobic tissue. U.S. Patent 3,989,867 issued to Sisson on November 2, 1976 teaches a breathable 20 backsheet provided with ~apered hollowed bosses which prevent the passage of liquids while allow-ing vapors to pass readily there-through.

While these backsheets do provide some 25 measure of improvement over the more common impermeable backsheets, and while the last two named devices are of particular value, devices providing for the more efEicient passage of vapor while still restricting the passage of liquid when 30 subjected to the pressures éncountered during no~mal wear;ng have still been sought.

SUMM~RY OF THE INVENTION
~ . .. _ ... . _ ~L~8;~ 3 .~`~' ~ ,(.

In accordance with the present invention there is provided a diaper comprising an absorbent core and a vapor pervious, l:iquid impervious ~breathable) backsheet whereLn the breathable 5 backsheet comprises two elements: an outer sheet and an inner panel. The outer sheet is so con-structed as to be vapor pervious and relatively liquid impervious in a central region extending longitudinally along the length of the sheet from 10 the front waist region to the rear wais~ region of the diaper and impermeable in the two longitudinal regions adjacent to and lying on either side of the central region. The inner panel is an im-permeable sheet extending substantially completely 15 laterally across the width of the outer sheet in the ~rotch region of the diaper, bu~ extending only a fraction of the distance longitudinally along the length of the outer sheet in the crotch region. The two elements are superimposed to form 20 a backsheet.

Accordingly, it is an object of the present inventi~n to provide a disposable di.aper which allows the passage of vapor thereby providing ~5 cooling and drying ef~ects to the disposable diaper, but which retains liquid within the dis-posable diaper.

BRIEF DESCRIPTION OF THE DRA~INGS

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the 35invention wiLl be better understood from the de-26~3 .~, ~ ,.

~,.
tailed descriptlon appearing in the followingseetion taken in eonjunction with the accompany-ing drawings, in which the thicknesses of some of the materials are exagerated for clarity and in which:

Figure 1 is a perspective view of one em-bodiment of a diaper of this invention in an un-folded condition and having various layers cut away;

Figure 2 is an exploded perspective view o another embodiment of a diaper of this in-vention showing the manner in which the various components are superimposed;

Figure 3 is a cross section taken along line 3-3 of Figure 2;

Figure 4 is a representa~ional plan view of
2~ the outer sheet of this invention showing the various regions thereof;

Figure 5 is a representational plan view of the inner panel of this invention showing the variolls 25 regions thereof; and Figure 6 is a representational plan view of another embodiment of the inner panel of this invention.

DETAILED DESCRIPTION OE THE INVENTION
_. , .

The absorptive devices of this invention, and more particularly the disposable diapers o:E this ` ~

invention, comprise ~wo necessary parts: an absorbent core and a backsheet as hereinafter described. Optionally, and preferably, a topsheet is provided as a ~hird part. The ~opsheet, of 5 course, is an element which is designed to be interposed between the absorbent core of the diaper and the body of the wearer. The ollowing description of the invention includes the optional topsheet.
1~
Referring now to the drawings and in parti-cular to Figure 1 thereof, disposable diaper 21 is one preferred construction of the disposable diaper of ~he present invention. Diaper 21 is 15 fabricated from multiple plies of various materials.
The preferred construction illustrated in Figure 1 includes topsheet 22, absorbent core 23, inner panel 24, and outer sheet 25.

Unless otherwise indicated hereinafter, the use of the term "backsheet" will denote the backsheet of this invention which comprises an inner panel and an outer sheet as hereinafter defined.

Inner panel 24 is superimposed on outer sheet 25 to form the backsheet. Absorbent core 23 is superimposed on inner panel 24 and outer sheet 25;
topsheet 22 is superimposed on absorbent core 23.
30 Disposable diaper 21 will have a ~ront waist area 26, a rear waist area 27, and a crotch area 28.
When disposable diaper 21 is worn, front waist area 26 is generally placed adjacent the waist of ~`p the wearer at the front o the wearer's body whi.l~
rear walst area 27 is generally placed adjacent the waist of the wearer at the rear of the wearer's body. Crotch area 28 is generally placed adjacent 5 the wearer's crotch area. In certain constructural configurations, front waist area 26 and reax waist area 27 are interchangeable; ~ha~ situation pre-vails in the embodi.ment shown in Figure 1.

Disposable diape~ 21 can be considered to be divided into two portions by an imaginary longi-tudinal center line running generally from front waist area 26 to rear waist area 27. Disposable diaper 21 can also be considered to be divided lS into two porticns by an imaginary lateral center line running generally across the area through crotch region 28. (It should be noted that the embodiment illustrated in Figure 1 is symmetrical about the two imaginary center lines, but other 20 embodiments need not be so symmetrical.~

As noted, absorbent core 23 is superimposed over inner panel 24 and outer sheet 25 and top-sheet 22 is superimposed over absorbent core 23.
25 Topsheet 22 can be longer in the longitudinal dimension than absorbent core 23 and so that it can be folded around and under the longi~udinal ends of absorbent core 23 as shown in Figure 1.
The combination of topshee-t 22 and absorbent core 30 23 is super:imposed on outer sheet 25 so ~hat lateral edges and l.ongitudinal ends are generally adjacent and parallel.

Topsheet 22 can be any compliant, soft feel-35 ing, porous paper or nonwoven fabric web. Ex-29~3 amples of suitable topsheets are described in U.S.Patent Re. 26,151 issued to Duncan et al. on January 31, 1967. The particular topsheet sugc1ested by Duncan et al. is a hydrophobic nonwoven rayon web bonded with a thermoplastic binder.

Other suitable topsheets are shown in U.S. Patent
3,860,003 issued to Buell on January 14, 1975. An especially preferred topsheet is a spunbonded nonwoven polyester fabric made from fibers of rom about 2.2 to about 2.5 denier and having a basis weight of about 17 grams per s~uare meter.

Absorbent core 23 can be formed from any of the materials well known to those of ordinary skill in the diaper art. Suitable examples include multiple plies of creped cellulose wadding~ fluffed cellulose fibers or wood pulp fibers sometimes known as airfelt, and textile fibers. The absorbent core can be semi-rigid as described in the Buell patent7 A preferred absorbent core is formed from airlaid comminution grade wood pulp as i~ well known to those skilled in the art~ A basis weight of from about 0.02 to about 0.04 gram per square centimeer is preferred.

The backsheet of this invention is a combination comprising two elements, inner panel 24 and outer sheet 25.

r ~ ( Outer sheet 2S is shown in represen~ational plan view in Figure 4. Outer shee~ 25 is provided with regions of two types: impermeable and vapor pervious, relatively liquld impervious. Imper-5 meable regions will permit essentially no trans-port of liquid or vapor therethrough. Vapor pervious, rela~ively liquid impervious regi.ons will have a vapor transfer rate greater than about 0.6 gram per 100 square centimeters per hour and lO will allow liquid to pass therethrough at a liquid transfer rate of less than about 5%.

Liquid transfer rate as used herein is a measure of the liquid barrier properties of a 15 relatively liquid impervious material.

The sample to be evaluated is placed between a wetted standard core and a fluid collection device. The wetted standard core is subjected to 20 uniform pressure in such a manner that any liquid expelled from the wetted standard core must pass through the sample into the fluid collection device. Naturally, if the sample is impermeable, I10 liqui.d will pass through it. The more liquid 25 which passes through the sample, the less liquid impervious is the sample.

The standard core is formed from airlaid comminution grade wood pulp and has a basis weight 30 of 0.023 gram per square centimeter. It is covered by a tissue (as hereinaf~er described) and is in the form of a circle 7.5 centimeters in diameter. It is wetted with five times its weight of a synthetic urine wh:ich is distilled water the surface tension of which has been reduced ~o 45 dynes per centimeter by the addition of a nonionic surfactant (such as Tri~on X 100~ made by Rohn) and Haas Company of Philadelphia, PA.) and which also contains 1% by weight sodium chloride.

The fluid collection device comprises two plies of Whatmann #4 Laboratory Filter Paper, each 12.7 centi-meters in diameter.

The samplet wetted core, and fluid collection device are subjected to a 3,073 gram weight uniformly distri-buted across the surface of the wetted standard core.
At the end o~ 5 minutes, the weight is removed, the test assembly is disassembled, and the amount of liquid in the fluid collection device is measured by weighing.
The liquid transfer rate is defined as the amount of liquid, in terms of percent of liquid originally present in the wetted standard core, which passes through the sample into the fluid collection device during the five minute test period.

Vapor transfer rate is measured by a similar technique. The standard core mentioned above is placed on an impervious support and is wetted with five times its weight of the synthetic urine described above. The sample to be evaluated is firmly stretched across the core in such an orientation as it would have when used in a disposable dlaper of this invention. The whole assembly is placed in a 23C, 50~ relative humidity atmosphere for one hour. The amount of ]iquid which evaporates from the core is determined by - ~82~
.,'. ~ (.

weighing. The vapor transfer rate is defined as the amoùn~ of liquid evaporated and is expressed in grams of liquid per 100 square centimeters of sample per hour.

In outer sheet ~5, the vapor pervious, rela-tively liquid impervious region is a central region extending longitudinally along imaginary longl~udinal center line 33 as shown in Figure 4.
10 The regions extending longitudinally adjacent ~o and lying on either side of the immediately hereinbefore described central region are im-permeable to both liquid and vapor. In Figure 4, the vapor pervious, relatively liquid impervious 15 region is indicated generally by Z while the impermeable regions are indicated generally by C
and D. (Reference letters are used at this poînt in the discussion to refer generally to specific areas of outer sheet 25; they will be used later 20 in this discussion as measurements in the de-scription of the relative sizes of the impermeable and the vapor pervious, relatively liquid im-pervious regions.) The width of outer sheet 25 is shown by WO and its length by Lo~
The outer sheet can be constructed of any suitable material and in any suitable manner so long as the respective regions are impermeable and vapor pervious, relatively liquid impervious.
One material which has been ound suitable for the outer sheet is a thermoplastic film (such as common polyethylene film) which has been 26~3 per~orated in any convenient manner. A praferred degree of perforation can be described in terms of a dimension-less R value which is defined as R = d ~

wherein d is the average diameter, in centimeters, of the perforations in the film; OA is the total open area of the perforated film, expressed as a percentage; and c is the average caliper (or length) oE the perforations.
Normally, when apertures are formed in a thermoplastic film, they take the form of somewhat irregular cones open at both apex and base. Average diameter is the arithmetic average of the diameter of the cones so formed. Pore caliper is the average height of the cones so formed. (Of course, if the apertures should be uni-formly cut from the film without the normal formation ofthe cones, c will be film thickness.) A performated film having an R value between about 2 and about 40, preferably between about 5 and about 25, usually has the proper liquid transfer rate and vapor transfer rate for use in the present invention.

Another construction of outer sheet 25 utilizes the tapered capillaries described in U.S. Patent 3,929~135, issued to Thompson on December 30, 1975u This patent describes an absorptive device having as one element an unidirectionally liquid impervious sheet provided with tapered capillaries of critical dimensions. This element r ~L ~l 826i 03~

described by Thompson can be used as the basis fox oute~ shee~ 25. That is to say, outer sheet 25 can be provided with tapered capillaries, as t~ugh~ by Thompson, in the vapor pervious, r~-5 lative liquid împervious r~gion Z. Outer sheet25, in ~his embodiment, can be any suitable impermeable material, such as low density poly-ethylene, o~ from about 0.013 ~o about ~.076 millimeter, pre~erabl~ about 0.020 ~o about 0.030 i0 millime~er, ~hickness. I~ can be provided with tapered capillarie~ having a base in the plane o~
outer sheet 25 and an apex. remote from the plane of outer sheet 25. The apice~ will, in general, lie in an imaginary plane remote from the plane of 15 the outer shee~ 25. These ~apered capillaries will be provided with apex diameters, ~ase diame-ters, angles of taper and heights as described and deEined in the Thompson pat~nt. Figure 3 repre-sents the cross sectioTIal view of outer shee~ 25 20 taken along the line 3-3 of Figure 2 and ass~es that outer sheet 25 of Figure 2 is provided ~ith such tapered capillaries. ~igures 1 and 2, o~
course, are generalized representations of diapers of this invention and are not limited to struc-~5 tures having tapered capillaries as defined here.)The tapered capillaries should have a base di.ame~er cf from abou~ 0.013 to about 6.35 millimeters and an apex diameter o Erom abou-~ 0.0025 to about 2.54 millimeters. The~ shollld have a height of 30 from about 0.025 to about 1.02 millimeters. The angl~ of taper should be greater tha~ about 0 but less than a~bout 90. There should be from abou~
to about 1~400 tapered capillari.es per square centime~er. Preferably the tapered capillaries will have base diameters, apex diameters, and heights in the range of~ respectively, about 0.76 to about 1.27, about 0.25 to about 0.51, and about 0,25 to about 0.51 millimeters. Preferably, there 5 should be frorn about 46 to about 132 tapered capillaries per square centimeter.
.
It was noted above that the elements de-scr;bed by Thompson are unidirectionally liquid 10 impervious. That is to say, outer sheets provided wi~h tapered capillaries will, in normal cir-cums~ances, permit liquid to flow in one direction only and not in the reverse direction. The liquid impervious direction is that from least diameter 15 ~o greatest diameter of the tapered capillaries.
This direction can be described alternatively by noting that when the bases of the tapered capil-laries are in the plane of the sheet and the apices of the tapered capillaries are in an ~ imaginary plane remote from the plane of the sheet, the fluid impervious direction is from the imag;nary plane of the apices to the plane of the sheet.

Outer sheet 2S must be used in an orientation such that the direction o relative liquid im-permeabili~y is from the absorbent core to the exterlor surface of the diaper. In the usual case, this means that the apices of the tapered 30 capillaries in the ou~er sheet will be oriented in the direction of absorbent core and away from the exterior surface of the diaper.

Other materials, such as nonwoven sheets, can 35 be used as the outer sheet so long as they meet the requirements delineated above.

2~3 - ~4 -Inner panel 24 Gan be constructed from any liquid impermeable material. ~xamples of such materials can be readily invisioned by those skilled in the art~ The only requirements are that the materials be impermeable to liquid, flexible to such an extent that they do not interfere with the fit of the disposable diaper about the wearer, and of :Low bulk so that they do not appreciably add to the overall bulk of the disposable diaper thereby making it uncomfortable to wear. Naturally, the material shoul~ be innocuous to human skin and physically compatible with outer sheet 25 and absorbent core 23 and topsheet 22. One espec-ially suitable material is polyethylene having a thickness of from about 0.013 to about 0.025 mm.

Inner panel 2~ is shown in representational plan view in Figure 5. Center line 33 is an imaginary longitudinal center line while center line 32 is an imaginary latitudinal center line. The width of inner panel 24 is indicated generally by Wi and its length by X. Reference letter X denotes the impervious region of inner panel 24. In the embodiment illustrated in ~igure 5 and Figure 1, the length of the impervious area X is the total longitudinal length of inner panel 24.

An alternate embodiment of the inner panel is shown in representational plan view as 24' in 6~

.

Figure 6. Inner panel 24' is shown as a sheet having an impervious region X generally centered about imaginary lateral cen~er line 32. Regions A
and B ex~end laterally adjacent ~o and lie on 5 either side o~ impermeable region X. Regions A
and B must be essentially completely vapor perme-able. That is to say, they must offer no practi-cal resistance to vapor transfer therethrough. As a practical matter, materials which offer essen-lO ~îally no resistance to vapor transfer also freelypermit the passag~ of liquids.

As in Figure 1, in Figure 6 reference numerals 26, 27, and 28 represent, respectively, front 15 waist area, rear waist area, and crotch area. The general width of inner panel 24' is indicated by Wi, its length by Li.

Inner panel 24' can be based on a tissue such 20 as a high wet strength Kraft pulp paper tissue having a basis weight of, for example, 69.9 kilo-grams per 3,000 square meters. This tissue is treated in any suitable manner to render region X
thereof impervious to liquid. For example, the 25 tissue can be treated in region X with melted polyethylene or w;th a suitable wax as is well known to those skilled in the art. The impevious region can also be formed by affixing a ther~o-plastic film to the tissue in the appropriate 30 location. The only constraints placed upon the method in which the tissue is treated L-o render region X impervious are, in general, those re-strictions placed on inner panel 24 as described above. That is to say, after trea~ment, region X

2~3 must be impervious to liquids, must be flexible, mus~ be no rnore bulky ~han appropriate for its intended use, must be innocuous to human skin, and must be compatible with the other elements of the 5 disposable diaper. Preferably, the surface from which the tissue is treated is, in use, disposed away ~rom the absorbent core.

Inner panel 24' as shown in Figure 6 can be, 10 and preferably is, an envelope tissue cor~nonly used about absorbent core 23. In most disPosabl~
diapers which use an envelope tissue about the absorbent core, the envelope tissue generally faces the absorbent core on both its planar 15 surfaces. It must be emphasized that in the practice of the present inventlon, when ~he en-velope tissue is treated to provide inner panel 24', only the envelope tissue disposed toward the outer sheet is so treated.
Inner panel 24' can be a thermoplastic film wherein regions A and B are perforated in any convenient manner and region X is lef~ unper-fora~ed.
Inner panel 24' can be, in fact, any material meeting the criteria mentioned above.

Figure 2 is an exploded perspective view of 30 an ernbodlment of the diaper of this invention in which inner panel 24' is a tissue wherein crotch area 28 has been treated ~o forrn impermeable region X as indica~ed. As before, regions 26, 27, and 28 are, respectively, the :Eron~ wais~ area, 32~)3 ;, .. .

the rear waist area, and the crotch area. Top-sheet 22 is superimposed on absorbent pad 23.
These two elements are then superimposed on inner panel 24~ which, in turn, is superimposed on outer S sheet 25. This staclc of elements is then Eolded to form a diaper in the manner illustrated in Figure 1.

~s noted above, ~he reference letters in the 10 ~igures represent relative dimensions. Reference let~er Ll denotes the longitudinal length of the inner panel 24' (i.e. ~he length in the direction from the front waist latitudinal edge ~o the rear waist longitudinal edge.) The longitudinal 15 length of the impermeable region (which extends essentially across the entire lateral width of the diaper) is indicated by X. Preferably~ X is from about ~5% ~o about 85%, preferably about 65%, of the length of the absorbent core. I,i, when Li and 20 X do not coincide, is of any convenient leng~`h de-pencling on the length of the absorbent core. The lengths A and B are then selectecl ~or convenience with the only restraint being that the impermeable area must fall within the crotch region of the 25 diaper. (As used herein, the len gh of the absorbent core is the longitudinal dimension of the absorbent core and corresponds to ~he longi-tudinal dimension o~ the outer sheet as defined above.) Regions A and ~ can be folded about the 30 absorben~ core.

In a similar vein, referring to Figure 4, the vapor pervious, relatively liquid impervious region of outer sheet 25 extencls longitudinally 35 essentially the entire length of outer sheet 25.

.

6~3 . .

The 'la~eral width of this central vapor pervious, relatively impervious region is desi~nated by Z.
The impermeable regions of outer sheet 25 likewise extend essentially the entire longitudinal length 5 of the outer sheet 25 and have w:idths, respectively, C and D. Impermeable regions C and D essentially provide the free side flap leg seal ~or the diaper.
In general, C and D are eac'h greater than about 5 centimeters, preferably each is about 7.6 centi-lO meters.

The lateral widths Wi of the inner panel andWO of the outer shee~ are convenient dimensions.
Preferably, the outer sheet is at least about 10 15 centimeters wider than ~he inner panel. The inner panel is normally substantially the same width as the absorbent core.

Normally, disposable diapers are used for 20 diapering infants. In this normal situation, the longitudinaI length Lo of outer sheet 25 is from about 30 to about 52 centimeters while the longi-tudinal length Li of the inner sheet 24' is from about 38 to about 53 centimeters. Preferably, the 25 width Wi of inner panel 24 is from about 21 to about 34 centimeters and the width W0 of outer sheet 25 is from about 31 to about 43 centimeters.
The absorbent core is generally from about 26 to about 45 centimeters in the longitudinal direction and from about 21 to about 34 centimeters in lateral width.

Disposable diapers can, however, be sized to fit adult humans. In fact, there is a great commercial demand for adult-sized disposable 32~
r diapers ~or use with incontinent human adults.
I~hen intendecl for use by adults, L~ is pre~erably from about 71 to about 102 centimeters while Li is from about 76 to about llO centimeters. Prefer-5 ably, the inner panel is from abou~ 30 to about 54centimeters wide and the outer sheet is from about 45 to about 79 centimeters wide. Absorbent pads are, then, about 58 to about 87 centime-ters in the lotlgitudinal direction and about 30 to about 54 1~ centimeters in lateral width. As before, X is from about 25% to about 85%, pre~erably about 65%, of the length of the absorbent core.

As indicated above, inner panels 24 and 24', 15 outer sheet 25, and the entire disposable diaper 21 are all represented in the drawings as rectangu-lar devices. These rectangular devices are essentially as described in U.S. Patent Re.
26,151. U.S. Patent 3,8~0,003 teaches disposable ',~3 20 diapers having unfolded configurations somewhat different from the rectangular configuration shown in the drawings. It i5 to be understood that the present invention can be readily adapted to configur-ations such as that taught by U.S. Patent 3,860,003.
25 In such circumstances the absolute dimensions of Lo and Li and absorbent core length and width will vary according to need. The various regions of inner panel 24 and 24' and outer sheet 25 will retain their relative dimensional relationships, 30 but the absolute width and length of these regions will vary.

The inner panel and the outer sheet can be associated in any of various ways. In a preferred 3~ embodiment, the two elements are not affixed to , 2~3 one another except, perhaps, at the folded lateral margins of the diaper~ Thîs is to say, the inner panel is merely placed adjacent the outer sheet between it and the absorbent core; they are not united one to another in any way.

In another preferred embodiment~ the inner panel is affixed to the outer sheet by adhesive beads or spots.
For example, multiple narrow beads of adhesive extend-ing parallel to the imaginary longitudinal centerline and extending essentially over the whole length of the impervious portion of inner panel 24 can be used to unite these two elements. These multiple beads can be spaced from about 0.6 to about 5 centimeters apart.
Beads of adhesive applied in this particular orienta-tion serve not only to unite the inner panel and theouter sheet, but also to restrict lateral migration of any liquid which may inadvextently migrate into the region between the inner panel and the outer sbeet.
Prevention of such lateral migra~ion of liquid serves to ensure that there is no leakage of liquid from the lateral edges of the diaper when used, as about the wearer's legs. Preferably~ a longitudinal bead of adhesive i5 applied to the diaper side flap region for the same reason even in the absence of other beads of adhesive in the diaper. Any adhesive, such as hot melt adhesive, well known to those skilled in the art can be used.

In order to better illustrate the invention, and not by way of limitation, the following examples are presented.

!~

2~i~3 EXA~IPLES

To demonstra~e the present invention, and not by 7~ay o li~i~ation, the following examples are presented.

~ isposc~ble diapers similar in form, size, and construction to a leading commerclally available diaper and of the design illustrated generally by Figure 1 were constructed.

Sample A
The absorbent core was formed o~ airlaid, comminution grade wood pulp, had a basis weight of 0.028 gram per square centimeter, and was approxi-mately 40.6 centime~ers in longi~udinal length by 30.2 centimeters and lateral width. The absorbent core wa~s covered on ~he face nearest the topsheet with a paper ~issue having a basis weight of 57.9 kilograms p~r 3000 square meters. ~ topsheet of spunbonded polyester fibers, having a basis weight of about 23.5 grams per square meter, and being :~b~r 30 2 Co1~ ~eeA~ by ~1~ at ~,7 c=ntlmo~ ~s .. . . . . ..

~ 2~i~3 :, superimposed over one face of the absorbent core.
l'he outer sheet was 0.025 millimeter polyethylene provided with ~apered capillaries having a base diameter of 0.813 milllmeter, an apex diameter of 5 0.279 millimeter, and a height of 0.401 milli-meter. There were 128 tape:red capillaries per square centimeter. The outer sheet was 48.3 centimeters (Lo) by 38.1 centimeters (W0). It had an R value of 11.4. The inner panel was a paper 10 tissue of 69.9 kilograms per 3000 square meters basis weight and was 47 centimeters (Li) by 30.2 centimeters twi). The impervious region was ob-~ained by coating the central por~ion of the tissue with melted polyethylene so the dimension X
15 was 26.7 centimeters. This inner panel was placed adjacent the ou~er sheet between it and the absorbent core as shown generally in Figure 2.
The baclcsheet comprising the outer sheet and inner panel was superimposed on the absorbent core-20 topsheet assembly and the total unit was foldedinto a disposable diaper generally as shown by Figure 1. A hot melt adhesive bead was placed longitudinally along each side flap region. It should be emphasized that the only points of 25 direct attachment between the outer sheet and the inner panel were in the folded side flap areas of the diaper.

Sa~ple B
Sample B was prepared as Sample ~, except the inner panel was an impervious polyethylene film which was 30.2 centimeters (Wi) by 26.7 centi-meters (X~. It was adhesively fastened to the outer sheet with double sided adhesive t~pe alon~
35 its laterally extendi.ng edges. The absorbent pad 6~3 '' was faced on its backsheet side with the 69.9 kilograms per 3000 square meters ~issue as before, but this tissue lacked an impervious region.

S Sample C
Sample C was the control sample and repre-sented a conventional disposable diaper. It was constructed as Sample B, except there was no inner paneI. The outer sheet was impermeable poly-ethylene of 0.025 millimeter thickness, therebyrepresenting a conventional disposable diaper backsheet.

To determine the amount of vapor which will evaporate from the disposable diaper of this invention as it is worn ~and thereby measure and demonstrate the breathability of the two element backsheet of this invention), the~following tests were conducted.
The sample was folded into the normal dis-posable diaper configuration as if it were to be affixed to an infant. That is to say, the front and rear waist areas were brought into close proximit~ one to another thereby Eolding the diaper into a U~ shape. The topsheet formed the inner surface of the U; the backsheet, either the two element backsheet of this invention or the conventional control backsheet, formed the outer surface of the U. In Samples A and B the inner panel was generally at the bottom oE the U. An al;quot of synthetic urine was added to the crotch region of each diaper to simulate soiling. The aliquot was either 70 milliliters to simulate 1~ 33 daytime usage or 150 milliliters to simula~e nighttime usage. The wetted diapers were sealed along all open edges with double sided adhesive tape to sim~late ~he closure o~ the diaper about S the legs and waist of an infant.

The samples were subjected to sta~ic and dynamic evaporation (breathability) tests.
For the static test, a diaper, prepared as indicated, was suspended with the waist regions uppermost and the crotch region freely hanging downwardly. The sample was placed in a 23C, 50%
relative humidity atmosphere for two hours. The weight loss occuring during this time was observed and recorded and reported as weight % of initial loading evaporated.

For the dynamic test, the diapers were pre-2~ pared and suspended as for the static test. In~his case, however, the diapers were manipulated to simulate an infant's movemen~. The manipula-tion was provided by a simple motorized mechanical device which pressed against the crotch region of the suspended diaper and alternately raised the crotch region through a distance of approximately 7.6 centimeters upwardly toward the fixed waist region and then lowered the crotch region to i~s original position at a rate of approximately 15 cycles per minute. Observations were made and data recorded as for the static test.

Five units of each diaper sample were tested and the avlerage results for the static test are shown in Table I, for the dynamic test in Table II.

Z1~3 - ~5 -'T~B~E I
. _ .... . .
ST~TIC TEST
Daytime Use Nightt-ime Use Sample % Evaporation Sample % Evaporation A~.64 A 1.65 B0.47 B 1.35 C0.07 C 0.36 'T~'BLE'II
. _ , D~NAMIC TEST
Da~Jtime Use Nighttime Use Sample % Evaporation Sample' % Evaporation A 1.78 A 2.2 ~ 1.59 B 1.88 15C 0.45 C 0.45 As can be readily observed, ~he diapers of this invention allowed more liquid to evaporate than did conven~ional disposable diapers. Thus, the diapers of this invention breathe more effect-ively than do conventional disposable diapers.
Sample A, wherein the inner panel is not affixed ~o the ou~er sheet other than in the folded side f'lap areas at the longitudinal edges of the diaper, was shown to be more'effective than another em-bodiment.

At the same time the evaporation (breathability) tests were being conducted, careful observations were made to determine if any liquid was present on the outer surface of the diapers. Essentially no liquid was observed on the outer surfaces of any of ~he samples.

:~L3l8~
( - 2~ -Diapers are con$truc~ed as Sample B, except the inner panel is omitted entirely. These diapers demonstrate adequate evaporation or breathability, but at the same time allow 2X-cessive quantities of liquid to pass through theouter sheet. 'rherefore, these samples are un-suitable for practical use 'because adjacen~
clothing is soiled.
Diapers corresponding to Samples A, B, and C
are prepared and are evaluated by use on living infants. The'mothers of the infants judge all samples ~o provide adequate protection from the wetting or soiling of outer garments and judge the diapers of this invention to be drier overall and cooler than conventional disposable diapers.

The foregoing detailed description of the invention has 'been couched in terms of disposable diapers. It is anticipated that this invention, comprising an absorbent core and a breathable backsheet of specific configuration, can be used in other embodiments. For example, the absorptive device of this invention can be shaped and sized for use as a surgical bandage and as a sanitary napkin. The details of the extension of the teachings of this invention to such embodimen~s are well within the skills of the ordinary artisan.

~1hat is claimed is:

. .

Claims (17)

Claims:
1. A disposable diaper comprising an absorbent core; a vapor pervious, relatively liquid impervious outer sheet; and a liquid impervious inner panel;
wherein said inner panel is substantially as wide as said absorbent core and is from about 25% to about 85%
of the length of said absorbent core; wherein said inner panel is superimposed on said outer sheet to form a breathable backsheet and said absorbent core is superimposed on said backsheet in such a manner that said inner panel is interposed between said absorbent core and said outer sheet and is located in the crotch region of said diaper.
2. The diaper of Claim 1 wherein said outer sheet has a liquid transfer rate of less than about 5% and a vapor transfer rate greater than about 0.6 gram per 100 square centimeters per hour.
3. The diaper of Claim 2 wherein said outer sheet is impermeable along the lateral margins thereof.
4. The diaper of Claim 1 wherein said outer sheet is impermeable along the lateral margins thereof.
5. The diaper of Claim 1, wherein said outer sheet is constructed of an impermeable film having perforations therethrough whereby the R value (degree of perforation) of the vapor permeable, relatively liquid impervious region of said film is from about 2 to about 40.
6. The diaper of Claim 5 wherein said R value is from about 5 to about 25.
7. The diaper of Claim 1, wherein said outer sheet is constructed of an impermeable film provided with tapered capillaries having a base in the plane of said film and an apex remote from a plane of said film;
wherein the diameter of said apex is from about 0.0025 to about 2.54 millimeters; the diameter of said base is from about 0.013 to about 6.35 millimeters; the height of said capillaries is from about 0.025 to about 1.02 millimeters; and the angle of taper of said capillaries is greater than about 0° and less than about 90°; and wherein there are from about 2 to about 1,400 tapered capillaries per square centimeter.
8. The diaper of Claim 7 wherein the base diameter of said tapered capillaries is from about 0.76 to about 1.27 millimeters, the apex diameter is from about 0.250 to about 0.51 millimeter; the height is from about 0.250 to about 0.51 millimeter; and there are from about 46 to about 132 tapered capillaries per square centimeter.
3. The diaper of Claim 1, wherein said inner panel is constructed from a sheet provided with an imperme-able region and at least one essentially completely vapor permeable region, wherein said impermeable region is substantially as wide as said absorbent core and is from about 25% to about 85% of the length said absorbent core.
10. The diaper of Claim 5 wherein said inner panel is constructed from a sheet provided with an impermeable region and at least one essentially completely vapor permeable region, wherein said impermeable region is substantially as wide as said absorbent core and is from about 25% to about 85% of the length said absorbent core.
11. The diaper of Claim 6 wherein said inner panel is constructed from a sheet provided with an impermeable region and at least one essentially completely vapor permeable region, wherein said impermeable region is substantially as wide as said absorbent core and is from about 25% to about 85% of the length said absorbent core.
12. The diaper of Claim 7 wherein said inner panel is constructed from a sheet provided with an impermeable region and at least one essentially completely vapor permeable region, wherein said impermeable region is substantially as wide as said absorbent core and is from about 25% to about 85% of the length said absorbent core.
13. The diaper of Claim 8 wherein said inner panel is constructed from a sheet provided with an impermeable region and at least one essentially completely vapor permeable region, wherein said impermeable region is substantially as wide as said absorbent core and is from about 25% to about 85% of the length said absorbent core.
14. A disposable diaper comprising a) an absorbent core comprising air laid comminuted wood pulp fibers and having a basis weight of about 0.03 gram per square centimeter;
b) a vapor pervious, relative liquid impervious outer sheet comprising a polyethylene film of about 0.025 milli-meter thickness provided with about 130 tapered capillaries per square centi-meter, said tapered capillaries having a base of about 0.81 millimeter diameter in the plane of said film and an apex of about 0.28 millimeter diameter in a plane remote from the plane of said film and a height of about 0.40 millimeter;
and c) an inner panel comprising a paper tissue having a basis weight of about 70 kilograms per 3000 square meters pro-vided with an impermeable region sub-stantially as wide as said absorbent core and about 65% of the length of said absorbent core;
wherein said inner panel is superimposed on said outer sheet to form a breathable backsheet and said absorbent core is superimposed on said back-sheet in such a manner that said inner panel is interposed between said absorbent core and said outer sheet and said impermeable region is located in the crotch region of said diaper.
15. The diaper of Claim 14 wherein said impermeable region comprises a thermoplastic film.
16. The diaper of Claim 14 wherein said impermeable region comprises paper fibers coated with thermoplastic polymers.
17. The diaper of Claims 14, 15, or 16 comprising as an additional element a fluid pervious topsheet.
CA000397104A 1981-02-27 1982-02-25 Breathable backsheet for disposable diaper Expired CA1182603A (en)

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US06/239,090 US4341216A (en) 1981-02-27 1981-02-27 Breathable backsheet for disposable diapers
US239,090 1994-05-05

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CA (1) CA1182603A (en)
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DK161053C (en) 1991-11-11
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NO155035B (en) 1986-10-27
US4341216A (en) 1982-07-27
BR8200884A (en) 1982-12-28
ATE14829T1 (en) 1985-08-15
IE52765B1 (en) 1988-02-17
JPS6364523B2 (en) 1988-12-12
DE3265334D1 (en) 1985-09-19
FI820690L (en) 1982-08-28
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NO155035C (en) 1987-02-04
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JPS57205505A (en) 1982-12-16
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FI70122B (en) 1986-02-28
IE820427L (en) 1982-08-27

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