CA1305289C

CA1305289C - Disposable diaper having an improved leg conforming cuff

Info

Publication number: CA1305289C
Application number: CA000570268A
Authority: CA
Inventors: James William Richardson
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 1987-06-25
Filing date: 1988-06-23
Publication date: 1992-07-21
Anticipated expiration: 2009-07-21
Also published as: FI883062A0; JP2633307B2; IE881939L; DE3873654D1; DE3873654T2; JPS6477606A; HK89596A; AU1836488A; FI883062A; MY103109A; US4816026A; KR970000978B1; NZ225168A; ATE79246T1; FI89865B; FI89865C; AU596554B2; PT87842B; PT87842A; KR890000046A

Abstract

DISPOSABLE DIAPER HAVING
AN IMPROVED LEG CONFORMING CUFF

ABSTRACT
A disposable diaper having an improved leg cuff. The disposable diaper is provided with an elastic member which is affixed to the diaper at its ends and unaffixed in its central portion. The elastic member is contained between seams having bond portions and hinge portions.

Description

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DISPOSABLE DIAPER HAVING
AN IMPROVED LEG CONFORMING CUFF

BACKGROUND Oi~ THE INVENTION

This invention relates to disposable diapers having elasticized leg openings and more particularly to disposable diapers having an improved leg conforming cuff. Stil I more particularly this invention relates to an improved leg cuff in which elastic members having an unadhered center portion are 10 contained between seams having bond portions and hinge portions.

Disposable diapers are wel I known artlcles of manufacture which are worn by infants and incontlnent persons. Disposable dlapers are worn about the lower torso and are intended to 15 absorb and contain urine and feces thereby preventing the urine and feces from soiling wetting or otherwise contaminating the articles (e.g. clothing bedding etc. ) which come into contact with the diaper wearer.

In general disposable diapers all have the same basic 20 structure whlch comprises an absorbent core encased between a liquid permeable user contacting topsheet and a liquid Impermeable backsheet. The prior art of course teaches numerous variations of and elements in additlon to the baslc topsheet backsheet and absorbent core arrangement. For example an Improvement in the ' , performance of disposable diapers has been achieved by the addition of an elastic means along that portion of the disposable diaper which contacts the wearer~s thigh thereby providing elasticized leg openings when the diaper is worn.
Typically the elastics used in the cuffs of disposable diapers are adhered to the diaper along their entire length. Thus, the elastics ~ust develop enough contractive force to contract the topsheet, the backsheet, and the adhesive. These contractive forces are often high enough to cause irritation and red marking around the wearer's leg.
U.S. Patent 3,417,751 which issued to I.L. Murdock on December 24, 1968, is directed to a baby pant in which a pad overlays the elastic member to reduce discomfort and to provide a seal about the infant's legs. U.S. Patent 4,081,301 which issued to K.B. Buell on March 28, 1978, is directed to a method and apparatus for attaching elastic strands to a diaper in which one embodiment attaches the ends of the elastic to the diaper while leaving the center portion unadhered.
The disposable diapers of the prior art lack the aspects of the present invention whereby an improved leg cuff i5 provided in which the contractive force needed to gather the cuff about the wearer's leg i6 reduced.
The reduction in the contractive force needed to gather the cuff is obtained by leaving the center portion of the elastic member unadhered to the diaper while containing the unadhered center portion between seams which have hinge portions.
It i5, therefore, an object of an aspect of the present invention to provide an improved leg cuff for disposable diapers.
An object of an aspect of the present invention is to provide an improved leg cuff which is gathered about the wearer's leg with reduced contractive force.
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13~SZ~39 An object of an aspect of the present invention is to provide an improved leg cuff in which the elastic members are affixed only at their ends and are contained between seams having hinge portions.
These and other objects of the invention will be more readily apparent when considered in reference to the following description and when taken in connection with the accompanying drawings.

SU~ARY OF THE INVENTION
In a particularly preferred embodiment of the ; present invention, a disposable diaper is provided. The diaper has elasticized longitudinal portions in which at least three elastic members are operatively associated with a cuff. The elastic members have two affixed portions which are affixed to the cuff and an unaffixed portion between the two affixed portions which is not affixed to the cuff.
The cuff has a first layer which overlays a portion of the cross sectional perimeter of the elastic members and a second layer which overlays another portion of the cross sectional perimeter. Seams affix the first layer to the second layer and are positioned adjacent to the elastic members. The seams have bond segments and hinge segments alternately positioned along the length of the ~, 25 seam. The first layer is affixed to the second layer at the bond segments and the first layer is unaffixed to the second layer on the hinge segments.
Another aspect of this invention is as follows:
~ A disposable diaper comprising:
,~ 30 an outer covering layer;
an absorbent means ~or absorbing liquids, said absorbent means being encased within said covering layer;
~, elasticized longitudinal portions at both longitudinal sides of the diaper, said elasticized /

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130SZ8g 3a longitudinal portions having a cuff and at least three individual and uninterconnected elastic members operatively associated with said cuff in an elastically contractible condition, said elastic members having a cross sectional perimeter, two affixed portions and an unaffixed portion between said two affixed portions, said cuff having a first layer overlapping a portion of said cross sectional perimeter and ~ second layer overlapping another portion of said cross sectional perimeter, said two affixed portions of said elastic being affixed to said cuff and said unaffixed portion of said elastic being unaffixed to said cuff; and seams affixing said first layer to said second layer, said seams being positioned adjacent to said elastic members and having bond segments and hinge segments alternately positioned along the length of said seams, said first layer being affixed to said second layer at said bond segments and said first layer being unaffixed to said second layer at said hinge segments.

BRIEF DFSCRIPTION OF TH~ DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the sub~ect matter regarded as forming the present invention, it is believed that the invention B
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Figure 1 is a partially cut away perspective view of the disposable diaper of the present invention prior to its being 5 folded for placement on the wearer;

Figure 2 is a sectional view taken along section line 2-2 of Figure 1;

Figure 3 is a partially cut away enlarged view of a part of the elasticized longitudinal portion of the disposable diaper shown 10 in Figure 1 and Figure 4 is a sectional view taken along section iine 4-4 of Figure 1.

DESCRIPTION OF A PREFi RRED EMBODIMENT

Referring now to the drawings there is shown a preferred 15 embodiment of the present invention as it would be used in a disposable dlaper intended to be worn by an infant. As used herein the term disposable dlaper refers to a garment generally worn by infants or incontinent persons whlch Is drawn up between the legs and fastened about the waist of the wearer and 20 further whlch is intended to be discarded after a single use ( i . e . it is not intended to be launderea or otherwise restored and reused ) .

Figure 1 is a partially cut away perspectlve vlew of the dlsposable diaper 10 of the present inventlon prior to its being 25 folded and placed on the diaper wearer by the diaper user. As can be seen in Figure 1 a preferred dlaper 10 basically comprises an outer coverlng layer 11 an absorbent means 14 and . an elasticlzed longitudinal portion 17 at both longitudinal sides of the dlaper 10. While the outer covering layer 11 absorbent ~: ;
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means 14, and elasticized longitudinal portion 17 may generally be assembled in a variety of well known configurations, a preferred disposable diaper configuration is described generally in U.S. Patent 3,860,003 entitled "Contractible Side Portions for Disposable Diaper"; which issued to K.B. Buell on January 14, 1975.
Still referring to Figure 1, it can be seen that a preferred outer covering layer 11 encases and contains the absorbent means 14 and, preferably, the outer covering layer 11 comprises a topsheet 12 and a backsheet 16 which are joined together in any suitable manner, either directly to each other or indirectly through an intermediate member. Figure 1 shows a preferred embodiment of the diaper 10 in which the topsheet 12 and the backsheet 16 are joined together directly and are coextensive ~aving length and width dimensions generally larger than those of the absorbent means 14. The topsheet 12 is superposed on the backsheet 16 thereby forming a periphery 20 of diaper 10. The periphery 20 defines the outer periphery or, in other words, the outer extend of the diaper 10. The periphery 20 comprises first end 22, second end 24, first longitudinal ~ide 26, and second longitudinal side 28.
The topsheet 12 may be affixed to the backsheet 16 in any suitable manner as is well known in the diaper manu~acturing art. In a preferred embodiment, a multiplicity of longitudinal adhesive bands 30 of hot-melt adhesive are applied along the full length of the backsheet 16 generally parallel to the longitudinal centerline 72 of the backsheet 16. The longitudinal adhe~ive bands 30 serve to affix the topsheet 12 to the backsheet 16 at those points where these three components come together. The extent and location of the points where the topsheet 12, backsheet 16, and 13(~52~9 5a longitudinal adhesive bands 30 come together will depend on the spacing between the longitudinal adhesive bands 30 and.on the distance the topsheet 12 and the backsheet 16 extend beyond the absorbent means 14. The number of longitudinal adhesive bands :~"~

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30 and the spacing therebetween should be sufficient to securely bond the topsheet 12 to the backsheet 16 in the area between the periphery 20 and the edge of the absorbent means 14.

A hot-melt adhesive suitable for use as longltudinal adhesive S bands 30 is manufactured by Century Adhesive Corp. of Columbus, Ohio, and marketed under the tradename R-10-A. It will be noted that the above described manner of affixing the topsheet 12 to the backsheet 16 causes the topsheet 12 to be affixeci to the backsheet 16 intermittently along the first and l0 second ends, 22 and 24. The absorbent means 14 is thereby encased between the topsheet 12 and the backsheet 16. Of course, many alternative methods of affixing the topsheet 12 to the backsheet 16 may be used with satisfactory results . For example, the topsheet 12 may be affixed to the backsheet 16 15 indirectly rather than directly as is shown in Figure 1. Thus, an intermediate member may be used to affix the topsheet 12 to the backsheet 16.

The diaper 10 has first and second waist portions 42 and 44 extending, respectively, from the first end 22 and the second end 20 24 of the diaper periphery 20 toward the lateral centerline 31 of the dlaper 10 a distance from about 1/5 to about 1/3 the length of the diaper. The waist portions 42 and 44 comprise those portions of the diaper 10 whtch, when worn, encTrcle the waist of the wearer . The crotch portlon 46 is that portion of the diaper 10 25 between first and second waist portions 42 and 44, and comprises that portion of the diaper 10 which, when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer.

The absorbent means 14 may be any means which is 30 generally compresslble, conformable, non-irritating to the wearer s skin, and whlch Is capable of absorbing and retalning liquids. A
- preferred absorbent means 14 has first and second opposed faces 32 and 34 respectively and comprises an absorbent layer 36 and :

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r 130S289 flrst and second tlssue layers 38 and ~0 respectively. The flrst and second tissue layers 38 and 40 overlay the malor surfaces of the absorbent layer 36 to form the first and second opposed faces 32 and 34 of the absorbent means 14.

The abso~bent layer 36 Is Intended to absorb and contain liquid and may be manufactured In a wlde variety of sl2es and shapes (e.g . rectangular hourglass etc. ) and from a wide varlety of llquid absorbent materials commonly used In disposable diapers such as comminuted wood pulp which is generally referred to as airfelt. Other liquid absorbing materials may also be used in the manufacture of the absorbent layer 36 such as a multiplicity of plies of creped cellulose wadding absorbent gelling material absorbent foams or sponges or any equivalent material or combination of :naterials. The total absorbent capacity of the absorbent layer 36 should however be compatible with the design liquld loading in the intended use of the disposable diaper 10. Further the size and absorbent capacity of the absorbent layer 36 may be varied to accommodate wearers ranging from infants through adults.

The preferred embodlment of diaper 10 illustrated in Figure 1 has an hourglass shaped absorbent layer 36 and is intended to be worn by infants ranging in weight from about 12 to about 26 pounds (about 5 kgs. to about 12 kgs). The absorbent layer 36 is therefo-e a batt of airfelt approximately 16 inches (41 cm) 2S long when measured along the long~tud~nal centerline 72 approxlmately 6.5 inches (16 cm) across the first and second ends 22 and 24 and approximately 5 inches (13 cm ) across the narrowest part of the crotch portion 46. The absorptive capacity of the airfelt used for the absorbent layer 36 is sufficient to absorb and retaln from about 8 to about 16 grams of water per gram of absorbent material. Accord~ngly the airfelt used in the preferred embodiment shown in Flgure 1 weighs from about 15 to about 56 grams and has a generally uniform caliper. It should be understood however that the size shape configuratlon and ,~

--~ 130S289 total absorbent capacity of the absorbent layer 36 may be varied to accommodate wearers ranglng ~rom Infants through adults.
Therefore, the dimensions, shape, and configuration of the absorbent layer 36 may be varied (e.g. the absorbent layer 36 5 may have a varying caliper, or a hydrophillic gradient, or may contain absorbent gelling materials).

The first and second tlssue layors, 38 and 40, are intended to improve the tensile strength of the absorbent core 14 and to reduce the tendency of the absorbent layer 36 to split, lump or 10 ball when wetted. The first and second tissue layers, 38 and qO, also help to improve lateral wicking of liquids, thereby providing a more even distribution of liquid in the absorbent layer 36.
While a number of materials and manufacturing techniques may be used to manufacture the first and second tissue layers, 38 and 15 40, satisfactory results have been obtained with sheets of tissue paper having a basis weight of approximately 10 pounds per 3000 square feet ( 16 gms per square meter) and having an air permeability of approximately 100 cubic feet per minute per square foot (30 cubic meters per minute per square meter) over a 20 0.5 inch (13 mm) water pressure drop. While the first and second tissue layers, 38 and 40, are preferably coterminous with the absorbent layer 36, thoy may have different dimensions, a different configuratTon, or they may be omitted entirely.
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The absorbent means 14 is suporlmposed on the backsheet 16 25 and is pre-erably affixed thereto by any means as is well known in the diaper art. For example, the absorbent core 14 may be secured to the backsheet 16 by a unTform continuous layer of adhesive, a patterned layer of adhesive, or any array of lines or spots of adhesive. In the preferred embodiment illustrated in 30 Figure 1 the longltudinal adhesive bands 30 are used to affix the absorbent core 14 to the backsheet 16.

The backsheet 16 is impermeable to liquids and prevents llquids absorbed by the absorbent means 14 from wetting the '.

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undergarments, clothing, bedding, and other obJects which contact the wearer of the disposable diaper 10. Preferably the backsheet 16 Is a polyethylene fllm of from about 0.0005 to about 0.002- Inches (about 0.012 to about 0.051 mm) thick, although S other flexible, llquid Impermeable materials may also be used; As used herein, the term flexible refers to materials whlch are compllant and whlch readlly conform to the shape and contours of the human body. A suitable polyethylene fllm is manufactured by Monsanto Chemical Company and marketed In the trade as Film No. 8020. The backsheet 16 Is preferably embossed and/or matte finished to provide a more clothllke appearance. Further, the backsheet 16 may have passages which permit vapors to escape from the absorbent means 14 while still preventing liquid from passlng through the backsheet 16. In a preferred embodiment, 15 the backsheet 16 has a modified hourglass shape extending beyond the absorbent layer 36 a minimum distance of at least about 0. 5 inches (about 1 . 3 cm) around the entire diaper perlphery 20.

The topsheet 12 is compliant, soft feeling, and non-irritating 20 to the wearer s skin and prevents the wearer of the diaper 10 from contactlng thc absorbent core 14. Further, the topsheet 12 is llquld permeable permitting llqulds to readily penetrate through its thickness. A sultable topsheet 12 may be manufactured from a wide range of materlals, such as natural flbers (e.g., wood or 25 cotton flbers), synthetic flbers (e.g., polyester, polyethylene, polypropylene), or a comblnation thereof. Alternatively , the topsheet 12 may be a foam, such as the retlculated foams which are well known In the art or any of the formed films which are also well known in the art.

A number of manufacturlng technlques can be used to manufacture the topsheet 12. For example, the topsheet 12 may be woven, nonwoven, spunbonded, carded, or the like. A
preferred topsheet 12 is carded, and thermally bonded by means well known to those skilled In the nonwoven fabrics art.

13~5289 .

Preferably the topsheet 12 has a weight of from about 18 to about 25 grams per square yard, a minimum dry tensile strength of at least about 400 grams per centimeter in the machTne direction and a wet tensile strength of at least about 55 grams per centimeter 5 in the cross machine direction.

A cuff 50 is positioned along the first longitudinal side 26 and another cuff 50 is positioned along the second longitudlnal side 28. In general, the cuffs S0 comprise the portion between the first and second longitudinal sides 26 and 28 and the - 10 corresponding longitudinal side of the absorbent means 14.The cuffs S0 are gatherable areas which may be either unitary (i.e., cuff S0 has at least one continuous and undivided element in common with the outer covering layer) or integral (i.e., the cuff S0 is a separate element affixed to the rest of the diaper 10) with 15 the outer covering layer 11. Referring now to Figures 2, 3, and 4, it can be seen that in the preferred embodiment illustrated the cuff 50 comprises a first layer 60 and a second layer 62. In the preferred embodiment illustrated in the Figures, the cuffs 50 are unitary with the outer covering layer 11 and the first layer 60 is 20 formed by extending the topsheet 12 beyond the edge of the absorbent means 14 and the second layer 62 is formed by extending the backsheet 16 beyond the edge of the absorbent means 1 4, Each elasticized longitudinal portion 17 comprises at least 25 three elastic members 18 which are operatively associated with each cuff 50 in the crotch portion 46 in an elastically contractible condition so that in a normally unrestrained configuration, the elastic members 18 effectively contract or gather the cuff 50. As used herein the term "operatively associated" refers to two or 30 more comioonents which act together. In the preferred embodlment shown in the Figures, the elastic in members 18 are positioned between the first layer 60 and the second layer 62 and are operatively associated with both cuffs 50 in the crotch portion 46. Thus, the elastic members 18 are affixed to the cuffs S0 so as to cause the cuffs 50 to contract when the elastic members 18 are allowed to contract.
Referring specifically to Figure 4, it can be seen that the elastic members 18 each have two af$ixed portions 19 and an unaffixed portion 21 between the two affixed portions 19. The affixed portions 19 of the elastic members 18 are affixed to the cuff 50 and the unaffixed portion 21 is unaffixed to the cuff 50. For example, the affixed portions 19 may be affixed to the second layer 62 using an adhesive bead 27. A suitable method for incorporating elastic members 18 into a disposable diaper is described in U.S. Patent 4,081,301 entitled "Method and Apparatus for Continuously Attaching Discrete, Stretched Elastic Strands to Predetermined Isolated Portions of Disposable Absorbent Products" which issued to K.B. Buell on March 28, 1978.
Referring specifically to Figures 2 and 3, it can be seen that the elastic members have a cross sectional perimeter and that the first layer 60 overlays at least a portion of the cross sectional perimeter of the elastic members 18 and the second layer 62 overlays another portion of the cross sectional perimeter of the ela~tic members 18. The first and second layers 60 and 62 are affixed to each other along a plurality of seams 64. The seams 64 are positioned along the longitudinal sid~s of the elastic members 18 at least in a segment of the unaffixed portion 21 and comprise bond segments 68 and hinge segments 70 alternately placed along the length of the seam~ 64. The bond segments 68 serve to bond the first layer 60 and the ~econd layer 62 together, thereby confining at least a portion of the unaffixed portlon 21 of the elastic members 18 between two of the seams 64.
The bond ~egments 68 may be formed in a number of 3S ways that will suggest themselves to one skilled in the art. For example, the bond segments 68 may be formed by ~,' .

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13,05289 gluing the first layer 60 to the second layer 62. In the preferred embodiment shown in the Figures, the bond segments 68 are formed by heat sealing the first layer 60 to the second layer 62. The bond segments 68 have sufficient strength to maintain the attachment between the first and second layers 60 and 62. The bond segments 68 are relatively rigid and are not readily contracted by the elastic members. Thus, if the dimension of the bond segments 68 in a direction parallel to longitudinal center line 72 is too long, the elasticized longitudinal portion 17 will require relatively high contractive forces to gather the cuff 50. It has been found that the length of the bond segment is preferably less than about 10 cm.
In the hinge segments 70, the first and second layers 60 and 62 are unbonded to each other and the hinge segments 70, therefore, remain flexible. Thus, as the cuffs 50 are gathered by the elastic members 18, the hinge segments 70 permit the first and second layers 60 and 62 to buckle, thereby reducing the contractive force needed to gather the cuffs 50. The hinge segments 70 have a length which is short enough to prevent the elastic members 18 from becoming interposed between the bond segments 68. It has been found that hinge segments 70 having a length less than about 5 cm work well.
In the preferred embodiment illustrated, the elastic members 18 are operatively associated with the cuffs 50 by being affixed to the cuffs 50 using a suitable adhesive which will be of sufficient adhesiveness to hole the elastic members 18 to the cuff 50 while the elastic members 18 are stretched. An adhesive which has been used with satisfactory results is manufactured by Findley Adhesives Corporation of Elm Grove, Wisconsin, and i5 marketed under the trade name FindleyTM H-2031-01.

' ' 13(:~5289 12a Suitable elastic members 18 may be manufactured from a wide variety of elastic materials such as natural rubber, or elastomeric films such as Kraton,TM
ethylene propylene-dimonomer, and polyurethane. The elastic members 18 can be operatively associated ,~
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, 130S;~89 with the cuffs 50 in an elastically contractible condltlon In at least two ways. For example the elastlc member 18 may be stretched and whlle In the stretched condltlon affixed to the uncontracted and unstretched cuffs 50. Alternatlvely the cuffs 50 may be 5 contracted (e.g. by pleatlng) and then amxlng the unstretched elastic member 18 to the contracted cuffs 50.

In addition the elastic members 18 may take a multltude of conflgurations. For example the width of the elastlc members 18 may be varied from about 0.015 inches to 1.0 inches (0.38 mm 25 lO mm) or more; or the elastic members 18 may be rectilinear or curvilinear. Still further the elastic members 18 may be affixed to the diaper 10 in any of several ways which are well known in the art. For example the elastic members 18 may be ultrasonically bonded or heat sealed into the cuffs 50 using a 15 variety of bonding patterns or the elastk members 18 may simply be glued to the cuffs 50.

One material which has been found to work well as an elastic member 18 is an elastic thread having a cross section of . 017 inches by .019 inches (about 0.43 mm by about 0.48 mm) and 20 whlch Is manufactured from natural rubber. Such a product is marketed by Fulflex undor the trade name 9212. The preferred elastlc member 18 produces a tenslle force of about 100 grams when stretched 100 percent from Its relaxed condltlon.

The dlaper 10 is provided wlth a fastening means 54 for 25 malntainlng the first and second walst portions 42 and 44 in an overlapping configuration when the diaper 10 is worn ~ see Figure 1 ) . Thus the diaper 10 is fitted to the wearer and a side closure formed.

More speclflcally the fastenlng means 54 afflxes the first 30 walst portlon 42 to the second walst portlon 44 thereby maintalnlng the flrst and second walst portlons 42 and 44 in an overlapping conflguration. Thus the fastening means 54 must be '' ` ' .

~30~Z~9 affixed to both the first waist portion 42 and the second waist portion 44 in a manner and with a strength that is sufficient to resist the forces acting to cause the first and second waist portions 42 and 44 to separate during wearing.
The fastening means S4 may comprise any of the well known means for achieving a side closure such as VelcroTM strips or patches, buttons, or snaps. A
preferred fastening means 54 is an adhesive tape as is well known in the diaper art.

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Claims

1. A disposable diaper comprising:
an outer covering layer;
an absorbent means for absorbing liquids, said absorbent means being encased within said covering layer;
elasticized longitudinal portions at both longitudinal sides of the diaper, said elasticized longitudinal portions having a cuff and at least three individual and uninterconnected elastic members operatively associated with said cuff in an elastically contractible condition, said elastic members having a cross sectional perimeter, two affixed portions and an unaffixed portion between said two affixed portions, said cuff having a first layer overlapping a portion of said cross sectional perimeter and a second layer overlapping another portion of said cross sectional perimeter, said two affixed portions of said elastic being affixed to said cuff and said unaffixed portion of said elastic being unaffixed to said cuff; and seams affixing said first layer to said second layer, said seams being positioned adjacent to said elastic members and having bond segments and hinge segments alternately positioned along the length of said seams, said first layer being affixed to said second layer at said bond segments and said first layer being unaffixed to said second layer at said hinge segments.

2. The disposable diaper of Claim 1 wherein said bond segments have a length less than about 10 cm and said hinge segments have a length less than about 5 cm.

3. The disposable diaper of Claim 1 wherein said seams are positioned adjacent to said elastic members only at the unaffixed portion of said elastic members.