CA2203794C

CA2203794C - Absorbent article having inflected barrier cuffs and method for making the same

Info

Publication number: CA2203794C
Application number: CA002203794A
Authority: CA
Inventors: David Mark Sageser
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 1994-11-09
Filing date: 1995-10-26
Publication date: 2001-03-13
Anticipated expiration: 2015-10-26
Also published as: BR9509709A; DE69517534D1; US5577540A; KR970706779A; CA2203794A1; US5542943A; CN1171733A; WO1996014815A1; AU708896B2; KR100234465B1; AU4135296A; JPH10509361A; ZA959484B; MX9703395A; ES2146786T3; EP0790815A1; EP0790815B1; ATE193825T1; DE69517534T2

Abstract

Absorbent articles having side panels that provide inflected barrier cuffs which promote better containment and fit. The absorbent article has a front waist region, a rear waist region, a crotch region and a pair of longitudinal edges. The absorbent article further comprises a chassis including a pair of longitudinally extending side panels, each of the side panels having a front ear flap section; a barrier cuff section having a first end edge located longitudinally inboard of the front ear flap section; a second end edge located in the rear waist region; a proximal edge and a distal edge; spacing means joined with each barrier cuff section; and closing means for securing at least a portion of the barrier cuff section juxtaposed the first end edge to the absorbent article inboard of the proximal edge. The distal edges are unsecured to any underlying structure of the absorbent article in the front and rear waist regions such that the distal edges form the longitudinal edges in the front and rear waist regions. The distal edge of the barrier cuff section is secured laterally inboard of the proximal edge in the crotch region such that the second end edges of the side panels located in the rear waist region are inverted relative to the first end edges to form an inflected barrier cuff that stands up in the crotch region when the absorbent article is fitted to a wearer.

Description

ABSORBENT ARTICLE HAVING INFLECTED BARRIER CUFFS
AND METHOD FOR MAKING THE SAME
FIELD OF THE INVENTION
The present invention relates to absorbent articles such as disposable diapers, incontinence briefs, undergarment absorbent inserts, feminine hygiene garments, and, more particularly, to absorbent articles having side panels that become inflected when the absorbent article is fitted to the wearer to provide barrier cuffs which improve the containment characteristics and fit of the absorbent article.
The major function of absorbent articles such as disposable diapers and incontinence briefs or undergarments is to absorb and contain body exudates.
Such articles are thus intended to prevent body exudates from soiling, wetting, or otherwise contaminating clothing or other articles, such as bedding, that come in contact with the wearer. The most common mode of failure for such products occurs when body exudates leak out of the gaps between the article and the wearer's leg or waist to adjacent clothing because they are not immediately absorbed within the article and the absorbent article is not able to sustain a good fit on the wearer such that gaps are created allowing the exudates to leak out of the absorbent article. For example, urine tends to be deposited onto the topsheet more rapidly than it can be absorbed and, therefore, the urine migrates to the gaps in the absorbent article where it can come in contact with clothing or other articles and can be absorbed by these articles. Additionally, loose fecal material that is not easily absorbed by the absorbent article tends to "float" on the liquid-receiving surface and work its way past the gaps in the article in the legs or waist of the wearer.
Contemporary disposable diapers have a topsheet, a backsheet, an absorbent core, and elasticized leg flaps generally formed from an elastic member being enclosed in the continuous topsheet and backsheet which extend beyond the edges of the absorbent core. These elasticized leg flaps prove effective generally to prevent wicking and overflow from the fluid laden diaper to clothing contacting the edges of the diaper in that the elasticized leg flaps present a fluid impervious barrier between the edge of the diaper and the contacting clothing, and in addition, provide a gasketing action about the legs of the wearer to maintain a seal about the leg and minimize gapping. However, leakage along the perimeter of the diaper may still occur. As the diaper is worn for longer periods of time, forces tend to act on the diaper to degrade the initial fit on the wearer. Large gaps and sagging of the diaper in the legs and waist are formed by the degradation in fit.
Thus, as liquids are deposited onto the topsheet, some of the liquid is not immediately absorbed through the topsheet and migrates toward the edges of the diaper where it can leak through or past the gaps in the diaper and come in contact with clothing or undergarments where it can be absorbed by and wicked into such garments.
Disposable diapers may be provided with barrier cuffs which inhibit loose fecal material or gushes of urine or liquids from soiling the wearer's clothing.
The barrier cuffs restrain the free flow of this material and provide a structure to hold such material within the diaper so that as such material freely floats or flows on the topsheet of the diaper, it is contained within the diaper. Despite the effectiveness of such structures in containing such material, it has been found that liquids can leak beyond the barrier cuffs and soil the wearer's clothing because the diaper construction does not promote a sustained fit of the diaper on the wearer.
Additionally, the barrier cuffs may not be properly applied to the wearer such that good initial fit is not achieved and the sustained fit is often worse.

WO 96/14816 pL I"/US95/13802 F.~camples of some disposable diapers and absorbent articles described in the patent literature are:
U.S. Patent No. Re 26,151 which reissued Jan. 31, 1967 (originally U.S.
Patent No. 3,180,335, dated Apr. 27, 1965) to Robert C. Duncan discloses a disposable diaper having inwardly folded side flaps and means to fasten the ends of the inwardly folded edges of the side flaps in position over the face of the absorbent pad of the diaper.
U.S. Patent No. 3,860,003 which issuod to Kenneth Barclay Buell on Jan.
24, 1985 discloses contractible side portions for disposable diapers. Such diapers have outwardly extending side flaps and elastic members forming seals about the leg.
U.S. Patent No. 4,490,148 which issued Dec. 25, 1984 to Bo Heckestrom discloses an incontinence brief or diaper that has inwardly folded side flaps that are fined at their ends co the backsheet, and which side flaps have elasticized- frx edges. 'The Bxkestrom patent follows the Duncan teaching that the side flaps are not secured in the ctocch area. Heckestrom positions the points of fasta~ing at the ends of the side flaps behind the waistband edges of the absorbent core, and faua~s them to underlying portions of the backsheu.
U.S. Patent No. 4,964,860 issued to Gipson et al. on Oaoba 23, 1990 dixloses a detachable two piece absorbent article having a disposable element having inflected side panel: (Fig. 2). The disposable element is temporarily sxtu~ed to a reble belt which holds the disposable assembly against the waist of the wnta.
U.S. Patent No. 5,087,265 issued to Bret A. Sims on Feb. 11, 1992 d~o~d ~ abaotbatt artick having an inflected barrier leg arff which provides improved waist containment and fit. While this absorbent artick has been effective, it is not economical to manufacwre. The barrier leg cuff is manufacdund independent of the absorbent core, baclcshxt and topsheet, and must be positioned and affixed to the topsheet as part of the manufacturing process.
Therefore, it is an object of an aspect of the present invention to provide an absorbent article which has the improved containment characteristics of the inflected barrier cuff described in the Sims patent and the two piece garment of Gipson et a!.
but which is more convenient and efficient to manufacture and use.
It is an additional object of an aspect of the present invention to provide an absorbent article having an inflected barrier cuff which acts as a restraint against the leakage of body exudates.
It is a still further object of an aspect of the present invention to provide an absorbent article that is easy to apply to the wearer and promotes better containment by being less sensitive to variations in the application of the diaper and providing improved sustained fit.
These and other objects of aspects 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.
SUMMARY OF THE INVENTION
The present invention provides absorbent articles such as disposable diapers, incontinence briefs, diaper holders, training pants, feminine hygiene garments, and the like, having inflected barrier cuffs that improve the fit and containment characteristics of the absorbent article which are more convenient and economical to manufacture and use than products currently on the market.
The absorbent article of the present invention preferably comprises a chassis having a front waist region; a rear waist region; a crotch region; a liquid pervious topsheet; a liquid impervious backaheet associated with the topsheet; an absorbent core positioned between the topsheet and the backiheet; and a pair of longitudinally extending side panels preferably formed from extensions of the topsheet, the backiheet, or both. The side panels each have a distal edge and a proximal edge, and extend longitudinaijy from the front waist region through the crotch region to the rear waist region. The side panels further comprise a spacing means disposed adjacent the distal edge of each side panel in the crotch region.
In accordance with one embodiment, a disposable absorbent article is provided having a front waist region, a rear waist region, a crotch region between the front waist region and the rear waist region, a pair of longitudinal edges, a lateral centerline and a longitudinal centerline, the absorbent article comprising:

4a a chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with the topsheet; an absorbent core interposed between the topsheet and the backsheet, the absorbent core having a pair of opposed side edges, a pair of longitudinally extending side panels, each of the side panels including a front ear flap section located in the front waist region; a barrier cuff section having a first end edge located longitudinally inboard of the front ear flap section; a second end edge located in the rear waist region; a proximal edge disposed adjacent one of the side edges of the absorbent core and a distal edge spaced apart from the proximal edge;
spacing means joined along the distal edge of each the barrier cuff section; and closing means for securing at least a portion of the barrier cuff section juxtaposed the first end edge to the absorbent article inboard of the proximal edge;
the distal edges being unsecured to any underlying structure of the absorbent article in the front waist region and the rear waist region such that the distal edges form the longitudinal edges in the front waist region and the rear waist region; and the distal edge of the barrier cuff section being secured laterally inboard of the proximal edge in the crotch region such that the second end edges of the side panels located in the rear waist region are inverted relative to the first end edges to form an inflected barrier cuff that stands up in the crotch region when the absorbent article is fitted to a wearer.
In accordance with a further embodiment, a disposable absorbent article is provided having a front waist region, a rear waist region, a crotch region between the front waist region and the rear waist region, a pair of longitudinal edges, a lateral centerline and a longitudinal centerline, the absorbent article comprising:
a chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with the topsheet; an absorbent core interposed between the topsheet and the backsheet, the absorbent core having a pair of opposed side edges, a pair of longitudinally extending side panels, each of the side panels including a front ear flap section located in the front waist region; a barrier cuff section having a first end edge located longitudinally inboard of the front ear flap 4b section; a second end edge located in the rear waist region; a proximal edge disposed adjacent one of the side edges of the absorbent core and a distal edge spaced apart from the proximal edge;
spacing means joined along the distal edge of each the barrier cuff section; and closing means for securing at least a portion of the barrier cuff section juxtaposed the first end edge to the absorbent article inboard of the proximal edge;
the front ear flap sections being separably joined to the barrier cuff sections, wherein the distal edges of the ear flap sections may be separated from the barrier cuff section when the absorbent article is fitted to a wearer such that the distal edges of the front ear flap sections form the longitudinal edges in the front waist region;
the distal edges being unsecured to any underlying structure of the absorbent article in the rear waist region such that the distal edges form the longitudinal edges in the rear waist region; and the distal edge of the barrier cuff section being secured laterally inboard of the proximal edge in the crotch region such that the second end edges of the side panels located in the rear waist region are inverted relative to the first end edges to form an inflected barrier cuff that stands up in the crotch region when the absorbent article is fitted to the wearer.
In accordance with a further embodiment, a method for manufacturing an absorbent article having inflected barrier cuffs comprises the steps of:
providing a generally rectangular chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with the topsheet; an absorbent core interposed between the topsheet and the backsheet, the absorbent core having a pair of opposed side edges, the chassis having a front waist region;
a rear waist region; a crotch region located between the front waist region and the rear waist region; a longitudinal centerline; a lateral centerline; and a pair of laterally opposed side panels extending longitudinally from the front waist region to the rear waist region, the side panels each having a proximal edge disposed adjacent one of the side edges of the absorbent core, a distal edge spaced apart from the proximal edge and a second end edge located in the rear waist region;

4c separating the side panels between the front waist region and the crotch region, the separation forming a side panel first end edge in the crotch region;
folding the distal edge juxtaposed the first end edge inwardly over the chassis; and securing a portion of the first end edge to the chassis in the crotch region to invert the first end edge relative to the distal edge in the rear waist region to provide an inflected barrier cuff that will stand up in the crotch region when the absorbent article is fitted to a wearer.
In accordance with a further embodiment, a method for manufacturing an absorbent article having inflected barrier cuffs comprises the steps of:
providing a generally rectangular chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with the topsheet; an absorbent core interposed between the topsheet and the backsheet, the absorbent core having a pair of opposed side edges, the chassis having a front waist region;
a rear waist region; a crotch region located between the front waist region and the rear waist region; a longitudinal centerline; a lateral centerline; and a pair of laterally opposed side panels extending longitudinally from the front waist region to the rear waist region, the side panels each having a proximal edge disposed adjacent one of the side edges of the absorbent core, a distal edge spaced apart from the proximal edge and a second end edge located in the crotch rear waist region;
separating the side panels between the front waist region and the crotch region, the separation forming a side panel first end edge in the crotch region;
folding the distal edge juxtaposed the first end edge inwardly over the chassis; and securing only a portion of the first end edge to the chassis in the crotch region to invert the first end edge relative to the distal edge in the rear waist region to provide an inflected barrier cuff that will stand up in the crotch region when the absorbent article is tilted to a wearer.
In one preferred embodiment, the side panels are folded inwardly and bonded.to the topsheet in the crotch region, while the side panels are outwardly folded in at least the rear waist region. Thus, when fitted to the wearer, the side panels become inflected along their length. This transitions the side panels from their snug, gasketing fit about the buttocks of the wearer to their stand-up configuration in the "no motion zones" of the crotch region. The resulting "inflected barrier cuff" positioned in the no motion zones of the crotch region of the wearer provides improved fit and containment characteristics throughout the time of use. The side panels can also be extended laterally outwardly in the front waist region to form front ear flaps that provide for better containment and a wider range of wearer sizes.
BRIEF DESCR_IP'1_'ION OF THE DRAWINGS
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 invention will be better understood from the following descriptions which are taken in conjunction with the accompanying drawings in which like designations are used to designate substantially identical elements, and in which:
Figure 1 is a perspective view of a disposable diaper embodiment of the present invention having portions cut away to reveal underlying structure, the body-facing surface of the diaper facing the viewer;
Figure 2 is a fragmentary sectional view taken along section line 2-2 of Figure 1;
Figure 3 is a fragmentary sectional view taken along section line 3-3 of Figure 1;
Figure 4 is a fragmentary sectional view of an absorbent article in accordance with an alternative embodiment of the invention;
Figure Sa is a fragmentary sectional view of an alternative embodiment of the invention;

WO 96!14815 PCT/US95/13802 Figure Sb is a fragmentary sectional view of another alternative embodiment of the invention;
Figure 6 is a fragmentary sectional view of another alternative embodiment of the invention;
Figure 7 is a perspective view illustrating another absorbent article in accordance with the present invention in which the side panels are inflected in the crotch region of the garment, the body-facing surface of the diaper facing the viewer;
Figure 8 is a perspective view of another disposable diaper embodiment of the present invention having ear flaps in the rear waist region, the body-facing surface of the diaper facing the viewer;
Figure 9 is a perspective view of the garment of Figure 1 with the side panels folded inward for packaging;
Figure l0a is a perspective view of an alternative embodiment of the present invention having a belt;
Figure lOb is a perspective view of an alternative embodiment of the present invention having a reusable belt;
Figure 11 is a perspective view of an alternative embodiment of the present invention having an attachment system in the front and rear waist regions, the garment-facing surface of the diaper facing the viewer;
Figure 12a is a perspective view of an alternative embodiment of the present invention wherein the side panles are separated between the front waist region and the crotch region, the body-facing side of the diaper faces the viewer; and Figure 12b is a perspective view of an altenadve embodiment of the diaper shown in Figure 12a wherein the separation in the side panels between the front waist region and the rear waist region is curvilinear, the body-facing side of the diaper faces the viewer.

DETAILED DESCRIPTION OF TH INVENTION
As used herein, the term "absorbent article" refers to articles which absorb and contain body exudates and more specifically refers to articles which are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. Absorbent articles are typically differentiated by whether they are reusable or disposable. "Disposable" refers to articles which are intended to be discarded after a single use (i.e., they are not intended to be laundered or otherwise restored or reused). The absorbent articles of the present invention are preferably disposable absorbent articles. The absorbent articles may be further defined by whether they are "unitary" such that they do not require separate manipulative parts or whether they comprise an element of a diaper system such as a separate holder and liner. The absorbent articles of the present invention are preferably unitary. A preferred embodiment of a unitary disposable absorbent article of the present invention, diaper 20, is shown in Figure 1. As used herein, the term "diaper" refers to a garment generally worn by infants and incontinent persons about the lower torso of the wearer. It should be understood, however, that the present invention is also applicable to other disposable absorbent articles such as incontinence briefs, undergarment absorbent inserts, disposable training pants, belted diapers, diaper holders, sanitary napkins, and the like.
Figure 1 is a plan view of one preferred embodiment of diaper 20 of the present invention in its flat-out, uncontractEd state (i.e., with all elastic induced contraction pulled out) with portions of the structure being cut-away to more clearly show the construction of the diaper 20 and with the portion of the diaper 20 which contacts the wearer facing the viewer. The diaper 20 is shown in Figure 1 to have a body-facing surface 40 (facing the viewer in Figure 1), a garment-facing surface 41 opposed to the body-facing surface 40, a front waist region 22, a rear waist region 24, a crotch region 26, and a periphery which is defined by the outer edges of the diaper 20 in which the longitudinal edges are designated 30 and the arid edges are designated 32. The waist regions generally comprise those portions of the diaper 20 which, when worn, encircle the waist of the wearer.
The waist regions may include an elastic element such that they gather about the waist of the wearer. . The crotch region 26 is that portion of the diaper 20 positioned between the front waist region 22 and the rear waist region 24, and comprises that portion which, when worn, is positioned between the legs of the wearer and covers the lower torso of the wearer. The diaper 20 also has a lateral centerline which is designated 34 and a longitudinal centerline which is designated 36.
The diaper 20 comprises a liquid pervious topsheet 38; a liquid impervious backsheet 42 having an inner surface 23 (shown in Figures 2-4) and an outer surface 28 opposed to the inner surface 23; an absorbent core 44 having side edges that are designated side edges 50 and waist edges 52; side panels 62 each having a proximal edge 64, a distal edge 66, a first end 72, and a second end 74;
spacing means 76 such as elastic members 77 for spacing the distal edge 66 away from the body-facing surface 40; and closing means 78 for securing at least a portion of the side panel 62 inboard of the proximal edge 64 in the front waist region 22.
In a preferred embodiment of the diaper 20 in which the backsheet 42 has length and width dimensions generally larger than those of the absorbent core 44, the backsheet 42 extends beyond the edges of the absorbent core 44 to thereby form the periphery of the diaper 20 and the side panels 62. The periphery defines the outer perimeter or, in other words, the edges of the diaper 20. The periphery comprises the longitudinal edges 30 and the end edges 32. As shown in Figures and 2, the topsheet 38 may be coterminous with the backsheet 42 along the end edges 32 as well as the longitudinal edges 30 of the diaper 20.
Preferably, the proximal edge 64 of the side panel 62 defines the longitudinal edge 30 of the diaper 20 in the front waist region 22, and preferably comprises an extension of the topsheet 38 or the backsheet 42, or both. The distal edge 66 of each side panel 62 defines the longitudinal edge 30 of the diaper 20 in the rear waist region 24. The distal edge 66 is preferably not secured to any underlying elements of the diaper 20 in the crotch region 26 or the rear waist region 24. However, the distal edge 66 is preferably secured to the underlying structure (topsheet 38) of the diaper 20 laterally inboard of the proximal edge 64 in the front waist region 22 by the closing means 78, which preferably comprises an adhesive. (As used herein, the term "laterally inboard" is defined as the direction toward the longitudinal centerline 36 of the diaper 20.) Therefore, the distal edge 66 , is closed in the front waist region 22 (i.e., it is not open nor capable of being saway from the body-facing surface 40).
Figure 2 is a fragmentary sectional view taken along line 2-2 of Figure 1 and depicts one preferred construction of the side panel 62 showing the topsheet 38, the backsheet 42, the absorbent core 44, and the elastic members 77. The absorbent core 44 is disposed between the topsheet 38 and the backsheet 42;
the topsheet 38 and the backsheet 42 extending beyond the side edge 50 of the absorbent core 44 to form the side panel 62. In the embodiment shown, the topsheet 38 is secured to the backsheet 42 along the distal edge 66 by a bead of adhesive 35. Preferably, a layer of adhesive 37 is used to secure the absorbent core 44 to the backsheet as described later. The spacing means 76, such as a plurality of elastic members 77, is joined adjacent the distal edge 66 of each side panel 62. Preferably, an elastic attachment means 86 joins the elastic members to the diaper 20. The distal edge 66 is thus spaced away from the body-facing surface 40 of the topsheet 38 by the elastic gathering action of the elastic members 77; a channel 88 being thereby formed between the proximal edge 64 and the distal edge 66.
Figure 3 is a fragmentary sectional view taken along line 3-3 of Figure 1 and depicts one preferred construction of the side panels 62 in the front waist region 22. The topsheet 38 and the backsheet 42 extend beyond the side edge 50 of the absorbent core 44 to form the side panels 62. As shown in Fig. 3, the topsheet 38 is folded upon itself and secured by the first closing means 78.
In the embodiment shown, the outer surface 28 of the backsheet 42 is adjacent the skin of the wearer when the garment is donned. Therefore, it is desirable to adopt designs in which the outer surface 28 is formed from or is covered with cloth or a cloth-like substitute such that a skin-friendly surface is provided against the wearer's skin.
- The absorbent core 44 may be any absorbent material which is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids and certain body exudates. The absorbent core may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, WO 96/1~815 PC'T/US95/13802 hourglass, asymmetric, etc.) and from a wide variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles, such as comminuted wood pulp which is generally referred to as airfelt. Examples of other suitable absorbent materials include creped cellulose wadding, absorbent foams, absorbent sponges, superabsorbent polymers, absorbent gelling materials, or any equivalent materials or combination of materials. The total absorbau capacity of the absorbent core 44 should, however, be compatible with the design exudate loading and the intended ux of the diaper 20. Further, the absorbent capacity and configuration of the absorbent core 44 may be . varied to accommodate wearers ranging from infants through adults (e.g., the absorbent core may have a varying caliper, or a hydrophilic gradient, a capillary differential, low density cones, or may or may not contain absorbent gelling materials).
The absorbatt core 44 may comprix a layer of absorbent material comprising hydrophilic fiber and particles of absorbent gelling material (hydrogel) such as the absorbent structure described in U.S. Patent 4,610,678 entitled "High-Density Absorbent Structure" which issued to Paul T. Wiseman and Steven A. Goldman on September 9, 1986 Preferred embodiments of the absorbent core 44 are ga~errlly described ~in U.S. Fata~t No. 5,234,423 entitled "Absorbent Article With Flasbc Waist Feature and Enhanced Absorbency", issued to Alemany et al.
on August 10, 1993; and U.S. Patent No. 5,217,445 entitled "Absorbent Structures Containing Superabsorba~t Material and Web of Wetlaid Stiffened Fibers" issued to Young a al. on June 8, 1993 Other exemplary absorbent cores useful in the present invention are daaibed in U.S. Patent No. 5,124,188 entitled 'Porous, Absorbent, Polymeric Macrostructures and Methods of Making the Same", issued to Roe et al., on June 23, 1992; U.S. Patent No. 5,137,537 entitled "Absorbent Structure Containing Individualized, Polyarboxylic Acid Crosslinked Wood Pulp Cellulox Fibers", issued to Herioo a al., on August 11, 1992; U.S. Patent No. 5,180,622 entitled "Absorbalt Members Containing Intaparticle Crosslinloed Aggregates", issued to Berg, a al., on January 19, 1993; U.S. Patent 5,260,345 entitled "Absorbent Foam Materials for Aqueous Hody Fluids and Absorbent Articles Containing Such Materials" issued to DesMalais a al., on November 9, 1993; U.S. Patent wo 9masis pcr~s9sn3soi tt 4,673,402 entitled "Absorbent Article With Dual-Layered Cores" which issued to Paul T. Weisman, Dawn I. Houghton and Dale A. Gellert on June 16; and PCT
Publication No. WO 92/11830, published on July 23, 1992, entitled "Absorbent Article Having Rapid Acquiring, Multiple Layer Absorbent Core".
The backsheet 42 is positioned adjacent the absorbent core 44 adjacent the surface that faces away from the wearer and is preferably sxured thereto by core attachment means 37 such as those well known in the art. For example, the backshezt 42 may be secured to the absorbent care 44 by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines or spots of adhesive. A adhesives which has been found to be satisfactory is manufactured by H.B. Fuller Company of St. Paul Mine. and marketed as HL-1258. The core attachment means preferably comprise an open pattern network of filaments of adhesive as is shown in U.S. Patent 4,573,986 entitled "Disposable Waste-Containment Garment" which issued to J. A. Minetola and David R.
Tucloer on. March 4, 1986. . An exemplary attachment means of an 'open pattern network of filaments comprises several lines of adhesive filaments swirled into a pattern such as is illustrated by the apparatus and methods shown in U.S. Patent No. 3,911,173 issued to Sprague, Jr. on Oa. 7, 1975; U.S. Patent No. 4,785,996 issued to Zixkler, et al. on Nov. 22, 1978; and U.S. Patent No. 4,842,666 issued to Werenicz on June 27, 1989.
Altavatively, the attachment means may comprise heat bonds, pressure bonds, ulhasonic bonds, dynamic mxhanical bonds, or any other suitable attachment means of combinations of these attachment means as are Imowrt in the art.
The b42 is impervious to liquids and is preferably manufactured from a thin plastic film, although other flexible liquid impervious materials may also be used. The backsheet 42 prevents the ea~udates absorbed and contained in the absorbatt come 44 from weuing articles which contact the diaper 20 such as bedsheets and unde.rgarmatts. Further, the backshaet 42 may permit vapor ~
esmp~e from the absorbatt core 44 while still preventing exudates from passing through the backsheet 42. The backsheet 42 may thus comprise a woven or nonwovert material, polymeric films such as thermoplastic films of, for example, polyethylene or polypropylene, or composite materials such as film-coatad nonwoven materials. Alternatively, the backsheet 42 may comprise a laminate of a nonwoven layer and a polymeric film, including embodiments wherein the nonwoven layer extends beyond the dimensions of the polymeric film. An exemplary backsheet 42 is a polyethylene film having a thiclmess of from about 0.012 mm (0.5 mil) to about 0.051 cm (2.0 mils). As used herein, the term "flexible" refers to materials which are compliant and which will readily conform to the general shape and contours of the human body. A suitable polyethylene film is manufactured by ?redegar Film Products, Inc. of Terre Haute, IN, and is marketod in the trade as Tredegai X8526. The backsheet 42 is preferably embossed and/or matte finished to pmvide a more cloth like appearance.
The topsheet 38 is compliant, soft feeling, and non-irritating to the wearer's skin. Further, the topshea 38 is liquid pervious permitting liquids to readily parettatc through its thickness. A suitable topsheet may be manufactured from a wide range of materials, such as porous foams, reticulated foams, formed films, apatured plastic films, natural fiber (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers) or from a combination of natural and synthetic fibers. Them are a number of manufacturing techniques which may be used to manufacture the topshett 38. For example, the topsheet 38 may be woven, non-woven, spunbonded; carded, or the like. One preferred topsheet 38 comprises staple length polypropylene fibers having a denier of about 2.2, such as P-8, manufactured by Veratec, Inc., a Division of the International Paper Company, of Walpole, Massachusetts. As used herein, the term "staple length fibers" refer to thox fiber having a length of at least about 15.9 mm (0.625 inches). A preferred topshea 38 is carded, and thermally bonded by means weU
known to those skilled in the fabrics art.
In a prefazed anbodiment, the tapshea 38 is .made of a hydrophobic manorial to isolate the watra's skin from liquids in the absorbent core 44. If the tapsirea 38 is made of a hydrophobic material, at least the upper surface of the topahea 38 is treated to be hydrophilic so that liquids will transfer through the topShea 38 more rapidly. This diminishes the likelihood that body exudates v~iill flow off the topshaei 38 rather than being drawn through the topsheet 38 and being absorbed by the absorbent core 44. The topsheet 38 can be rendered *Trade-mark hydrophilic by treating it with a surfactant including spraying the topsheet material with a surfactant or immersing the material into the surfactant. A
more detailed discussion of such a treatment is contained in U.S. Patents 4,988,344 entitled "Absor~ba~t Articles with Multiple layer Absorbent Layers" issued to Reining et al., on January 29, 1991, and U.S. Patent 4,988,345 entitled "Absorbent Articles with Rapid Acquiring Absorbent Cons" issued to Reining on January 29, 1991 .
The topsheet 38 and the backsheet 42 may be joined together in any suitable manner as in well lmown in the diaper manufacturing art. As used herein, the term "joined" encompasses configurations whereby the topsheet 38 is directly joined to the backsheet 42 by affixing the topnheet 38 directly to the backsheet 42, and configurations whereby the topsheet 38 is indirectly joined to the backsheet 42 by affixing the topSheet 38 to intermediate members which in turn are affixed to the backsheet 42. In a preferred embodiment, the topsheet 38 and the backsheet 42 are joined directly to each other in the diaper periphery by attachment means 35 such as an adhesive or any other attachment means as is known in the art.
Suitable attachment means are discussed previously with regard to the backsheet 42.
The diaper 20 further comprises a pair of side panels 62 that provide a strucwre to restrain the free flow of body exudates along the body-facing surface 40 of the diaper 20, and to hold and contain such acudates within the diaper 20.
In a preferned embodiment, the side panels 62 are liquid impermeable. Thus, in the front waist region Z2, whore the side panels 62 are folded over the body_ facing surface 48 of the absorbait core 44, the side panels 62 prevent liquid deposited on the topshea 38 from migrating beyond the absorbent core 44. This helper assure that any liquids not immediately absorbed by the absorbent core will be abs~bed before they migrate to areas from which the liquids can leak out of the diaper 20. In the crotch region 26, the side panels 62 stand-up in the "no motion' xona of the warn and provide a liquid impermeable barrier cuff that conforms to the wearer's body providing containment of body exudates well beyond when the diaper 20 has been loaded. In the rear waist region 24, the side panels 62 provide a gasketing action about the buttocks of the wearer that helps prerrent gapping that can lead to leaks.

Each side panel 62 is a flexible member having a proximal edge 64 and a distal edge 66., The distal edge 66 of the side panel 62 is that part of the side panel 62 that is spaced laterally outwardly from the absorbent core 44 when the side panel 62 is in a flat-out state (before the side panel 62 is folded and joined to the topsheet 38 in the front waist region 22). The distal edge 66 of each side panel 62 is preferably not secured to any underlying elements of the diaper 20 in at least the rear waist region 24, preferably in both the rear waist region 24 and the crotch region 26. The distal edge 66 is preferably spaced away from the body-facing surface 40 in the crotch region 26 so that the side panel 62 may form a channel 88 (as shown in Fig. Z) to enhance the containment of the diaper 20.
As used herein, "spaced" includes embodiments wherein the distal edges 66 may assume one or more positions relative to the body-facing surface 40 including at some times assuming a position adjacent the body-facing surface 40. In a preferred embodiment, as shown in Figure 1, the distal edge 66 of each side panel 62 is disposed laterally inboard of the proximal edge 64 in the front waist region 22 so as to present a more effective barrier against the flow of exudates. The distal edges 66 are maintained inboard of the proximal edges 64 in the front waist region 22 by the first closing means 78 so as to obviate their inversion.
The proximal edge 64 is that portion of the side panel 62 that is disposed adjacent the side edges 50 of the absorbent core 44. (When the side panels 62 are in a flat-out configuration, the proximal edge 64 is spaced laterally inboard from the distal edge 66.) The distal edge 66 is spaced apart from the proximal edge and their spatial relationship to each other defines the effective width of each of the side panels 62. The proximal edges 64 and the distal edges 66 may be in a parallel, nonparallel, rectilinear or curvilinear relationship. In addition, each of the side panels 62 may have a variety of different cross-sectional areas including circular, square, rectangular or any other shape. Preferably, the proximal edge 64 is spaced from the distal edge 66 in a parallel and rectilinear relationship.
The effective width of the side panel 62 is an important parameter in reducing leakage of body exudates out of the diaper 20. If the effective width of the side panel is too small, then gaps will be formed between the leg of the wearer and the distal edge 66 such that liquids may flow over the distal edge 66 to the periphery of the diaper 20.

As shown in Figure 1, the distal edges 66 are preferably laterally spaced apart from each other in the front waist region 22. However, the lateral spacing between the distal edges 66 can range from being crossed over each other to abutting each other to being laterally spaced apart up to the width of the proximal edges in the front waist region 22. Thus, in a preferred embodiment as shown in Figure 1, the distal edges 66 may be laterally spaced apart from about -25 mm (-1 inch) (overlapping edges) up to about 150 mm (6 inches). Preferably, the distal edges 66 are spaced apart so that the side panel will fit in the innermost leg crease of the wearer rather than ride along the wearer's outer thigh.
The distal edges 66 are also shown in Figure 1 to be disposed parallel to each other and perpendicular to the end edge 32 of the diaper 20 in the front waist region 22. While this is a preferred embodiment, the distal edges 66 may alternatively be angled toward or away from each other, preferably toward each other, such that the distal edges 66 are disposed non-perpendicular to the end edges 32. Angling the side panels 62 relative to the end edge 32 may assist in allowing the side panel 62 to remain spaced from the body-facing surface 40 in the crotch region 26 during use.
The distal edges 66 are preferably laterally spaced apart from each other in the crotch region 26. The lateral spacing of the distal edges 66 is especially important in the crotch region 26 to prevent body exudates, especially urine, from leaking out of the diaper 20 in the leg regions of the wearer. If the distal edges 66 are laterally spaced too far from each other, then the side panels 62 have an increased tendency to "flip out" in the crotch region 26 such that urine can flow over the side panels 62. If the distal edges 66 are spaced too close to each other, then the side panels 62 provide a reduced area for deposition of exudates such that exudates could be deposited directly onto the side panels 62 and flow to the edges of the diaper 20.
The distal edge 66 of each side panel 62 is preferably disposed laterally outboard of each proximal edge 64 in the rear waist region 24 of the diaper 20 when the diaper 20 is in a flat-out uncontracted condition. The term "outboard" is defined as the direction away from the longitudinal centerline 36 of the diaper 20.
(i.e., the direction opposite from the direction defined by the term "inboard.
") Thus, the side panel 62 extends laterally outwardly in the rear waist region when the diaper 20 is in a flat-out uncontracted condition. The laterally extending portion of the side panel 62 promotes better containment that is less sensitive to application variations and provides a sustained contoured fit about the buttocks of the wearer.
Because the distal edge 66 is disposed inboard of the proximal edge 64 in the front waist region 22 and outboard of the proximal edge 64 in the rear waist region 24, the distal edge 66 becomes "inflected" along its length when the diaper 20 is fitted to a wearer. This inflection transitions the side panels 62 from snugly fitting about the buttocks (the laterally outwardly extending portion) to standing up in the "no motion" zone of the crotch region 26 for better containment. The resultant "inflected barrier cuff" is easier to apply to the wearer and ensures that the fit of the side panel 62 is in the "no motion" zone in the crotch region 26 with a snug fit about the wearer's buttocks in at least the rear waist region 24.
It has been found that the inflected barrier cuff thus provides both a gasketing action about the buttocks of the wearer to provide a sustained snug fit which reduces leakage of body exudates, especially runny BM, and a stand-up barrier cuff in the crotch region 26 and the front waist region 22 to constrain, contain and hold body exudates within the diaper along the channel 88.
However, it has been found that if the side panel 62 is "flipped out" too far toward the front waist region 22 along the length of the side panel 62, then body exudates will tend to flow over the side panels 62. Thus, it is preferred that the inflected barrier cuffs, in use, provide a gasketing action about the buttocks of the wearer to provide a snug fit (i.e., the flipped out portion of the barrier cuffs is positioned) in less than about 509 of the length of the diaper, more preferably less than about 4096 of the length of the diaper 20, and most preferably only in the rear waist region 24. (The percent length of the flipped out portion is defined as that length of the diaper in which the side panel is flipped out divided by the total length of the diaper times 1009b.) Thus, the stand-up portion of the side panel (distal edge 66 disposed inboard of the proximal edge 64) is provided, in use, in at least about 50 % of the length of the diaper, preferably at least about 60 ~ of the length of the diaper, and most preferably from the front waist region 22 to and throughout the crotch region 26.

The flipped out portion of the side panel 62 can be maintained in less than about 50~ of the length of the diaper 20 in a number of different ways. For example, the closure means 78 can extended in the longitudinal direction, thus ensuring that the flipped out portion is maintained in less than about 50 y of the length of the diaper 20. Alternatively, as shown in Figure 7, a crotch attachment means 100 may be disposed in the crotch region 26 of the diaper 20 for securing the distal edge 66 inboard of the proximal edge 64.
The crotch attachment means 100 can comprise any attachment means as is known in the art, including those described below with respect to the closure means 78 that maintains the distal edges 66 inboard of the longitudinal edges 30 in the front waist region 22. Further, the bond provided by crotch attachment means 100 may be breakable such that the user may release all or a portion of the distal edge 66 in the crotch region 26 to obtain the desired fit.
The closing means 78 for securing the first end 72 of the side panels 62 closed is shown in Figure 1. The closing means 78 provides a more comfortable fit for the wearer and secure the distal edges 66 of the side panels 62 in the proper position to form an inflected barrier cuff. In a preferred embodiment as shown in Figure 1, the closing means 78 is disposed in the front waist region 22. The remaining portions of the distal edges 66 are preferably not secured to any underlying structure of the diaper 20 so that the distal edges 66 are left freely openable. In a preferred embodiment, the length of the closure means 78 is from about 25 mm (about 1 inch) to about 100 mm (about 4 inches), more preferably between about 35 mm (about I.5 inches) and about 75 mm (about 3 inches). lfiis construction is preferred so as to create a snug fit about the buttocks of the wearer to especially prevent leakage of loose fecal material.
While each of the closing means 78 may comprise any of several securement means as are known in the art such as ultrasonic bonds or heat/pressure bonds or seals using a variety of bonding patterns, or adhesives and/or glues, the closing means are preferably adhesive beads consisting of adhesive such as manufactured by H.B. Fuller Company of St. Paul Minn. and marketed as HL-1258.
As shown in Figure 1, the spacing means 76 preferably comprise elastic WO 96114815 PCZ'NS95/13802 members 77 that are operatively associated with each of the side panels 62 adjacent the distal edge 66. The elastic members 77 are preferably secured to the side panels 62 in as elastically contractible condition so that in a normally unrestrained configuration, the elastic members 77 effatively contract or gather the distal edge 66 of the side panels 62. The elastic members 77 can be sxured to the side panels 62 in an elastically contractible condition in at least two ways as is discussed in U.S. Patent 3,860,003 entitled 'Contractible Side Portion For Disposable Diaper', which issued to Kenneth B. Buell on January 26, 1974 , In addition, the length of the elastic member ?7 in general is dictated by the diaper design. In the embodiment illustrated in Figure 1, the elastic member 77 extends along essentially the entire length of the side panels 62 in the crotch region 26, although other lengths are cogninble. The elastic member: 77 are preferably not disposed in the front waist region 22. 'The lack of gathering of the distal edge 66 adjacent the end edge helps reduce the forces which tend to puU the diaper 20 downward, resulting in sagging and gapping of the diaper 20 in the waist regions.
As shown in Figure 2, the elastic member 77 is operatively associated with the side panels 62 by securing it to or within the side panels 62 with an elastic attachment means 86. The elastic attachment means 86 should be flexible and of suffiaalt adtlesivaKSa to hold the elastic member 77 in its stretched condition.
While the elastic members ?7 may be secured to the side panels 62 adjacent only the ends of the elastic member 77, it is preferable to secure the entire length of the elastic member 77 to the side panels 62. (In one preferred embodiment of the present invaltion, wherein the absorbent article comprises ear flaps 54 (as shown in Fig. 8), the elastic members 77 may be joined to the ear flaps 54 in the rnr waist region 24.) The elastic attachment means 86 herein are preferably glue beds made of bot melt adhesive such as marketed by Findley Adhesives IrtoorporaiDed, Elmgrove, Wisconsin, as F'Indley Adhesives 581, although the elastic member: 77 may be affixed to the side panels 62 in any of several other ways which are well Ialown in the art. For example, the elastic members 77 may be ultr~onically bondad or heatlprawre seals! into the side panels 62 using a variety of bonding patterns, or the elastic members 77 may simply be glued to the side panels 62. A more detailed description of the manner in which the elastic members ?7 may be positioned and sxured to the side panels 62 can be found in WO 96/14815 pCT/US95I13802 U.S. latent 4,081,301, entitled "Method and Apparatus for Continuously Attaching Dixrete, Stretched Elastic Strands to Predetermined Isolated Portions of Disposable Absorbent Products" which issued to Kenneth B. BueU on March 28, 1978, and in U.S. Patent 4,253,461, entitled "Absorbent Brief" issued to Danny L. Strickland and Ronald B.Visxher on March 3, 1981, It should be noted that one or more (a plurality of) elastic members 77 can be used to elasdcize each side panel 62.
Preferably, three elastic members 77 are used to elasticize each side panel 62.
An elastic member 77 which has bxn found suitable is an elastic strand having a cross section of 0.18 mm by 1.5 mm and made from natural rubber as available from Easd>ampton Rubber Company of Stewart, Virginia, under the aademark L-1900 Rubber Compound. Other suitable elastic members 77 can be made from natural rubber, such as elastic tape sold under the trademark Fultlex 9411 by Fulflex Company of Middletown, Rhode Island. The elastic member 77 may also comprise any heat shr;nkable material as is well lrnown in the art.
Other suitable elastic materials may comprise a wide variety of materials as are well known in the art include elastomeric films, polyurethane films, Lycra, elastomeric adhesives, elastomaic foams and formed elastic scrim. In addition, the elastic members 77 may take a multitude of configurations. For example, the width of the elastic members 77 may be varied; the elastic members may comprise a single strand or several parallel or non-parallel strands of elastic material; or the elastic members 77 may be rectilinear or curvilinear.
T1m spacing means 76 may alternatively comprise several other elements.
For example, the side panels 62 may have stiffening means disposed in or on each side pond 62. The stiffening mans must be sufficiently stiff so that the distal °dge 66 i::pooed away from the body-facing surface 40. Suitable materials for the stiffening means include foams, nonwovea fabrics, batting, polyethylene film, formed films, spray glues, foamed elastomerics, polyester, polyurethane, or high loft material.
The spacing means 76 may also comprise means for shortening the length of the distal edge 66 in comparison to the length of the edge of the diaper 20.
The distal edge 66 can be shorta>ed by making a fold or pleat in the distal edge 66.

This fold or pleat is secured by any of the holding means well known to those of ordinary skill in the art, such as adhesives, or heat sealing. Alternatively, a section may be cut out of the distal edge 66 and the resultant edges brought together to form a butt or lap joint. The distal edge 66 may also be shortened by attaching a length of the distal edge 66 to the topsheet 38 at a position different from where the distal edge 66 would lie when the diaper 20 is in a flattened out condition. Other shortening means as are known in the art can also be used.
The manner in which the diaper 20 is applied to a wearer will vary depending on the embodiment that is being used. Thus, the preferred methods for using the different embodiments are described in more detail below. In each case, however, the distal edges 66 of the side panels 62 are pulled laterally outwardly such that the distal edges 66 are disposed outboard of the proximal edges 64 in the rear waist region 26. This provides a gasketing configuration about the buttocks of the wearer. The distal edges 66 of the side panels 62 remain inboard of the longitudinal edges 30 in the front waist region 22. Thus, the side panels 62 become inflected, forming barrier cuffs that stand-up in the wearer's "no motion"
zone in the crotch region 26.
Figure 4 is a fragmentary sectional view of an alternative embodiment of the present invention taken in the front waist region 22. In this embodiment, the topsheet 38 folds around the side edges 50 of the absorbent core 44.
Preferably, at least a portion of the topsheet 38 extends between the backsheet 42 and the garment-facing side 46 of the absorbent core 44. The topsheet 38 and the absorbent core 44 are preferably joined to the backsheet 42 using a layer of adhesive 37 or any other means as are known in the art. Further, as shown in Figure 4, the backsheet 42 includes a longitudinal hem 33 enclosing the elastic members 77. The hem 33 is preferably formed by wrapping a portion of the backsheet 42 around the elastic members 77 and securing the backsheet 42 to itself, inboard of the elastic members 77, with a bead of adhesive 35.
Preferably, the backsheet 42 is wrapped around the elastic members 77 such that the inner surface 23 of the backsheet 42 contacts the elastic members 77 and the adhesive bead 35. This configuration helps prevent any liquid that is deposited on the inner surface 23 of the backsheet 42 from migrating beyond the distal edges 66 of the side panels 62 in the rear waist region 24 and the crotch region 26. This embodiment is generally considered less desirable than other embodiments, however, because only one ply of material is present in the side panels 62.
Particularly, the side panels 62 come under substantial stress when the garment is worn. Depending on the nature of the backsheet 42, single ply side panels 62 may not be strong enough for active wearers.
Figure Sa illustrates another embodiment of the present invention. In this embodiment, the topsheet 38 comprises lateral extensions 21a which wrap around the backsheet 42 and are preferably secured to the outer surface 28 of the backsheet 42 with an adhesive bead 39 or other bonding means (e.g., pressure, heat, ultrasonics, etc.). This embodiment is particularly useful when the backsheet 42 is formed from a plastic film. Since most wearer's do not like the feel of plastic next to their skin, covering the backsheet 42 with the extension 21a of the topsheet 38, which is typically made from a nonwoven fabric, presents a fabric effect on the body-facing surface 40 of the inwardly folded side panels and provides the feel of cloth against the skin. (A particularly desirable material for use as the backsheet 42 is a polyfilm lined nonwoven, however, the backsheet 42 may comprise a woven or nonwoven material, polymeric films such as thermoplastic films or polyethylene or polypropylene, or composite materials such as film-coated nonwoven materials.) Another suitable construction of the side panels 62 provides the backsheet 42 comprising a laminate of a nonwoven and a polymeric film, wherein the nonwoven extends beyond the dimensions of the polymeric film to form the side panels 62.
Figure Sb is yet another alternative embodiment of the present invention wherein the topsheet 38 has lateral extensions 21b that comprise separate members joined to the topsheet 38. The lateral extensions 21b wrap around the backsheet 42 and are preferably secured to the outer surface 28 of the backsheet 42 with an adhesive bead 39 or other bonding means (e.g., pressure, heat, ultrasonics, etc.).
In a preferred embodiment, the lateral extensions 21b comprise nonwoven materials that are hydrophobic, and thus, prevent liquids deposited on the topsheet 38 from wicking beyond the liquid impervious backsheet 42 disposed in the side panels 62. The lateral extensions 21b may be joined to the topsheet 38 by any means that are well known in the art, including, but not limited to, adhesives and dynamical mechanical bonding as described in U.S. Patent 4,919,783 entitled 'Dynamic Mechanical Bonding Method and Apparatus' issued to Ball et al., on April 24, 1990~
Figure 6 illustrates another embodiment of the present invention wherein the baclcsheet 42 includes a portion 25 which is wrapped around the elastic members 77 forming a longitudinal hem 33. The hem 33 is preferably formed by wrapping a portion of the backsheet 42 around the elastic members 77 and securing the backsheet 42 to itself, inboard of the elastic members 77, with a bead of adhesive 35. Preferably, the backshea 42 is wrapped around the elastic members 77 such that the inner surface 23 of the backsheet 42 contacts the elastic members 77 and the adhesive bead 35. This configuration helps prevent any liquid that is deposited on the inner surface 23 of the backsheet 42 from migrating beyond the distal edges 66 of the side panels 62 in the rear waist region 24 and the crotch region 26. The topsheet 38 is preferably secured to the outer surface 28 of the portion 23 of the backsheet 42 that wraps around the elastic members 77 with an adhesive layer 39 or another suitable bonding means. In this configuration, the topsheet 38 will be presaitod against the sbn of the weartr in at least the rear waist region 24. , Figure 8 shows one aluernative embodiment of the present invention having ear flaps 54 extending laterally outwardly from the distal edges 66 of the side panels 62 in the rear waist region 24. The ear flaps 54 provide a structure which, along with the front waist region 22 and the rear waist region 24, encircle the waist of the wearer. Fach ear flap 54 has a proximal edge 51 and a distal edge 53. In a preferred embodiment, at least one ear flap 54 is joined to each of the side petrels GZ. The proximal edge 51 of the ear flap 54 is preferably joined to distal edge 66 of the side panel 62. The proximal edge S 1 of the ear flap 54 may be joined to gumatt facing surface 41 of the backsheet 42, or uo the body-facing surface 40 of the topshea 38, or betweat the topsheet 38 and the backsheet 42.
'The ear flaps may be joined to the side panels 62 by my means as are lrnown in the art; for example, the ear flaps 54 may be continuously or intermittently bonded to the side panels 62 using heated or unhntcd adhesive, heat bonding, pressure bonding, ultrasonic bonding, dynamic mechanical bonding or any other m~Od that is latown in the art.

The ear flaps 54 may take on a number of different sizes, shapes, configurations and materials. In a preferred embodiment, as shown in Fig. 9, the ears flaps may be generally rectangular in shape, having dimensions of between about 2 and 8 inches in the lateral direction and between about 2 and 8 inches in the longitudinal direction; the dimensions being measured while the ear flaps are in a relaxed or unextended condition. Further, the ear flaps 54 may comprise a single piece of material or two or more pixes of material operatively associatod to form each ear flap 54.
The ear flaps 54 are preferably joined to the distal edges 66 of the side panels 62 in the rear waist region 24 by attachment means (not shown) such as those well known in the art. A suitable means for attaching each ear flap 54 to the side panel 62 is fusion bonding (e.g. ultrasonic, heat or pressure bonding).
' Alternatively, the ear flaps 54 may be intermittently or continuously bondod to the side panels 62 using adhesive, dynamic mechanical bonding or any other method that is lanown in the art.
The ear flaps 54 are preferably extensible in at least the lateral direction, and may be formod form any suitable extensible, stretchable, or elastomeric material. (As used herein, the term "extensible" refers to materials that can increase in at least one dimension. The term "stretchable" refers to materials that are extensible when stretching forces are applied to the material, and offer some resistance to extatsion. The term "ela~tomeric" refers to materials that extend in at least one direction when a force is applied and return to approximately their original dimensions after the force is released.) One elastomeric material that has been found oo be especially suitable for use ilt the ear flaps 54 is a laminate of two oowasooclc layer with an elutomeric film sandwiched between the coverstock layers. As used herein, the term "coverstock" may include any woven or tlonwoval rtlataials. M example of a suitable coverstock material is the nonwoven material manufactured by Veratec, Inc., a Division of the International Paper Company, of Walpole, Mass., designated P-8. M example of a suitable film ~ be sandwiched betwoen coverstock layers is the elastomeric film, EXX-500, manufactured by the Exxon Chemical Company of Lake Zurich, B..
Stutable alternative rt~ataials for use as the ear flaps 54 include woven webs;
nalwoven webs; films, including polymeric films; foams; laminate materials, *Trade-mark Sep-30-88 15:51 From-SIM MCBURhEY 4165851163 T-468 P.02/03 F-654 W~ 9brlial~ Pi?1U595~138o=

including film tatninates, nonwaven laminates, or zero su-sin laminatzs;
elastomexs; el4svameric scrims; composites; st;uc:,ua1 elasac-like film wets:
or any combination of rt~rrnals as ate known in the art. U.S. laauent 5,151,09 entitled 'Absacbent wrticle wits Dynamic Elastic lNais: Feature Having s txrndisppsw Resiliau Flexural Hinge" issued to Burn a err., a~n September Z9, 1Q92, and U.S. Patent 5,16,897 entitled "Method For Incsxmentally stratchin8 a taro Sttain 5ttxtch Laminaee Web to Impatt Elassicity Thereto" issued to webcr a al., on DecEmbe: 1, 149 describe suitably ram scrdin laminates grad presznined scratch larnirtates~
The ear #~ps 54 preferably additian~Y carnpriae fas~nng elements 56 adjacent their 4ista! sd8es 53. While the faswtinS elements Sb may cca~p~sse any of s aumbex of fa~in~ ele~nr~ as are xnawa in the art such as mechanical lastatars, hc~k and loop type fas~s, preas~rrQ sensitive adhesives, ~d cohesive mamtials, in 4 preferred embodittumt of the present invention, the faurstins alemena S6 preferrbly remptisa tape tabs. 'the tape rob fasteners 56 as bE any of thax tape tabs well known in the ast, such as tt~e adhesive fasteairy 4pG tabs disclosed irt U.S. PW t 3,8:48,594 eatitlad "Tape FasteninS System For >5ispoastbtc Diaper" issue4 rn Rantteth 8. BudI on Navenabex ~9, 1974.
F~~ampleu of outer fin= ay:uxns, ir~ciadin~ mochaniral fasxttitt8 systems era disclosed in iLS. patent 4,$69.724 issued tn Sc:ipp: o~n Septembrr 28. 1989; U.S. Pa:a~t 4.846,813 issareid to $crippa on luly i I. 1989; and U.S. patent 3,242,436 issued to Well, Hump, Qexr and Falcant on September 7, 1993-The anhodimatt of the prearnt inveaaat compri#in8 oar Flaps 54 is p~taably fated to the wetlt~i ;rt failavva. Tile ear tlaf» 54 a~ initially vofaldod frvtn their folded floafi8ursaott for paela,8ia; (as shown in Fi=. 9) and pulled lst~ally auy ua cippaaiue dira~icns. Ths rw w~isx tee ~4 is poaiaw~d wrde~ the we~ts:r'x beck and the rettuinda of the disper is dawn ~w~t the waat~a's leis. The ftaltt v~ixt rr~ ~3 is then pasicianad across the fmnt of the wraazr's waist. The esr flaps S4 are tl~ wtar~aNnd the weara'a waist; the side panelx arc ~ioned avct attended so as to conform to the size an4 shaper of the wetlret. Tile est flaps 34 are that f~xeaad to the ftnnt waist reHion ~3 by meats of the fauntin8 e)aa>aus S6 disposed utj~nt the dtsn! adge~ 3~ of the ear WO 96!14815 PC"TIUS95I13802 flaps 54.
Figures l0a and lOb show alternative embodiments of the present invention additionally comprising belts. As shown in Figure 10a, the belt 120 can be permanently attached to the diaper 20. Alternatively, as shown in Figure lOb, the belt 120 can be a reusable separate element that is releasably affixed to the diaper 20 during use. In either case, the belt 120 is preferably disposed in the rear waist region 24 adjacent the end edge 32 of the diaper 20. The belt 120 may take on a number of different sizes, shapes, configurations and materials as are known in the art. An example of an absorbent article comprising belts that are suitable for use with the present invention is described in U.S. Patent 4,964,860 entitled "Detachable Two Piece Absorbent Garment" issued to Gipson et al., on October 23, 1990.
As shown in Figures l0a and lOb, the embodiments of the present invention that comprise belts preferably additionally comprise fastening elements disposed in the front waist region 22. These front waist region fastening elements 122 provide a means for fastening the front waist region 22 to the rear waist region 24 or the belt 120 when the diaper 20 is fitted to the wearer. In a preferred embodiment, at least one front waist region fastening element 122 is disposed in the front waist region 22. More preferably, as shown in Figures l0a and lOb, a front waist region fastening element is disposed adjacent each longitudinal edge 30 of the diaper in the front waist region 22. The front waist region fastening elements 122 may take on a number of different sizes, shapes and materials. In one preferred embodiment, the front waist region fastening elements 122 comprise pressure sensitive adhesives. Alternatively, the front waist region fastening elements 122 may comprise hook and loop type fastening material, as described in the above mentioned U.S. Patent 4,964,860.
The belted diaper configuration of the present invention is preferably fitted to the wearer by first inflecting the side panel 62. This is done by either pulling laterally outwardly on the side panels 62 in the rear waist region 24, or by pulling laterally outwardly on the ends of the belt 120 which in turn provides tension to flip out the side panels 62 in the rear waist region 24. The rear waist region 24 of the diaper 20 is then placed under the wearer's back. The diaperer then pulls the Sep-30-99 15.51 From-SIM MCBURNEY 4165951163 T-468 P.D3/03 F-654 ~Q 9b~1~a1'~ PCI2'59511331)Z

rstnaindrr of the dupes 24 berwxn the wearer's logs so char the front waiu rEgion 22 is posetionod ac~u the front of the wearer. 'Ihe belt 120 is then fast.~d ~b~t rhs waist of the wrsrawnd rlu front waist region fastening elements 122 are fastened ro the belt 120 forming a closurc bctweon the franc wait region 22 and the rrar waist rrgion Z4. In this configuration, the distal edges 66 of dte side pana~ b2 in ctra rear waist region 24 provide a gasacet apouc the buuxlcs of the ware and provide an inflected barrier cuff that ;tends up in the no rnodon ume of the crotch region 26.
Fixurs 11 sa pwd embodimatt of the present uwmtion catnprisittg a means for fa:tatirtg the absarbatc article tA the wearer's pants. In a prrferred embodiment, the pad 1120 comprises a front waist r~ion set-urement member 112 and a rear w~isz region sccuremcnt member 11D. 'rne franc waist region se~utement member 112 is preferably dixposad ad,EsGatt the end edge 32 of the pad 1120 in the front waiu region 22, and the r~nr waist region setctremcac mEmber 11Q i3 p~f~dIy dispoxd acljaxnt the end edge ~2 of the pad llZp in the rear weirs r~ion 2~. My adi~ive. eve. ical tasting means, hack and loop type fastcna or sny other ~~ mrxtt~ known ~n the art can be used for the so~r~tncnt tncrcibctx. with pssensitive adt~ivrs being preferred. w suitable adhesive i~ Ilts~tt lorh 34-2$23 manutacxurs~d by the National Stuck and G'haaial Gompattty of Pridgcwara, NJ. SWit~tbla adhcsi~G fasta~s arc sire dn~ibod in D.S. Pat~u x,917,697. sxtdtlcd ~ 5aniory Naplins Having Maps and s~ Itelie#' Moans issued to Osbortt. III et al.. oa April 17, 1990. If a pressacne seaiitive adhe~ve i~ used, the adhesiv; itt tyg~lly ~aovaad with a remavabic rr~c liuc in ardes m keep the a~ve from dryrirt~ out, txcotning aoniattanated of ~taiet= to s su:~ other thin the intatdad surface prier to tnt:.
Suitalble t~slea~ lid acs ~d is tits a3~a mexltionod U.S. patact 4,917,697. Arty aomially available; ieleue lit~as cwntnortly uaa4 for sv~
puxpoacs can be utilised he~irt. Hon-litnitirtg exempla of st~table rdase liners ~ ~t.~ai~c~-~ su.~x ~lra*ana ar.~ol~s~-~ suox 4Prd' both of wlti~h are nt~avfd by the w~sil corpocatlon of Ma>asha, wI.
~ pad embodirrtaat of the ~t irtvenciort, as thc>vra in Fisuta 11, i:
fitted to the wt~r by first inflecting the side pals 62. 'I?~is is done by pulling >arG~lly outwardly ott ttt~ sib patlGls 61 in the reer wait ie$~on 24. 'I'tu did ~T~de-mark se 30/08/1989 ~15:5E 4165951163 Direceived then removes any release liners) and positions the pad into the wearer's undergarment. , Preferably, the front waist region 22 should be positioned in the front of the wearer's undergarment and the rear waist region 24 should be placed in the rear of the wearer's undergarment. In this configuration, the distal edges 66 of the side panels 62 in the rear waist region 24 provide gasketing about the wearer's buttocks while the distal edges 66 of the side panels 62 in the crotch region 26 stand up to provide an inflected barrier cuff in the wearer's no motion zone.
Figures 12a and 12b show yet other alternative embodiments of the present invention. The diapers 20 shown in Figures 12a and 12b each have a front waist region 22, a rear waist region 24, a crotch region 26, a lateral centerline 34 and a longitudinal centerline 36. The diaper 20 preferably further comprises a liquid pervious topsheet 38, a liquid impervious backsheet 42, an absorbent core 44, side panels 62, a spacing means 76 (such as the elastic members 77), and closing means 78. ('The spacing means 76 and the closing means 78 may comprise any of those hereinbefore described with regard to this invention.) In the embodiments shown in Figures 12a and 12b, the side panels 62 each include a front ear flap section 10 located in the front waist region 22, and a barrier cuff section 12 that extends longitudinally from the crotch region 26 to at least the rear waist region 24. Each side panel 62 has a proximal edge 64 and a distal edge 66. Each barrier cuff section 12 has a first end edge 14 located longitudinally inboard of the front ear flap section 10 and a second end edge 16 located in or juxtaposed the rear waist region 24. (As used herein, the term "longitudinally inboard" is defined as the direction toward the lateral centerline 34 of the diaper 20.) In one preferred configuration of the embodiments shown in Figures 12a and 12b, the distal edges 66 of the side panels 62 are unsecured to any underlying structure of the diaper ~20 in the front waist region 22 and the rear waist region 24 while the distal edge 66 of at least a portion of the barrier cuff section 12 juxtaposed the first end edge is secured laterally inboard of the proximal edge 64 by the closing means 78. This configuration inverts the second end edges 16 of the side panels 62 with regard to the first end edges 14, thus creating an inflected barrier cuff that stands up in the crotch region 26 when the diaper 20 is fitted to a wearer. This configuration also provides a front ear flap 10 in the front waist region 22 of the diaper 20 that can be extended laterally outwardly to pmvide a greater amount of material in the front waist region 22 to better contain exudates or to provide a greater area to which the rrar waist region 24 may be joined when the diaper 20 is fitted to a wearer. This embodiment of the present invention can also be provided with rear waist region ear flaps 15. The rear waist region ear flaps 15 may comprise any of the materials and may be joined in any way as previously discussed in this application with regard to the ear flaps 54.
Further, the rear waist region ear flaps 15 may be permanently joined with said front waist region 22 to form a pant.
In an alternative configuration of the embodiments shown in Figures 12a and 12b, the inflected barrier cuffs may comprise side panels 62 that are 'z-folded' (not shown). As used herein, the team 'z-folded' refers to side panels that comprise at least some portion which is folded over itself such that at least one surface of the side panel is juxtaposed and in an overlapping configuration with another portiotl of the same surface of the side panel. The z-folded configuration provides the benefits described above with regard to an inflated barrier cuff while ensuring that a skin-friendly material is against the skin of the weans throughout the length of the barrier cuff: Some preferred embodiments of z-folded side panels are disclosed in co-pending ~, Patent Application Serial No. 2199367 filed on September g, 1995.
The diapers shown in Figures 12a and 12b may be manufactured using the following method. First, a generally rectangular chassis 18 is provided having a inner surface 11, an opposing outer surface 13, a front waist region 22, a rear waist reg~ 24, a crop region 26 located baweea the front waist region 22 and the rear waist r~ioa 24, a lasaal calterline 34, a longidrdinal centerline 36, and a pair of >aterally opposed side panels 62 extending longitudinally from the front waist region 22 to the rear waist region 24. The side panels each have a proximal edge 64, s distal edge 66 and a second end edge 16 located in the rear waist ~ 24.
The side panels 62 are separated between the front waist region 22 and the crotch region 26 forming a first end edge 14 located in the crotch region 26.
The side panels 62 may be separated by any means as are known in the art, including, but not limited to, slitting, cutting, tearing, or perforating, using knives, lasers, heat, pressure, ultrasound or any combination of these. In one preferred embodiment, as shown in Figure 12a, the separation is a relatively straight separation in a direction relatively parallel to the lateral centerline 34.
However, in other preferred embodiments, one of which is shown in Figure 12b, the separation is curvilinear or at an angle to lateral centerline. (As used herein, the term "curvilinear' refers to any separation that is not relatively straight, but rather comprises at least one curve.) Either befort or after the separation step has been completed, the side panels 62 are folded over the chassis 18. Once the separation step has been performed, a portion of the side panel juxtaposed the first end edge 14 is sxured to the inner surface I1 of the chassis 18 in the crotch region 26. This ensures that at least a portion of the side panel 62 juxtaposed the first end edge 14 is inverted relative to the second end edge 16, thus, providing an inflated barrier cuff that stands up in the crotch region when the diaper is fitted to a wearer. (If a z-fold configuration is desired, at least a portion of each side panel 62 juxtaposed the first end edge 14 is folded back upon itself and preferably sxured thereto.) If a pant oonfiguratioft is preferred, the rear waist region ear flaps 15 arc permanently joined with said front waist region 22 to form the pant. A more detailed discussion of methods for manufacturing diapers with inflated barrier cuffs is disclosed in co-pending CA Patatt Application Serial No. 2192067 which was filed on May 30, 1995.
The configuration of the diaper 20 shown in Figures 12a and 12b is preferably fitted to the wear~a by extending the side panels 62 laterally outwardly in at least the rear waist region 24. If desired, the side panels 62 may be extended laterally outwardly in the front waist region 22 forming front ear flaps 10.
(If the diaper 20 was manufactured with perforations at the separation between the front waist rrgion 22 and the crotch region 26, the user will have to tear or otherwise completely separate the perforations to release the front ear flaps 10 fmm the barrier cuff section of the sidt panels 62.) The rrar waist region 24 is placed under the wearer's back and the remainder of the diaper is drawn between the legs of the wearer. The front waist region 22 is then positioned across the front waist of the wearer. The rear waist region 24 is then wrapped around the wearer's waist and joined to the front waist region 22. The front ear flaps 10, when extended provide a surface to which the rear waist region 24 may be joined. In embodiments comprising rear waist region ear flaps 15, the rear waist region ear flaps 15 may be joined to the front waist region 22 or the front ear flaps 10.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A disposable absorbent article having a front waist region, a rear waist region, a crotch region between said front waist region and said rear waist region, a pair of longitudinal edges, a lateral centerline and a longitudinal centerline, the absorbent article comprising:
a chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with said topsheet; an absorbent core interposed between said topsheet and said backsheet, said absorbent core having a pair of opposed side edges, a pair of longitudinally extending side panels, each of said side panels including a front ear flap section located in said front waist region; a barrier cuff section having a first end edge located longitudinally inboard of said front ear flap section; a second end edge located in said rear waist region; a proximal edge disposed adjacent one of said side edges of said absorbent core and a distal edge spaced apart from said proximal edge;
spacing means joined along said distal edge of each said barrier cuff section; and closing means for securing at least a portion of said barrier cuff section juxtaposed said first end edge to the absorbent article inboard of said proximal edge;
said distal edges being unsecured to any underlying structure of the absorbent article in said front waist region and said rear waist region such that said distal edges form said longitudinal edges in said front waist region and said rear waist region; and said distal edge of said barrier cuff section being secured laterally inboard of said proximal edge in said crotch region such that said second end edges of said side panels located in said rear waist region are inverted relative to said first end edges to form an inflected barrier cuff that stands up in said crotch region when the absorbent article is fitted to a wearer.

2. The absorbent article of claim 1 additionally comprising an ear flap joined to and extending outwardly from each said side panel in the rear waist region.

3. The absorbent article of claim 2 wherein said ear flaps additionally comprise a fastening means for securing the absorbent article about the waist of the wearer.

4. The absorbent article of claim 3 wherein said fastening means comprises a tape tab having one end secured to said ear flap and a second end for attachment to said front waist region.

5. The absorbent article of claim 2 wherein said ear flaps comprise a stretch laminate comprising a layer of elastomeric film sandwiched between two layers of nonwoven fabric.

6. The absorbent article of claim 1 wherein said side panels are z-folded in at least said barrier cuff section.

7. A disposable absorbent article having a front waist region, a rear waist region, a crotch region between said front waist region and said rear waist region, a pair of longitudinal edges, a lateral centerline and a longitudinal centerline, the absorbent article comprising:
a chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with said topsheet; an absorbent core interposed between said topsheet and said backsheet, said absorbent core having a pair of opposed side edges, a pair of longitudinally extending side panels, each of said side panels including a front ear flap section located in said front waist region; a barrier cuff section having a first end edge located longitudinally inboard of said front ear flap section; a second end edge located in said rear waist region; a proximal edge disposed adjacent one of said side edges of said absorbent core and a distal edge spaced apart from said proximal edge;

spacing means joined along said distal edge of each said barrier cuff section; and closing means for securing at least a portion of said barrier cuff section juxtaposed said first end edge to the absorbent article inboard of said proximal edge;
said front ear flap sections being separably joined to said barrier cuff sections, wherein said distal edges of said ear flap sections may be separated from said barrier cuff section when the absorbent article is fitted to a wearer such that said distal edges of said front ear flap sections form said longitudinal edges in said front waist region;
said distal edges being unsecured to any underlying structure of the absorbent article in said rear waist region such that said distal edges form said longitudinal edges in said rear waist region; and said distal edge of said barrier cuff section being secured laterally inboard of said proximal edge in said crotch region such that said second end edges of said side panels located in said rear waist region are inverted relative to said first end edges to form an inflected barrier cuff that stands up in said crotch region when the absorbent article is fitted to said wearer.

8. The absorbent article of claim 7 additionally comprising an ear flap joined to and extending outwardly from each said side panel in the rear waist region.

9. The absorbent article of claim 8 wherein said ear flaps additionally comprise a fastening means for securing the absorbent article about the waist of the wearer.

10. The absorbent article of claim 7 wherein said ear flap is permanently joined in said front waist region to form a pant.

11. The absorbent article of claim 8 wherein said ear flaps comprise a stretch laminate comprising a layer of elastomeric film sandwiched between two layers of nonwoven fabric.

12. The absorbent article of claim 7 wherein said side panels are z-folded in at least said barrier cuff section.

13. A method for manufacturing an absorbent article having inflected barrier cuffs, said method comprising the steps of:
providing a generally rectangular chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with said topsheet; an absorbent core interposed between said topsheet and said backsheet, said absorbent core having a pair of opposed side edges, said chassis having a front waist region;
a rear waist region; a crotch region located between said front waist region and said rear waist region; a longitudinal centerline; a lateral centerline; and a pair of laterally opposed side panels extending longitudinally from said front waist region to said rear waist region, said side panels each having a proximal edge disposed adjacent one of said side edges of said absorbent core, a distal edge spaced apart from said proximal edge and a second end edge located in said rear waist region;
separating said side panels between said front waist region and said crotch region, said separation forming a side panel first end edge in said crotch region;
folding said distal edge juxtaposed said first end edge inwardly over said chassis; and securing a portion of said first end edge to said chassis in said crotch region to invert said first end edge relative to said distal edge in said rear waist region to provide an inflected barrier cuff that will stand up in the crotch region when the absorbent article is fitted to a wearer.

14. The method of claim 13 wherein said step of separating said side panels is performed by slitting said side panels.

15. The method of claim 13 wherein said separation is made relatively perpendicular to said longitudinal centerline.

16. The method of claim 13 wherein said separation is made at an angle that is less than 90° or more than 90° to said longitudinal centerline.

17. The method of claim 13 wherein said separation is generally curvilinear.

18. The method of claim 13 wherein said step of separating said side panels between said front waist region and said crotch region includes perforating said side panels.

19. The method of claim 13 further comprising the step of leaving said distal edge of said side panel in said rear waist region unsecured to any underlying structure of the absorbent article.

20. A method for manufacturing an absorbent article having inflected barrier cuffs, said method comprising the steps of:
providing a generally rectangular chassis comprising a liquid pervious topsheet; a liquid impervious backsheet joined with said topsheet; an absorbent core interposed between said topsheet and said backsheet, said absorbent core having a pair of opposed side edges, said chassis having a front waist region;
a rear waist region; a crotch region located between said front waist region and said rear waist region; a longitudinal centerline; a lateral centerline; and a pair of laterally opposed side panels extending longitudinally from said front waist region to said rear waist region, said side panels each having a proximal edge disposed adjacent one of said side edges of said absorbent core, a distal edge spaced apart from said proximal edge and a second end edge located in said crotch rear waist region;
separating said side panels between said front waist region and said crotch region, said separation forming a side panel first end edge in said crotch region;
folding said distal edge juxtaposed said first end edge inwardly over said chassis; and securing only a portion of said first end edge to said chassis in said crotch region to invert said first end edge relative to said distal edge in said rear waist region to provide an inflected barrier cuff that will stand up in the crotch region when the absorbent article is fitted to a wearer.