DIAPER HAVING TRANSVERSE PARTITION WITH ANGLED LINES OF ATTACHMENT
FIELD OF THE INVENTION The present invention relates to disposable absorbent articles, and more particularly to disposable absorbent articles having a partition to reduce the migration of fecal material deposited on the diaper.
BACKGROUND OF THE INVENTION Disposable absorbent articles, such as diapers, are well known in the art. Disposable absorbent articles retain and absorb body exudates, such as urine and fecal material deposited thereon.
Significant advances have been made in the art relative to absorbing and retaining urine deposits. For example, disposable absorbent articles seldom leak and may be relatively thin due to the incorporation of absorbent gelling materials.
However, fewer attempts have been made in the art to handle deposits of fecal material in disposable absorbent articles. Fecal material has the undesirable proclivity of smearing onto the wearer's skin, causing epidermal irritation and complicating the task of cleaning the wearer when the soiled diaper or other disposable absorbent article is removed.
To overcome this proclivity, certain attempts have been made in the art to isolate the fecal material from the skin of the wearer. Such attempts generally provide a void or hole into which the fecal material is deposited and retained (hopefully), so that the location of the fecal material is limited to the position of the void or hole. Examples of such attempts are found in U.S. Patent 4,662,877 issued May 5, 1987, to Williams; U.S. Patent 4,892,536 issued January 9, 1990, to DesMarais et al.; U.S. Patent 4,968,312 issued November 6, 1990, to Khan; U.S. Patent 4,990,147 issued February 5, 1991 , to Freeland; and U.S. Patent 5,062,840 issued November 5, 1991 , to Holt et al.
Positive attempts in the art have been made to add a transverse partition to the diaper. The transverse partition is disposed on the topsheet of the diaper.
The transverse partition limits the migration of fecal material to the rear portion of the diaper in which the fecal material is deposited. However, it is very difficult to add a laterally oriented member, such as the transverse partition during manufacture. Generally, manufacture of a diaper involves multiple operations, virtually all of which occur to a moving web or discrete diaper. The web or the discrete diapers move in the machine direction. Adding a transversely oriented member presents great difficulties, particularly if one wishes to perform this operation at commercial speeds.
Accordingly, it is an object of this invention to provide a disposable absorbent article having a transverse partition which limits the migration of fecal material within the disposable absorbent article. It is further an object of this invention to provide a disposable absorbent article having a partition which is readily attachable to upstanding longitudinally oriented barrier leg cuffs. It is finally an object of this invention to provide a diaper having a transverse partition which is readily attachable to the upstanding barrier leg cuffs in commercial manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top plan view of the diaper according to the present invention shown partially in cutaway, and having one rectilinear line of attachment and one curvilinear line of attachment, each line of attachment having the same angular deviation from the longitudinal centerline of the diaper. The lines of attachment diverge as the front waist is approached.
Figure 2 is an offset vertical sectional view taken along line 2-2 of Figure 1.
Figure 3 is an instantaneous vertical sectional view taken along line 3- 3 of Figure 1.
Figure 4 is a fragmentary side elevational view taken along line 4-4 of Figure 1.
BRIEF SUMMARY OF THE INVENTION The invention comprises a diaper having a longitudinal centerline and a transverse centerline orthogonal thereto. The longitudinal and transverse axes define the plane of the diaper. The diaper further has a Z-direction orthogonal to the plane of the diaper. The diaper has a periphery defined by a front waist margin, a rear waist margin, and two longitudinal side margins intermediate and connecting the front and rear waist margins.
The diaper further comprises a liquid pervious topsheet, a liquid impervious backsheet joined to the topsheet, and an absorbent core intermediate the topsheet and the backsheet. The diaper also has a pair of upstanding generally longitudinally oriented barrier leg cuffs. Each of the barrier leg cuffs extends outwardly from a proximal end joined to the topsheet to a distal end spaced from the proximal end.
The diaper further has a generally transversely oriented transverse partition. The transverse partition is joined to the topsheet at a proximal end and extends outwardly therefrom. The transverse partition is joined to each of the barrier leg cuffs at a line of attachment. The lines of attachment have a projection onto the plane of the diaper. The projection onto the plane of the diaper diverges as one of the waist margins is approached. Preferably, the lines of attachment of the transverse partition diverge as the front waist margin is approached. The transverse partition is preferably disposed at angular relationship relative to the topsheet.
DETAILED DESCRIPTION OF THE INVENTION As used herein, the term "absorbent article" refers to devices which absorb and contain body exudates and are placed against or in proximity to the body of the wearer to absorb and contain discharges. The term "disposable" describes absorbent articles not intended to be laundered or otherwise restored or reused (i.e., they are intended to be discarded after a single use and preferably recycled, composted, or otherwise disposed of in an environmentally compatible manner). A "unitary" absorbent article refers to an article formed of separate parts united together to form a coordinated entity that does not require separate manipulative parts, like a separate holder and liner. A preferred embodiment of a disposable absorbent article
of the present invention is the unitary disposable absorbent article, diaper 20, shown in Figure 1. As used herein the term "diaper" refers to a disposable absorbent article generally worn by infants and incontinent persons about the lower torso. It should be understood, however, that the present invention is also applicable to other disposable absorbent articles such as incontinence briefs, incontinence undergarments, and diaper holders and liners.
Figure 1 is a plan view of diaper 20 of the present invention in its flat, uncontracted state (with elastic induced contraction pulled out, and portions of the structure cut away to more clearly show the construction of the diaper 20). The portion of the diaper 20 which faces or contacts the wearer, i.e., the inner surface, is oriented towards the viewer. The diaper 20 has a longitudinal centerline L-L and a transverse centerline T-T. As used herein the longitudinal centerline L-L or dimension is aligned front to back and bisects the standing wearer into left and right body halves. The transverse centerline T-T or dimension is orthogonal the longitudinal centerline L-L and lies within the plane of the diaper 20. The Z-direction is orthogonal to both the longitudinal and transverse centerlines L-L, T-T and extends outwardly from the plane of the diaper 20.
The diaper 20 has a chassis comprising a liquid pervious topsheet 24, a liquid impervious backsheet 26 at least partially peripherally joined to the topsheet 24, and an absorbent core 28 between the topsheet 24 and the backsheet 26. The topsheet 24 has an inwardly oriented surface which is oriented towards the core 28, and an outwardly oriented surface which is oriented towards and/or contacts the wearer. The longitudinal and transverse centerlines L-L, T-T define a plane coincident the outwardly oriented surface of the topsheet 24.
The diaper 20 further comprises a transverse partition 38 attached to the outwardly oriented surface of the topsheet 24 and extending away from the plane of the diaper 20 as illustrated in Figure 2. It is to be recognized that the transverse partition 38, rather than the transverse centerline T-T (unless the two are coincident) divides the diaper 20 according to the present invention into front and rear portions 31 , 33, which are worn about the front and rear of the wearer, respectively. Between the front and rear portions 31 , 33 of the diaper 20 is the crotch portion 35 of the diaper 20.
The diaper 20 further comprises longitudinally oriented barrier leg cuffs 32, preferably one on each side of the longitudinal centerline L-L. The diaper 20 may also include tape fasteners 36 positioned in the rear portion 33 for fastening the diaper 20 about the wearer. The diaper 20 can also have an elastic waistband and gasket leg cuffs (not shown). Commonly assigned U.S. Patents 3,848,594 issued Nov. 19, 1974 to Buell, Re B1 4,662,875 reissued May 5, 1987 to Hirotsu et al.; are incorporated herein by reference to illustrate tape fasteners 36; 3,860,003 issued Jan. 14, 1975 to Buell; 4,081 ,301 issued March 21 , 1978 to Buell; 4,695,278 issued Sept. 22, 1987 to Lawson; 4,808,177 issued Feb. 28, 1989 to DesMarais; and 4,938,755 issued July 3, 1990 to Foreman, are incorporated herein by reference to illustrate gasket cuffs and barrier leg cuffs 32; and 4,515,595 issued May 17, 1985 to Kievit et al.; and 4,816,025 issued March 28, 1989 to Foreman, are incorporated herein by reference to illustrate elasticized waist features.
The diaper 20 has a pair of upstanding barrier leg cuffs 32, one disposed on each side of the longitudinal centerline LL. Each barrier leg cuff 32 extends outwardly from a proximal end. The proximal end is joined to the diaper 20, and preferably is joined to the topsheet 24 of the diaper 20, although it will be recognized that, depending upon the exact configuration selected, the proximal end of the barrier leg cuff may be joined to the backsheet 26, or any other component of the diaper 20 without deviation from the invention described and claimed herein. The barrier leg cuff 32 extends from the proximal end to a distal end, the distal end being spaced apart from the proximal end. Particularly, the proximal and distal ends of the barrier leg cuff 32 are spaced apart in the Z-direction.
The barrier leg cuffs 32 are generally longitudinally oriented, i.e., have a principal direction which is generally parallel to the longitudinal centerline L-L. It will be understood that the barrier leg cuffs 32 may have slight deviations from being parallel to the longitudinal centerline L-L, or may be curvilinear and still be considered longitudinally oriented by one of ordinary skill.
The barrier leg cuffs 32 are preferably elastic, to accommodate the transverse partition 38 which is preferably inelastic. It is particularly important that the barrier leg cuffs 32 be able to elastically stretch and contract in the transverse direction. The barrier leg cuffs 32 may be made of a hydrophobic nonwoven material, a film, or combinations thereof. The barrier leg cuffs 32 may be ring-rolled, particularly in the region juxtaposed with the transverse partition 38.
The topsheet 24 and backsheet 26 of the diaper 20 have longitudinal and transverse dimensions generally larger than those of the absorbent core 28, so that the topsheet 24 and backsheet 26 may extend beyond the core 28 to thereby form the periphery of the diaper 20. The embodiment described herein is suitable for a wearer weighing about 7.3 to about 12.7 kilograms (16 to 28 pounds). It will be understood that if the diaper 20 is intended for use with larger or smaller wearers, including adults, the diaper 20 will have to be scaled accordingly.
Examining the components of the diaper 20 in more detail, the topsheet 24 and backsheet 26 are generally coextensive and at least partially peripherally joined. As used herein, the term "joined" refers to the condition where a first member or component is affixed or connected to a second member or component, either directly or indirectly where the first member or component is directly affixed to the second member or component, or connected to an intermediate member or component which in turn is affixed or connected to the second member or component. Components which are "joined" are intended to remain affixed or connected throughout the intended life of the diaper 20 and not to be separated unless and until the diaper 20 is discarded and as may be necessary for environmentally compatible disposal. Components which are "joined" cannot be separated without tearing or gross deformation of one or both components.
The topsheet 24 refers to any liquid pervious facing of the diaper 20 which contacts the skin of the wearer and prevents substantial contact of the absorbent core 28 with the skin of the wearer. The topsheet 24 is compliant, tactilely pleasant, and non-irritating to the skin.
A suitable topsheet 24 may be manufactured from porous foams, apertured plastic films, natural fibers, synthetic fibers, or a combination thereof. A particularly preferred topsheet 24 comprises polypropylene fibers and may be manufactured as a nonwoven web of spunbonded, carded, wet laid, melt blown, hydroentangled fibers. A particularly preferred topsheet 24 is carded and thermally bonded to have a basis weight of 14 to 25 grams per square meter. A suitable topsheet 24 is marketed by Veratec Inc., Division of International Paper Company, of Walpole, Massachusetts under the designation P-8.
The backsheet 26 is impervious to fluids such as urine and prevents fluids absorbed and contained by the core 28 from wetting the undergarments. As used herein, the "backsheet" refers to any partition disposed outwardly of the core 28 as the diaper 20 is worn and which contains absorbed liquid within the diaper 20. The backsheet 26 is preferably manufactured from a thin plastic film, although other flexible, liquid impervious materials may be used. As used herein, the term "flexible" refers to materials which are compliant and will readily conform to the general shape of the human body.
The backsheet 26 may be a polyolefinic film, such as polyethylene, having a thickness of about 0.01 to 0.05 millimeters. A suitable backsheet 26 can be made from a blend of 45 to 90 percent LLDP and about 10 to 55 percent polypropylene. Exemplary backsheet films are sold by Tredegar Industries of Terre Haute, Indiana under the designation RR8220 and RR5475.
The topsheet 24 and backsheet 26 may be joined by any means well known in the art, such as adhesive bonding or heat sealing. A particularly preferred method of joining the topsheet 24 and backsheet 26 is with hot melt adhesives such as are manufactured by Century Adhesives, Inc. of Columbus, Ohio and marketed as Century 5227, or BL1258 adhesive sold by the H.B. Fuller Company of St. Paul, Minnesota, or H2031 available from the Findley Adhesives Company of Elmgrove, Wisconsin.
As used herein, the term "core" refers to any component of the diaper 20 used for absorbing and retaining body exudates. The core 28 may be encased by one or more layers of tissue (not shown).
The absorbent core 28 may be made from a variety of materials such as comminuted wood pulp and may further contain particulate or fibrous absorbent gelling materials as are commonly known in the art. The absorbent core 28 may be made in accordance with the teachings of commonly assigned U.S. Patents 4,610,678 issued Sept. 9, 1986 to Weisman et al.; 5,137,537 issued Aug. 11 , 1992 to Herron et al.; and 5,147,345 issued Sept. 15, 1992 to Young et al., which patents are incorporated herein by reference. Absorbent gelling materials, if desired, may be made in accordance with commonly assigned U.S. Patent Re. 32,649, reissued April 19, 1988 to Brandt et al., and which is incorporated herein by reference.
Spanning at least a portion of the transverse dimension of the diaper 20 is an upstanding transverse partition 38. If the diaper 20 has barrier leg cuffs 32, preferably the transverse partition 38 spans the entire distance between the barrier leg cuffs 32. The transverse partition 38 has two ends, the ends being spaced apart in the transverse direction.
Each of the two ends of the upstanding transverse partition 38 is joined to one of the barrier leg cuffs 32, forming an H-shape. The transverse partition 38 is disposed on the body facing surface of the topsheet 24 and extends outwardly therefrom to present an abrupt discontinuity in the body facing surface of the topsheet 24. The transverse partition 38 obstructs the longitudinal migration of fecal material deposited in the rear portion 33 of the diaper 20 towards the front portion 31 of the diaper 20. As illustrated, preferably the transverse partition 38 may be generally straight, rectilinear, transverse and is preferably parallel to the transverse centerline T-T of the diaper 20. If desired, the transverse pattern 38 may even be coincident with the transverse centerline T-T of the diaper 20.
Referring to Figures 2-3, the transverse partition 38 has a proximal edge 43 which is preferably joined to the topsheet 24, and particularly the body facing surface thereof, by adhesive or other joining means, as are well known in the art. The transverse partition 38 extends outwardly from the plane of the diaper 20, with a vector component in the Z-direction, to a distal edge 42.
It is important the transverse partition 38 be upstanding and rise in the Z-direction above the plane of the outwardly oriented surface of the topsheet 24 to an effective height H spaced from the plane. The effective height H should be sufficient to present an abrupt discontinuity in order to obstruct the longitudinal movement of fecal material while the diaper 20 is worn. It is to be recognized that if the topsheet 24 has wrinkles, rugosities, undulations, or other deviations from planarity, these should be taken into account at the position of the transverse partition 38 when determining its effective height H. Otherwise such deviations from planarity in the topsheet 24 may diminish the effective height H of the distal edge 42 of the partition 38 above the topsheet 24, and not sufficiently obstruct the movement of fecal material.
As used herein, the "effective height" is the Z-direction distance from the plane of the outwardly oriented surface of the topsheet 24 to the distal edge 42 of the transverse partition 38. The effective height H is measured in the Z-direction while the diaper 20 rests on a horizontal surface, allowing elastic induced contraction to occur, thereby simulating the in-use condition. The distal edge 42 of the transverse partition 38 preferably has an effective height H above the body facing surface of the topsheet 24 of at least 1.5 centimeters, more preferably at least 2.5 centimeters, and most preferably at least about 3.5 centimeters.
As illustrated in Figure 3, the transverse partition 38 is preferably not orthogonal to the plane of the diaper 20, but instead is disposed in angular relationship therewith so that the distal edge 42 of the upstanding transverse partition 38 is oriented towards the rear portion 33 and the rear waist margin of the diaper 20. This arrangement provides the advantage that the pressure of the fecal material helps seal the transverse partition 38 against the wearer's body, minimizing the leakage of fecal material across the
transverse partition 38. This arrangement further minimizes the vertical forces necessary to maintain the transverse partition 38 in contact with the body of the wearer.
The transverse partition 38 may be made of a water pervious material, but is preferably made of a water impervious material. The water impervious material prevents (or minimizes the amount of) runny fecal material from reaching the genitalia of the wearer. Nonwoven materials, such as may be used to form the barrier leg cuffs 32, have been found to be particularly suitable in the transverse partition 38. Other suitable materials for the transverse partition 38 include foams, formed films, laminates thereof, etc.
The transverse partition 38 is preferably not elastically extensible. Any necessary elastic extensibility, particularly in the transverse direction, may be provided by the barrier leg cuffs 32. Suitable materials for the transverse partition 38 include breathable composite laminates, elongated films, nonwoven materials, and laminates thereof.
The transverse partition 38 may be generally made according to the teachings of commonly assigned U.S. Patent 5,554,142, issued September 10, 1996 to Dreier et al., the disclosure of which is incorporated herein by reference.
The transverse partition 38 is generally transversely oriented. By generally transversely oriented, it is meant that the transverse partition 38 is substantially parallel to the transverse direction T-T of the diaper 20. It is to be recognized that the transverse partition 38 may be curvilinear and still be considered transversely oriented by one of ordinary skill.
The transverse partition 38 is joined to the diaper 20, and preferably to the topsheet 24 of the diaper 20, at a proximal end. It will be understood by one of ordinary skill that various other constructions wherein the proximal end of the transverse partition 38 is joined to other components of the diaper 20, such as the backsheet 26, are feasible and do not deviate from the scope of the invention described and claimed herein.
The transverse partition 38 is joined to each of the barrier leg cuffs 32. The transverse partition 38 is preferably joined to each of the barrier leg cuffs 32 at the transverse ends of the transverse partition 38. By joining the transverse partition 38 to the barrier leg cuffs 32, an H-shaped pattern is formed. This H-shaped pattern prevents fecal material deposited in the rear portion 33 of the diaper 20 from migrating to the front portion 31 of the diaper 20. By containing the fecal material in the rear portion 33 of the diaper 20, the cleaning task becomes easier for the caretaker. Fecal material is not spread over such a large surface area of the wearer and is particularly advantageously kept away from the genitals.
The transverse partition 38 is joined to each of the barrier leg cuffs 32 at lines of attachment 44. The lines of attachment 44 have a projection onto the plane of the diaper 20. The projection of the lines of attachment 44 onto the plane of the diaper 20 are divergent as one of the waist margins is approached. As illustrated in Figure 1 , preferably the lines of attachment 44 diverge as the front waist margin is approached. A pattern which diverges towards the front waist margin is preferred over a pattern which diverges towards the rear waist margin because the barrier leg cuffs 32 are closest to each other and to the longitudinal centerline L-L at the distal edge 42 of the transverse partition 38. The distal edge 42 of the transverse partition 38 is oriented in angular relationship relative to the topsheet 24 and is angled towards the rear portion 33 of the diaper 20.
Alternatively, the lines of attachment 44 may be thought of as being disposed in a skewed, i.e., non-parallel, relationship to the longitudinal centerline L-L. A line of attachment 44 is considered skewed relative to the longitudinal centerline L-L if the theoretical extension of the line of attachment 44, in either longitudinal direction intersects the longitudinal centerline L-L, when the line of attachment 44 is projected onto the plane of the diaper 20. Preferably, the line of attachment 44 diverges away from the longitudinal centerline L-L as the front waist margin of the diaper 20 is approached.
Referring to Figure 4, the transverse partition 38 may be attached to the barrier leg cuffs 32 by any joining means which is well known in the art. Suitable joining means include heat sealing, adhesive joining, ultrasonic
welding, and preferably autogeneous bonding. A particularly preferred autogeheous bonding technique is disclosed in commonly assigned U.S. Patent 4,919,738, issued April 24, 1990 to Ball et al., the disclosure of which is incorporated herein by reference.
The line of attachment 44 may comprise either discrete bond sites or a continuous bond. Discrete bond sites are preferred because the resulting diaper 20 is generally more flexible, and hence more comfortable to the user, than a like diaper 20 made with a continuously bonded line of attachment. However, if discrete bond sites are selected for the lines of attachment 44, the discrete bond sites should not be spaced so far apart that fecal material, particularly low viscosity fecal material, can pass between the discrete bond sites and enter the front portion 31 of the diaper 20.
The lines of attachment 44 are preferably rectilinear, although the lines of attachment 44 may be curvilinear. If curvilinear lines of attachment 44 are selected, preferably the curvilinear lines of attachment 44 are concave towards the longitudinal centerline L-L, in order to maximize the volume available for fecal material to occupy. If curvilinear lines of attachment 44 are selected, preferably the curvilinear lines of attachment 44 are generally circular, and have a radius of curvature which is approximates the length of the proximal edge 43 of the transverse partition 38.
Referring back to Figure 1 , the lines of attachment 44 are projectable onto the plane of the diaper 20. When the lines of attachment 44 are projected onto the plane of the diaper 20, the theoretical extension of the lines of attachment 44 form an included angle A. Each of the lines of attachment 44 forms one ray of included angle A. Preferably, the longitudinal centerline L-L bisects included angle A. If the lines of attachment 44 are curvilinear, the theoretical extension between the extremities of the principal portions of the lines of attachment 44 are used in determining the projection onto the plane of the diaper 20. The included angle A may range from 60 to 150 degrees, and preferably ranges from about 70 to 130 degrees, and from 80 to 100 degrees.
Multiple and even parallel bond sites may be utilized to join the transverse partition 38 to each of the upstanding barrier leg cuffs 32. If such an arrangement is selected, then the lines of attachment 44 projected onto the plane of the diaper 20 are those lines of attachment 44 which control the position of the transverse partition 38 relative to the barrier leg cuffs 32. Generally, but not necessarily, the lines of attachment 44 which are disposed nearest the longitudinal centerline L-L of the diaper 20 are controlling and should be used in determining included angle A. If it cannot be determined which discrete bond sites form the controlling lines of attachment 44, or if multiple lines of attachment 44 control the attachment of the transverse partition 38 to the barrier leg cuffs 32, then any projection of any combination of lines of attachment 44 onto the plane of the diaper 20 may be utilized in determining included angle A.
As noted above, preferably the transverse partition 38 is disposed in angular relationship relative to the topsheet 24. More preferably, the transverse partition 38 is angled towards the rear portion 33 of the diaper 20.
The included angle A between the lines of attachment 44 will necessarily change as the angular relationship between the transverse partition 38 and the topsheet 24 changes. The concluded angle A will also change to accommodate differences in the length of the transverse partition 38 or differences in the effective height H of the transverse partition 38. Generally, as the effective height H of the transverse partition 38 increases and the angular relationship between the transverse partition 38 and the topsheet 24 remains constant, the included angle A of the lines of attachment 44 should remain constant. As the length, in the transverse dimension, of the transverse partition 38 increases measured at its proximal edge 43, generally the included angle A between the lines of attachment 44 should decrease. Also, as the angle between the transverse partition 38 and the topsheet 24 approaches 90 degrees, i.e., the transverse partition 38 becomes more perpendicular to the topsheet 24, the included angle A between the lines of attachment 44 should increase. Such changes are necessary to assure that the transverse partition 38 does not restrict the ability of the barrier leg cuffs 32 to reach their full height, and provide the best possible containment.
The aforementioned ranges of included angles are judged suitable for a diaper 20 fitting a range of infant wearers having a weight of 16 to 28 pounds, a transverse partition 38 having a length at the proximal edge 48 of about 5 1/2 inches, a length between the barrier leg cuffs 32 at the distal edge of about 1.125 inches, and an effective height H above the topsheet 24 of about 2 inches, and which is maintained in angular relationship relative to the topsheet 24 of about 64 degrees. The angular relationship of the transverse partition 38 relative to the topsheet 24 is measured according to the disclosure of commonly assigned U.S. Patent Application Serial No. 08/664,603, filed June 18, 1996 in the names of Roe et al., the disclosure of which is incorporated herein by reference.