LIGHT INCONTINENCE PAD

Disposable absorbent articles, such as adult pads or liners for light incontinence, with reduced lengths for improved fit and comfort.

FIELD OF INVENTION

The present invention relates generally to incontinence pads and sanitary napkins; and more particularly, but not by way of limitation, to female incontinence pads or liners that are smaller and thinner to provide protection specifically for light incontinence with improved fit, comfort, and discretion.

BACKGROUND

Examples of disposable absorbent articles that are wearable by a user include baby diapers, training pants, adult incontinence briefs and underwear, bladder control pads, and feminine hygiene articles, all of which may be made in disposable forms. “Disposable” refers to articles that are designed to be discarded after a limited use rather than being laundered or otherwise restored for reuse. Disposable absorbent products have met with widespread acceptance in the marketplace for a variety of applications, including infant and adult incontinence care, in view of the manner in which such products can provide effective and convenient liquid absorption and retention while maintaining the comfort of the wearer. Such disposable absorbent articles often include a topsheet that is configured to be closest to the wearer during use, a liquid-impermeable backsheet or outer cover, and an absorbent core between the topsheet and the backsheet. In some instances, such disposable absorbent articles also include an acquisition-distribution layer (ADL) disposed between the topsheet and the absorbent core.

Such disposable absorbent articles also include, for example, pads and liners for feminine hygiene and light incontinence uses, i.e., pads and liners adapted to absorb urine and/or blood. Many women suffer from light urinary incontinence. Most protective, absorbent pads available on the market today for female bladder control issues or menstruation management are designed in an oval shape or a dog-bone shape, primarily to afford coverage over both urethral area and vaginal area. One example of such a pad or liner is disclosed in U.S. Patent Application Publication No. US 2001/0014797.

Some such liners are shaped for certain types of undergarments, such as thong or t-back underwear. Examples of such liners are disclosed, for example, in U.S. Patent Application Publication No. 2004/0102747, and U.S. Patent Application Publication No. US 2002/0115978.

Some such liners are folded to form a desired shape. One example of such a liner is disclosed in U.S. Pat. No. 6,443,934.

SUMMARY

This disclosure includes embodiments of disposable absorbent articles, particularly pads or liners adapted for light-incontinence applications. Embodiments of the present pads are shaped to improve fit, comfort and discretion, such as, for example, by reducing size and potential for bunching. By way of example, embodiments of the present pads and lines are configured to be co-located with, for example extend under, a wearer's urethra, but not over the entirety of the wearer's vagina, thereby different in size and shape relative to prior art pads and liners, which are typically adapted to fit far enough posteriorly to extend under the entirety of the wearer's vagina. While the prior art approach may be considered necessary to provide sufficient protection and absorbency for feminine hygiene applications, such size is unnecessary for user's needing only light incontinence protection. The present pads and liners can therefore be configured to provide such light incontinence protection, while reducing the overall size of the pad or liner to improve comfort and discretion during use. In some embodiments, the present pads have a limited absorbent capacity, such as, for example, an absorbent capacity in grams of water or of saline of 150 g or less, 120 g or less, 100 g or less, 80 g or less, or 60 g or less.

Some embodiments of present disposable absorbent articles comprise: a pad configured to be inserted into a crotch portion of a wearer's garment or undergarment, where the pad comprises: a liquid-permeable topsheet; a liquid-impermeable backsheet; and an absorbent core disposed between the topsheet and the backsheet.

In some embodiments of the present pads, the pad has a body-facing surface defined by the topsheet, an outer surface defined by the backsheet, an anterior end, a posterior end, a perimeter, a length measured along a central longitudinal axis of the pad between the anterior and posterior ends, and a maximum width measured perpendicular to the length along the body-facing surface, the maximum width disposed closer to the anterior end than to the posterior end; the anterior end includes a first lobe on a left side of the central longitudinal axis, and a second lobe on a right side of the central longitudinal axis; and the posterior end extends from the anterior end by a distance that is greater than the maximum width. In some embodiments, a portion of the perimeter defining the anterior end includes: a first arc on a left side of the pad, and a second arc on a right side of the pad, where the first arc and second arc are separated along the perimeter on the anterior end by at least one additional arc or line. In some embodiments, a portion of the perimeter defining the posterior end includes a third arc that spans the central longitudinal axis. In some embodiments, the perimeter includes a left side segment extending between the first arc and the posterior end, and a right side segment extending between the second arc and the posterior end. In some embodiments, the left and right side segments are concave toward the central longitudinal axis. In some embodiments, the posterior end defines a third lobe.

In some embodiments of the present pads, the pad has a body-facing surface defined by the topsheet, an outer surface defined by the backsheet, an anterior end, a posterior end, a perimeter, a length measured along a central longitudinal axis of the pad between the anterior and posterior ends, and a maximum width measured perpendicular to the length, the maximum width disposed closer to the anterior end than to the posterior end; and the posterior end extends from the anterior end to define the length; and the length is 1 to 2.5 times the maximum width. In some embodiments, the length is 1.75 to 2.25 times the maximum width, and the maximum width is closer to the anterior end than to the posterior end. In some embodiments, the length is 1 to 1.5 times the maximum width. In some embodiments, the maximum width is disposed at a distance from the anterior end of 1%-25% of the length of the pad. In some embodiments, the maximum width is disposed at a distance from the anterior end of 15%-20% of the length of the pad. In some embodiments, the maximum width is disposed at a distance from the anterior end of 5%-10% of the length of the pad.

In some embodiments of the present pads, the absorbent core comprises a laminate of superabsorbent polymer (SAP) particles sandwiched between a first layer and a second layer, where at least one of the first and second layers is hydrophilic. In some embodiments, the laminate is folded.

Some embodiments of the present pads further comprises: an acquisition-distribution layer (ADL) disposed between the topsheet and the absorbent core.

In some embodiments of the present pads, the pad has a body-facing surface defined by the topsheet, an outer surface defined by the backsheet, an anterior end, a posterior end, a perimeter, a length measured along a central longitudinal axis of the pad between the anterior and posterior ends, and a maximum width measured perpendicular to the length, the maximum width disposed closer to the anterior end than to the posterior end; and a first portion of the backsheet on a left side of the pad is folded over the posterior end, and a second portion of the backsheet on a right side of the pad is folded over the posterior end, such that the first and second portions of the backsheet cooperate with the topsheet to define a pocket extending from the posterior end and opening toward the anterior end of the pad. In some embodiments, the first portion of the backsheet is bonded to the second portion of the backsheet. In some embodiments, the absorbent core comprises a laminate of superabsorbent polymer (SAP) particles sandwiched between a first layer and a second layer, where at least one of the first and second layers is hydrophilic. In some embodiments, the laminate is folded. Some embodiments further comprise: an acquisition-distribution layer (ADL) disposed between the topsheet and the absorbent core.

In some embodiments of the present pads, the absorbent core has a maximum thickness and defines one or more channels each having a thickness that is less than the maximum thickness. In some embodiments, the maximum thickness is defined by a plurality of layers of an absorbent sheet or web. In some embodiments, the one or more channels are each defined by embossed lines or regions at which the plurality of layers are compressed.

Some details associated with the embodiments described above and others are described below.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring now to the figures and, more particularly, toFIGS. 1A-1BandFIG. 2;FIG. 1Adepicts a top plan view of an embodiment10of the present incontinence pads;FIG. 1Bdepicts a bottom plan view of pad10; andFIG. 2depicts an exploded, lateral cross-sectional view of pad10taken along line2-2ofFIG. 1A. As shown, pad10has a length14, a maximum width18, a body-facing surface22, and an outer surface26. In this embodiment, body10comprises a liquid-impermeable backsheet or cover30that defines outer surface26, a liquid-permeable topsheet34that defines body facing surface22and is configured to be closest to the wearer during use, an absorbent core38disposed between the backsheet and topsheet, and an acquisition-distribution layer (ADL)42disposed between the topsheet and the absorbent core. Other embodiments may omit ADL42. “Liquid impermeable,” when used in describing a layer or multi-layer laminate, means that a liquid, such as urine, will not pass through the layer or laminate, under ordinary use conditions, in a direction generally perpendicular to the plane of the layer or laminate at the point of liquid contact. “Lamination” is the technique of manufacturing a material in multiple layers, so that the composite material has benefits of all the combined layers, such as, for example, improved mechanical strength or durability, improved stability, lower permeability to water, and/or other properties. A laminate includes two or more layers of material(s) that are a permanently assembled by heat, pressure, welding, or adhesives.

As shown inFIGS. 1A and 1B, pad10—in the depicted flattened or unfolded configuration—has a generally planar configuration. As shown, pad10has an anterior end46, a posterior end50, and a perimeter54along which topsheet34is bonded to backsheet38. As also shown inFIGS. 1A and 1B, length14reflects the maximum dimension of the pad measured along a central longitudinal axis58of the pad between the anterior and posterior ends, and width18is the maximum dimension measured perpendicular to the length along the body-facing surface. In this embodiment, maximum width18is disposed closer to anterior end46than it is to posterior end50.

The depicted embodiment of pad10has a tri-lobal configuration. More particularly, in the embodiment shown, anterior end46includes a first lobe66on a left side of the central longitudinal axis, a second lobe70on a right side of the central longitudinal axis, and posterior end50defines a third lobe74. By way of example, in this embodiment, a portion of perimeter54defining anterior end46includes: a first arc, between points P1and P2, on a left side of the pad; and a second arc, between points P3and P4, on a right side of the pad that is separated along perimeter54by at least one additional arc or line between points P2and P4. In this embodiment, a portion of perimeter54defining posterior end50includes a third arc, between points P5and P6, that spans central longitudinal axis58.

In the embodiment shown inFIGS. 1A and 1B, perimeter54also includes a left side segment that extends between the first arc at point P1and the posterior end, and a right side segment extending between the second arc at point P3and the posterior end. For example, as shown, the left side segment includes an arc extending between the first arc at point P1and the third arc at point P5, and the right side segment includes an arc extending between the second arc at point P3and the third arc at point P6. In this embodiment, the left side segments includes a fourth arc that is concave toward central longitudinal axis58, and the right side segment includes a fifth arc that is concave toward central longitudinal axis58. In some embodiments, the radius of the first arc is equal to the radius of the second arc and/or equal to the radius of the third arc. In some embodiments, the radius of the fourth arc is equal to the radius of the fifth arc, and the radius of the fourth arc is larger than the radius of the first arc.

In the embodiment shown inFIGS. 1A and 1B, core38has a perimeter62that is proportionally smaller than perimeter54of the overall pad such that the shortest distance between perimeter62of core38and perimeter54of pad10is substantially constant around perimeter54. Stated another way, at any given point along perimeter54, the shortest distance to perimeter62is substantially the same. In other embodiments, perimeter62of core38may have a shape, for example rectangular, that differs from the shape of perimeter54of the core.

As also described in more detail below, pad10is shaped such that anterior end46and, specifically maximum width18of pad10, contours to a wearer's legs to resist rearward movement of the pad relative to the wearer, while posterior end50of the pad extends rearward under the wearer's urethra but not under the entirety of the wearer's vagina. For example, in the depicted embodiment of pad10, posterior end50is sized to not extend under any portion of the wearer's vagina. By configuring pad10to avoid posterior end50from, in use, extending under the entirety of the wearer's vagina, the size of pad10is reduced relative to prior art pads, resulting in reduced bunching and increased wearer comfort. This purpose can be achieved, for example, by selecting the ratio of length14relative to maximum width18and the position of maximum width18relative to anterior end46. For example, in some embodiments, length14is 1 to 2.5 times maximum width18, and/or maximum width18can be disposed at a distance from anterior end46that is 1% to 25% of length14. In the embodiment shown inFIGS. 1A and 1B, length14is 1.75 to 2.25 times maximum width18, and maximum width18is disposed at a distance78from anterior end46that is 15% to 20% of length14. For example, length14may be equal to any one of, or between any two of: 75 mm, 100 mm, 125 mm, and/or 150 mm; and maximum width18may be equal to any one of, or between any two of: 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, and/or 100 mm.

In the embodiment shown inFIGS. 1A-1BandFIG. 2, pad10also includes an adhesive82covered by a release strip86. As will be appreciated by those of ordinary skill in the art, the release strip is configured to protect the adhesive until a wearer is ready to use the pad, at which time the release strip can be peeled away and removed from the adhesive by the user to expose the adhesive. The user can then position the pad in the user's garment or undergarment with the adhesive facing a crotch portion of the garment or undergarment, such that the adhesive will resist slippage of the pad relative to the garment or undergarment. In other embodiments, in addition to or as an alternative to adhesive82on the outer side of the pad, the pad can include adhesive on a body-facing side of the pad (the topsheet) to contact a user's skin to resist displacement of the pad relative to the user during use.

Liquid-impermeable backsheet30can include, for example, an inner liquid-impermeable film and an outer nonwoven backsheet that can be a nonwoven fabric. A “film” is a membrane-like layer of material formed of one or more polymers, which does not have a form consisting predominately of a web-like structure of fibers and/or other fibers. In some embodiments of the present articles, backsheet or outer cover30can be breathable, for example, an inner liquid-impermeable film of backsheet30can comprise a breathable film. The terms “breathable,” “breathable film,” “breathable laminate” or “breathable outer cover material” or “breathable backsheet” refers to a film, laminate, or outer cover material having a water vapor transmission rate (“WVTR”) of at least about 300 grams/m2/24 hours. Breathable materials typically rely on molecular diffusion of vapor, and are substantially liquid impermeable. “Nonwoven” fabrics, according to an INDA definition, are broadly defined as sheet or web structures bonded together by entangling fiber or filaments (and by perforating films) mechanically, thermally, or chemically. They are flat, porous sheets that are made directly from separate fibers or from molten plastic or plastic film. They are not made by weaving or knitting and do not require converting the fibers to yarn. The basis weight of nonwoven fabrics is usually expressed as gsm or grams per square meter. “Nonwoven backsheet” is a backing substrate layer in the outer cover; a nonwoven backsheet is most often a nonwoven layer facing away from the wearer.

As shown inFIG. 2, absorbent core38is disposed between backsheet30and topsheet34, and ADL42is disposed between topsheet34and absorbent core38. An “absorbent core” is a structure typically disposed between a topsheet and backsheet of an absorbent article and containing materials like SAP and/or cellulosic fibers that are configured to absorb liquid in the absorbent article. In some embodiments, the absorbent core (38) may also include a cover layer or envelope material. The absorbent core, and/or the cover layer or envelope material, may comprise: nonwovens, SAP, cellulosic or non-cellulosic materials, films, fibers, or one or more substrates made of any one two or all of these combination materials. “Superabsorbent” or “superabsorbent material” or “SAP” refers to a water-swellable, water-insoluble organic or inorganic material capable, under the most favorable conditions, of absorbing at least about 15 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride and, more desirably, at least about 30 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride and, even more desirably, at least about 50 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride. The SAP materials can be natural, synthetic and modified natural polymers and materials. In addition, the SAP materials can be inorganic materials, such as silica gels, or organic compounds such as cross linked polymers. “Layer” when used in the singular can be a single element or a plurality of elements. For example, a plurality of sheets may together define a single layer, such as, for example, a layer with a particular function to which the sheets of the layer contribute.

Specifically, in the embodiment shown, absorbent core38comprises a laminate of superabsorbent polymer (SAP) particles sandwiched between a first layer and a second layer, where at least one of the first and second layers is hydrophilic; in some embodiments, both layers of the laminate are hydrophilic. In this embodiment, the absorbent core does not include fluff pulp and may therefore be referred to as a “pulp-less core”). Other embodiments can include an absorbent core with pulp alone or pulp and SAP.

Referring now toFIGS. 3A-3E,FIG. 3Adepicts a top plan view of a second embodiment10aof the present incontinence pads, andFIGS. 3B-3Edepict cross-sectionals taken along the line3-3ofFIG. 3Aof various alternate embodiments of absorbent cores suitable for use in pad10a. Pad10ais substantially similar to pad10, with the exception that certain aspects of the absorbent core of pad10a, specifically that the absorbent core includes one or more channels94as described in more detail below.

FIG. 3Bdepicts a cross-sectional view of first alternate embodiment of an absorbent core38athat is suitable for use in at least some embodiments of the present pads. Absorbent core38ais substantially similar to absorbent core38, with the exception that absorbent core38ais C-folded. Specifically, as shown, end portions90of the laminate are folded over toward a centerline of the laminate to define a central channel94that can receive and at least partially trap fluids insulting the core.FIG. 3Cdepicts an additional embodiment38bof a folded absorbent core in which end portions90of the laminate are folded twice—once towards the centerline, and again back away from the centerline to define three layers of laminate on each side of channel94a. Other embodiments can be folded any number of times. Specific additional examples of folded cores that may be suitable for certain embodiments of the present pads are disclosed in U.S. Patent Application Publication No. US 2015/0245958, which is incorporated by reference in its entirety.

FIGS. 3D and 3Edepict additional examples38c,38dof the present absorbent cores that include multiple pieces of the absorbent laminate rather than a single piece folded to define multiple layers. Specifically, core38cofFIG. 3Dincludes a lowermost piece of laminate spanning the entire area of the core, and a plurality of smaller pieces of laminate to increase the thickness of the core on either side of channel94b. This configuration results in end portions of each layer both at the lateral edges of the core and, for the layers above the lower-most layer, bounding channel94b. As shown, core38cincludes a lowermost layer spanning the entire area of the core, and three partial layers above the lowermost layer; but, in other configurations, the core can include, for example, one such partial layer, two such partial layers, four such partial layers, five such partial layers, or more. The pieces of laminate may, for example, be bonded together by adhesive and/or via embossing. For example, the core inFIG. 3Eincludes a plurality of sheets of laminate spanning the full width of core38d, such that ends90are disposed only at the lateral edges of the core, and a line of embossing defines channel94calong a line or series of points at which the sheets are compressed. In the embodiment ofFIG. 3E, the sheets may be joined by the embossing alone, or may be bonded with adhesive as well. In some embodiments, the pieces of laminate are die cut before being assembled; in other embodiments, the pieces of laminate are assembled, for example by folding a single piece of laminate, and then the overall core is die cut from the assembled layers.

FIG. 3Fdepicts a further example of a core38ethat is substantially similar to core38bofFIG. 3Cwith the exception that, after being folded the second time, core38eis die cut or otherwise trimmed to remove the outer pair of folds.

While each ofFIGS. 3A-3Fdepict a single longitudinal channel94, other embodiments of the present cores and pads including such cores may include multiple longitudinal channels, a single lateral channel, or multiple lateral channels.

Referring now toFIGS. 4 and 5,FIG. 4depicts a perspective view of pad10shown in combination with an undergarment100worn by a wearer, andFIG. 5depicts a cross-sectional view of a portion of female anatomy with pad10positioned for use and shown in a longitudinal cross-section. As shown, undergarment100includes a waist band104, a front or crotch portion108, and a rear portion112. As also shown, pad10is positioned in crotch portion108with anterior end46facing forward. As shown inFIG. 5, pad10is shaped to permit posterior end50to extend to a point that is behind a wearer's urethra116but not all the way behind the user's vagina120. For example, posterior end50may not extend under the user's vagina at all, or may extend only part of the way under the user's vagina.

As also described in more detail below, pad10is shaped such that anterior end46and, specifically maximum width18of pad10, contours to a wearer's legs to resist rearward movement of the pad relative to the wearer, while posterior end50of the pad extends rearward under the wearer's urethra but not under the entirety of the wearer's vagina. For example, in the depicted embodiment of pad10, posterior end50is sized to not extend under any portion of the wearer's vagina. By configuring pad10to avoid posterior end50from, in use, extending under the entirety of the wearer's vagina, the size of pad10is reduced relative to prior art pads, resulting in reduced bunching and increased wearer comfort. This purpose can be achieved, for example, by selecting the ratio of length14relative to maximum width18and the position of maximum width18relative to anterior end46. For example, in some embodiments, length14is 1 to 2.5 times maximum width18, and/or maximum width18can be disposed at a distance from anterior end46that is 1% to 25% of length14. In the embodiment shown inFIGS. 1A and 1B, length14is 1.75 to 2.25 times maximum width18, and maximum width18is disposed at a distance78from anterior end46that is 15% to 20% of length14.

FIG. 6depicts a top plan view of a second embodiment10bof the present pads. Pad10bis substantially similar to pad10, with the exception that certain aspects of the shape of pad10bdiffer relative to pad10. For example, pad10bhas a different ratio of length14to maximum width18, maximum width18is disposed closer to anterior end46, and the left and right side segments of pad10binclude straight lines instead of arcs. Specifically, length14of pad10bis 1 to 1.5 times maximum width18, and maximum width18is disposed at a distance78from anterior end46of 5%-10% of length14of the pad. Additionally, in the embodiment shown inFIG. 6, perimeter50pad10bincludes a left side segment that is a straight line extending between points P1and P5, and a right side segment that is a straight line extending between points P3and P6.

FIG. 7depicts a top plan view of a third embodiment10cof the present pads. Pad10cis substantially similar to pad10b, with the exception that pad10cincludes a pocket200defined at or over at least a portion of posterior end50to assist with temporarily retaining liquid while the liquid is absorbed by the absorbent core. Specifically, in the embodiment shown, a first portion204of backsheet30on a left side of the pad is folded over posterior end50, and a second portion208of backsheet30on a right side of the pad is folded over posterior end50, such that the first and second portions204,208of the backsheet cooperate with topsheet34to define pocket200extending from posterior end50and opening toward anterior end46of the pad. First portion204can, for example, be bonded to second portion208, such as via adhesive, one or more ultrasonic bonds, and/or the like, to retain the pocket shape.

FIGS. 8A and 8Bdepict an embodiment of the present methods for forming the pad ofFIG. 7. In this embodiment, a sheet300of material forming backsheet30is oversized relative to perimeter54cof the pad, and sheet300is folded along lines304a-1,304a-2, as indicated by arrows308, such that the folded portions of sheet300overlap each other and the posterior end of the core as shown inFIG. 8B. Sheet300is coupled, for example bonded with adhesive, to topsheet34in the region between perimeter54cand core38but left unattached over core38to define a “cup” or “pocket” between the sheet300and topsheet34; and sheet300is cut, for example die cut, along perimeter54cto define the pad.

FIGS. 9A and 9Bdepict a second embodiment of the present methods form forming a first alternate configuration of the present pads with a posterior pocket. In this embodiment, a sheet300aof material forming backsheet30is oversized relative to perimeter54dof the pad, and sheet300ais folded along lines304b-1,304b-2, as indicated by arrows308, such that the folded portions of sheet300aeach overlap a portion of the posterior end of the core, and such that the folded portions of sheet300aabut each other, as shown inFIG. 9B. Sheet is coupled, for example bonded with adhesive, to topsheet34in the region between perimeter54dand core38but left unattached over core38to define a “cup” or “pocket” between the sheet300and topsheet34; and sheet300ais cut, for example die cut, along perimeter54dto define the pad.

FIGS. 10A and 10Bdepict a second embodiment of the present methods form forming a second alternate configuration of the present pads with a posterior pocket. In this embodiment, a sheet300bof material forming backsheet30is oversized relative to perimeter54eof the pad, and sheet300bis folded along a single line304c, as indicated by arrow308, such that the folded portion of sheet300boverlaps the posterior end of the core, as shown inFIG. 10B. Sheet300bis coupled, for example bonded with adhesive, to topsheet34in the region between perimeter54eand core38but left unattached over core38to define a “cup” or “pocket” between the sheet300and topsheet34; and sheet300bis cut, for example die cut, along perimeter54eto define the pad.

FIGS. 11A-11Fdepict plan views of designs upper and lower sides of the present pads. In each ofFIGS. 11A-11E, dashed lines do not comprise part of the respective design depicted; i.e., dashed lines depict features that are not required for the design. For example, in the design ofFIG. 11F, the release liner may have only a single piece. In some embodiments of the present pad designs, any one of the designs of an upper or lower designsFIGS. 11A-11Fmay stand alone, in which case an individual design does not include opposing side. In other embodiments of the present pad designs, a design of an upper side of any ofFIGS. 11A-11Dmay also include a design of a lower side of any ofFIGS. 11E-11F.