Absorbent article having containment flaps with receiving reservoirs

An absorbent article includes an absorbent core located between a bodyside liner and an outer cover. A containment flap is joined to the bodyside liner. A reservoir wall attaches to the containment flap and a base structure comprising, in combination, the bodyside liner and an outer cover. Passageways in the containment flaps allow exudates to flow from the region between the flaps and into a reservoir defined outwardly from the containment flap. In one embodiment, a surface near the outer edge of the reservoir wall is attached to the bodyside liner. In another embodiment, the reservoir wall attaches to the outer cover of the absorbent article. In yet another embodiment, the reservoir wall attaches to the containment flap, first near a distal edge thereof, and secondly near the base of the containment flap.

BACKGROUND OF THE INVENTION 
1. Technical Field 
The present invention relates to an absorbent article for receiving body 
exudates. Such absorbent articles may have containment flaps for impeding 
or containing spread or flow of the body exudates. 
2. Description of the Related Art 
Absorbent articles such as infant diapers, training pants, adult 
incontinence products, and the like are well known. Such articles have 
achieved a wide acceptance due to their ability to receive and absorb body 
exudates. In order to move bowel movements and other exudates away from 
the user's body, the prior art has considered utilizing an aperture in the 
center of the absorbent article. 
For example, U.S. Pat. No. 4,892,536 to DesMarais et al. discloses a diaper 
with a large passageway in the center section of the bodyside liner to 
facilitate movement of solid and semi-solid waste materials away from the 
user's body. This arrangement was supposed to reduce contact of the waste 
with the skin of the wearer. 
Freeland, U.S. Pat. No. 4,990,147 and Freeland et al., U.S. Pat. No. 
5,269,775 are other patents that disclose similar attempts to prevent 
solid waste materials from contacting a wearer of a diaper. 
The patents listed above all attempt to place the solid waste in direct 
contact with the absorbent core through a relatively large opening 
centrally located in the bodyside liner. Accordingly, the solid waste 
occupies a reservoir, centrally located in the absorbent article, between 
the bodyside liner and the absorbent core. There is no teaching of 
modifying any containment flaps to provide a path or direction for 
exudates to travel transversely across the length or width of the 
absorbent article to a receiving reservoir at or adjacent the outer 
perimeter of the absorbent article. Further, the aperture location shown 
in the above patents may not readily collect an overflow of urine. The 
sudden presence of a large quantity of urine was not addressed by these 
patents. 
SUMMARY OF THE INVENTION 
In order to improve the leakage protection of a diaper, the present 
invention modifies one or more containment flaps of an absorbent article 
by providing passageways or openings, preferably near the base of the 
flaps that lead into a receiving reservoir, at or adjacent the outer 
perimeter of the absorbent article. The reservoir receives urine, fecal 
material or other exudates which travel through the openings e.g. as 
pressure builds from a pool against the flap. The openings in the 
containment flaps thus prevent the exudates from leaking over or around 
the containment flaps by providing an alternative path for releasing the 
pressure against the containment flaps. 
In one aspect, the present invention resides in an absorbent article having 
a front portion, a rear portion and a crotch portion connecting the front 
and rear portions, the crotch portion having opposite longitudinal side 
portions. The absorbent article includes a base structure, the base 
structure comprising, in combination, a liquid-permeable bodyside liner 
and an outer cover. An absorbent core is located between the bodyside 
liner and the outer cover. A containment flap is joined to the bodyside 
liner and includes at least one passageway formed through the containment 
flap. A reservoir wall is attached to the flap and the base structure to 
form a reservoir for exudates. 
Another embodiment of the invention resides in an absorbent article having 
a front portion, a rear portion and a crotch portion connecting the front 
and rear portions, the crotch portion having opposite longitudinal side 
portions. The absorbent article includes a base structure, the base 
structure comprising, in combination, a liquid-permeable bodyside liner 
and an outer cover. An absorbent core is located between the bodyside 
liner and the outer cover. First and second longitudinally extending leg 
cuffs are located in the crotch portion at oppositely disposed 
longitudinal side portions thereof. The absorbent article also includes a 
pair of containment flaps containing at least one passageway and extending 
longitudinally from the front portion to the rear portion of the article, 
the flaps being joined to the bodyside liner. Respective first and second 
reservoir walls are attached to a respective one of the containment flaps 
at corresponding first loci. A second locus of each reservoir wall is 
attached to the base structure at a position disposed outwardly from the 
respective containment flap and inwardly from the outer edge of the 
bodyside liner. 
In another embodiment, the reservoir wall may be attached to the outer 
cover outwardly of the flaps. 
In yet another embodiment, the reservoir wall may be attached at the top 
distal end of the containment flap and at the lower base of the 
containment flap. This arrangement forms the reservoir with the 
containment flap and reservoir wall only. 
The passageways may comprise slits, apertures of various shapes, as well as 
breaks in the seams joining the respective containment flaps to the 
bodyside liner. The apertures preferably have an open area of no more than 
about 7 square centimeters for each flap, and preferably have 
cross-sectional areas corresponding to diameters from 5 to 25 millimeters. 
At least one passageway, and preferably at least three passageways are 
contemplated for each containment flap. 
Further, the passageways may be formed by cuts in the containment flaps, 
the cuts being serpentine in configuration and forming serpentine edges, 
and being effected before attachment to the bodyside liner. The serpentine 
edges provide lobes and open or cut-out spaces between the respective 
lobes. The containment flaps are not attached to the liner at these spaces 
when the distal ends of the lobes are bonded or otherwise attached to the 
bodyside liner at intermittent locations. These spaces then comprise the 
passageways referred to earlier. 
Further, the passageways may be formed by cuts in the containment flaps, 
the cuts being zig-zag in configuration and forming zig-zag edges, and 
being effected before attachment to the bodyside liner. The zig-zag edges 
provide teeth and open or cut-out spaces between the respective teeth. The 
containment flaps are not attached to the liner at these spaces when the 
distal ends of the teeth are bonded or otherwise attached to the bodyside 
liner. These spaces then comprise the passageways referred to earlier.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
The present invention relates to absorbent articles designed to absorb body 
exudates. While the preferred embodiments of the present invention will be 
described in terms of a disposable diaper adapted to be worn by infants 
and toddlers about the lower torso, the present invention is equally 
applicable to other absorbent articles such as adult incontinent briefs, 
training pants and the like. 
The present invention can best be understood by a reference to the drawings 
in which like numerals represent like elements. FIG. 1 illustrates a 
diaper 8 suitable for use in the present invention. The diaper 8 of FIG. 1 
shows the containment flaps 10, the passageways 12, the bodyside liner 14 
and the reservoir wall 16. FIG. 1 also shows attachment means, such as 
hook and loop fasteners 18, 20, for securing the diaper upon a child. The 
first fastener 18 comprises a mechanical fastener such as the hook of a 
hook and loop fastening system mounted on the outer cover 22. The second 
fastener 20 then comprises a corresponding loop material attached to the 
outer cover 22 and adapted to releasably engage with the hook material of 
the first fastener 18. Further, other well known fastening means may be 
used to support the diaper 8 upon a person. Also, as shown in FIG. 1, the 
passageways 12 are preferably located at or adjacent the base 23 of the 
containment flaps 10. 
The containment flaps 10 shown in FIGS. 1 and 2 include elasticized 
material 24 to shape and position the flap. The flap material may be 
somewhat permeable. The containment flaps 10 may be joined to the bodyside 
liner by heat sealing, sonic bonding, adhesive bonding or the like. 
Adhesive bonding includes the use of glue lines, glue dots or other 
arrangements. 
Containment flaps 10 may include flap elastics 24 as shown in FIG. 2. These 
flap elastics may suitably comprise one or more individual strands of 
elastomeric material. For example, a plurality of elastic strands may be 
configured in a spatially separated, generally parallel arrangement. The 
elastic strands can be distributed over the full width of the flap and 
formed of a rubber material. The elastic strands may also be placed in an 
intermediate position or fold of the containment flap 10 in a lengthwise 
direction. The elastic strands may run the entire length of the 
containment flap 10 or only a portion of the length of the containment 
flap near the crotch of the diaper 8. A suitable elastic strand may, for 
example, be composed of a 470 decitex LYCRA.RTM. elastomer, 620 decitex 
LYCRA.RTM. elastomer or other elastomers with suitable characteristics. 
Flap elastics 24 are preferably integrated into containment flaps 10 at 
least adjacent the distal edge 26 of the respective containment flap 10 
and remote from bodyside liner 14 in a stretched condition such that the 
contraction of the elastic components thereof gathers and shortens the 
distal edge 26 of the containment flap 10 from the fully extended 
condition. As a result, the distal edge 26 of the containment flap 10 
tends to position itself in a spaced relation away from the bodyside liner 
14 toward a generally upright and approximately perpendicular 
configuration in especially the crotch portion of the diaper as shown in 
FIGS. 2, 5 and 6. 
Leg cuffs 28 are suitably formed by portions of the outer cover 22 and/or 
the bodyside liner 14, which extend transversely beyond the longitudinal 
sides of the absorbent core 30. The leg cuffs 28 may also be formed from 
separate materials which are attached to the outer cover 22 and/or the 
bodyside liner 14. Leg cuffs 28 include leg elastics 32. Materials 
suitable for forming leg elastics 32 include strands or ribbons of a 
polymeric, elastomeric material which are adhered to the diaper 8 at the 
leg cuff 28 while in a stretched position, or which are attached to the 
diaper 8 while the diaper is pleated, such that elastic constrictive 
forces are imparted to the leg cuff 28. Further, the leg elastics 32 shown 
in FIGS. 2 and 5 may be made of a material similar or identical to the 
flap elastics 24. 
The containment flaps 10 may be constructed of a material which is the same 
as, or different than the material comprising bodyside liner 14. 
Alternatively, the containment flaps 10 may also be made from a material 
which is the same as the material of outer cover 22. The containment flaps 
10 are preferably liquid impervious. The containment flap 10 may be formed 
from a polymeric film material or from e.g. a nonwoven material which is 
substantially liquid impervious. The containment flaps 10 may be formed by 
a single or multiple layer of material with appropriate elastics secured 
thereto as shown in FIG. 5. FIGS. 2, 5 and 6 show the presence of the 
elastics 24 in the containment flap. Other arrangements are also 
contemplated. For example, the elastics may be placed at multiple 
locations on the containment flap 10. 
A suitable bodyside liner 14 may be manufactured from a wide selection of 
web materials, such as porous foams, reticulated foams, apertured plastic 
films or natural fibers. For example, the bodyside liner 14 may comprise 
wood or cotton fibers. Other possible materials are synthetic fibers, such 
as polyester or polypropylene fibers, or a combination of natural and 
synthetic fibers. Bodyside liner 14 is suitably utilized to help isolate 
the liquids held in the absorbent core 30 from the wearer's skin. 
Various woven and nonwoven fabrics may be used for bodyside liner 14. For 
example, bodyside liner 14 may be composed of a meltblown or spunbonded 
web of polyolefin fibers. The bodyside liner may also comprise a carded 
and/or bonded web composed of natural and/or synthetic fibers. The 
bodyside liner may also be composed of a substantially hydrophobic 
material wherein the hydrophobic material is treated with a surfactant or 
otherwise processed to impart a desired level of wettability and 
hydrophilicity. In a particular embodiment of the present invention, the 
bodyside liner 14 may comprise a nonwoven, spunbond, polypropylene fabric 
composed of about 2.8-3.2 denier fibers formed into a web having a basis 
weight of about 22 grams per square meter and a density of about 0.06 
grams per cubic centimeter. The fabric is then surface treated with about 
0.28 weight percent of a surfactant. The bodyside liner 14 may comprise a 
multiplicity of components or layers which correspond to any of the 
materials disclosed herein, as well as others known in the art. 
It is generally preferred that the outer cover 22 of the diaper 8 be formed 
from a material which is substantially impermeable to liquids. A typical 
outer cover 22 may be manufactured from a thin plastic film or other 
flexible liquid-impermeable material. For example, the outer cover 22 may 
be formed from a polyethylene film having a thickness of from about 0.012 
millimeters to about 0.051 millimeters. If the outer cover 22 should have 
a more clothlike feeling, it may comprise a polyethylene film laminated to 
a surface of a nonwoven web, such as a spunbond web of polyolefin fibers. 
For example, a polyethylene film having a thickness of about 0.015 
millimeters may have thermally laminated thereto a spunbond web of 
polyolefin fibers having a thickness from 1.5 to 2.5 denier per filament, 
which nonwoven web has a basis weight of about 24 grams per square meter. 
Further, the outer cover 22 may be formed of a woven or nonwoven fibrous 
web which has been totally or partially constructed or treated to impart a 
desired level of liquid impermeability to selected regions that are 
adjacent or proximate the absorbent core 30. Still further, the outer 
cover 22 may optionally be composed of a microporous material which 
permits vapors to escape from the absorbent core 30 while still preventing 
liquid exudates from passing through the outer cover 22. The outer cover 
22 and bodyside liner 14, in combination form a base structure 33 for the 
diaper 8. 
The absorbent core 30 suitably comprises a matrix of hydrophilic fibers, 
such as a web of cellulosic fluff, in combination with a high-absorbency 
material commonly known as superabsorbent material. In a particular 
embodiment, absorbent core 30 comprises a mixture of superabsorbent 
hydrogel-forming particles and wood pulp fluff. In place of the wood pulp 
fluff, one may use synthetic, polymeric, meltblown fibers or a combination 
of meltblown fibers and natural fibers. The superabsorbent material may be 
substantially homogeneously mixed with the hydrophilic fibers or may be 
otherwise combined into the absorbent core. 
Alternatively, the absorbent core 30 may comprise a laminate of fibrous 
webs and superabsorbent material or other suitable means of maintaining a 
superabsorbent material in a localized area. 
The absorbent core 30 may have any of a number of shapes. For example, the 
absorbent core may be rectangular, I-shaped or T-shaped. It is generally 
preferred that the absorbent core 30 be narrower in the crotch portion 
than the rear or front portion. 
The high-absorbency material in the absorbent core 30 can be selected from 
natural, synthetic and modified natural polymers and materials. The high 
absorbency materials can be inorganic materials, such as silica gels, or 
organic compounds, such as crosslinked polymers. The term crosslinked 
refers to any means for effectively rendering normally water-soluble 
materials substantially water insoluble but swellable. Such means can 
include, for example, physical entanglement, crystalline domains, covalent 
bonds, ionic complexes and associations, hydrophilic associations such as 
hydrogen bonding, and hydrophobic associations or Van der Waals forces. 
The top edges (See FIGS. 2 and 5) of the reservoir walls 16 are preferably 
attached to the containment flaps 10 at or near the distal edges 26 of the 
containment flaps 10 and away from the bodyside liner 14. The reservoir 
walls can be formed of materials similar to those contained in the outer 
cover 22. The reservoir walls 16 preferably are formed of an impermeable 
nonwoven material or film, and/or combination of the two. Examples of 
materials for the reservoir walls 16 include a polyethylene film having a 
thickness of about 0.012 millimeters or a polyethylene film thermally 
laminated to a spunbond web of polyolefin fibers. The reservoir walls 16 
are also preferably attached to the base structure 33 outwardly from the 
containment flap 10 and toward the outer edge of the diaper 8 as shown in 
FIGS. 2 and 5. This arrangement forms a reservoir 34 to receive exudates. 
At a first locus of attachment, a first surface of a reservoir wall 16, 
near an upper edge 35 thereof, is bonded or attached to a corresponding 
surface of the respective containment flap 10 near the distal edge 26. The 
lower edge 36 of the reservoir wall 16 is attached to the base structure 
33 and/or containment flap 10 near base 23. For instance, a surface near a 
lower edge 36 of the reservoir wall 16 is attached to a corresponding 
surface of the base structure 33. Therefore, the reservoir wall 16 is 
attached to the containment flap 10 and base structure 33 to thereby form 
the reservoir 34. 
This arrangement allows urine and/or fecal material and the like to travel 
through the passageway 12, including in response to pressure against the 
containment flap 10. The exudates are then received by the reservoir 34 
formed between the reservoir wall 16, the containment flap 10, and 
optionally the base structure 33. In general, the exudates pass through 
the passageway 12 into reservoir 34 in preference to leaking past or over 
the containment flaps 10. The reservoir wall 16 may be attached to the 
containment flap 10 and base structure 33 by sewing, heat sealing, sonic 
bonding, adhesive bonding or the like. 
The passageways 12 of a containment flap 10 are large enough that a runny 
bowel movement and/or urine may pass through, but small enough to avoid 
entrapment of body parts. The passageways 12 may comprise slits, apertures 
of various shapes, as well as interruptions in the joinder between the 
containment flap and the bodyside liner. The apertures of passageways 12 
may have a total combined open area from 0.1 to 7 square centimeters for 
each containment flap 10. Preferably each aperture has an open area 
corresponding to a cross-sectional area of a diameter from about 5 to 
about 25 millimeters. Preferably each individual aperture is no greater 
than 0.5 square centimeters to avoid any possibility of penile 
strangulation. Slits may have a length from about 5 to about 25 
millimeters. Preferably, the slits are less than 12 millimeters long to 
avoid any possibility of penile strangulation. In most instances, all of 
the apertures combined, have a total open area for both containment flaps 
10 of no greater than 12 square centimeters. The passageways 12 may be 
intermittently spaced the entire length of the containment flap 10 as 
shown in FIG. 1 or may be confined to a targeted area. One such area would 
be along the back portion of the flap to collect exudates from bowel 
movements. A preferred area for the passageways 12 is along the base or 
bottom 23 of the containment flap 10 near the bodyside liner 14 as shown 
in FIG. 1. 
While any number of passageways may be effective with respect to 
applicant's invention, preferably at least three passageways are present 
in each containment flap 10. 
The passageways 12 may be formed by cutting a single piece of material into 
two containment flaps 10 in a zig-zag manner as shown in FIGS. 3 and 3a. 
After the cut is completed, two containment flaps with zig-zag edges are 
created from one piece of material as shown in FIG. 3a. Then, the distal 
portions 38 of the teeth 40 formed by the zig-zag edges of each 
containment flap 10 are sewn, bonded, or otherwise attached, preferably 
longitudinally onto the bodyside liner 14 at intermittent locations. When 
the containment flaps 10 are attached, open spaces 42 between the teeth 40 
are left unattached or unbonded. This arrangement forms passageways 12 
from the spaces 42 between the teeth 40 of the containment flaps 10 and 
there is no waste of any piece of the material when forming passageways 
12. 
Further, a serpentine pattern may be cut from a sheet of material as shown 
in FIGS. 4 and 4a. This sheet of material, when cut into two pieces, then 
becomes two containment flaps with serpentine edges. The distal portions 
44 of the lengths or lobes 46 formed by the serpentine edges of each 
containment flap 10 are then sewn, bonded or otherwise attached, 
preferably longitudinally onto the bodyside liner 14 at intermittent 
locations. When the containment flaps 10 are attached, the open spaces 48 
between the lobes 46 are left unattached or unbonded. This arrangement 
forms passageways 12 from the spaces 48 between the lobes 46 of the 
containment flaps 10. The second flap 10 created by edges of the 
serpentine cut is attached in a similar manner. Once again, the spaces 48 
between the lobes 46 of the serpentine pattern then comprise passageways 
12 which allow exudates to travel to the reservoir 34. Forming the flaps 
10 in this manner ensures there is no waste of any piece of the material 
when forming passageways 12. 
While a zig-zag pattern and a serpentine pattern have been illustrated, 
there are an infinite variety of other patterns which also may be 
utilized. The chief criteria for selecting a pattern is to provide the 
proper number of, and dimensions for, passageways 12. 
The volume of the receiving reservoir 34 is controlled, at least in part, 
by the locus at which the upper edge 35 of the reservoir wall attached to 
the containment flap 10 and the locus at which the lower edge 36 of the 
reservoir wall 16 is attached to a surface of the base structure 33 or to 
the base 23 of containment flap 10. Attaching the lower edge 36 of the 
reservoir wall 16 to the outer cover 22 at a surface of the base structure 
33 as shown in FIG. 5 contributes to an increased volume for the reservoir 
34. In the illustrated embodiments, the longitudinal ends of the 
containment flaps 10 are also bonded or otherwise attached to the base 
structure 33. Similarly, the longitudinal ends of reservoir 34 are closed 
by securement of reservoir wall 16 to containment flap 10 along a line 
traversing from generally lower edge 36 to upper edge 35. This arrangement 
forms a reservoir 34 connected via the passageways 12 to the central 
portion 50 of the diaper 8 which may contain a sudden flow of exudates 
which could otherwise leak around or over the containment flaps 10. As 
shown in FIG. 1, central portion 50 extends for a length along the center 
of diaper 8. FIGS. 1 and 2 show bodyside liner 14 positioned between 
containment flaps 10 for contact with the skin of a user. 
Further, as shown in FIG. 5, spacing the reservoir wall 16 outwardly from 
or beyond the leg elastics 32 maximizes the volume capacity of reservoir 
34. This arrangement also allows exudates contained in reservoir 34 to 
pass through the bodyside liner 14 to reach the absorbent core 30. This 
allows more of the exudates to reach the absorbent core 30. In such 
instances where exudates travel first into reservoir 34 and thence to the 
core 30, reservoir 34 acts as a temporary holding locus, holding the 
exudates away from the user's body until liquid portions thereof are 
absorbed by core 30. This increases the efficiency and capability of the 
diaper 8 to operate effectively during a sudden release of exudates 
without leaking. 
The spacing between containment flaps 10, across the central portion 50 of 
the diaper 8 can be varied in accordance with a variety of acceptable 
design parameters. As the containment flaps 10 are spaced closer together 
to minimize the stain area on the buttocks due to a bowel movement, the 
volume available between the flaps 10, absent the invention, to contain 
exudates is reduced. Absent the invention, as exudates fill the pocket in 
the central portion 50 of the diaper, the exudates begin to go over the 
flap, and/or up the back of the diaper. Therefore, the invention shown 
herein reduces the stain area and provides greater comfort to the wearer 
because an alternate path of low resistance is provided for movement of 
exudates through passageways 12 and away from the wearer's skin. With 
respect to urine, the same logic may be applied. A sudden flow of urine 
may be released more rapidly than the core 30 can absorb it. The excess 
urine can pass through passageway 12 to the reservoir 34 and be held there 
until it is absorbed by the absorbent core 30. Once in the reservoir 34, 
the urine can flow back out the passageway 12 to the absorbent core 30, or 
can flow through the bodyside liner 14 directly to the absorbent core 30. 
This arrangement also allows for faster, more efficient absorption by the 
core 30 since urine is contacting a greater surface area of the core. The 
invention may also be arranged so that a portion of the reservoir is 
directly above the absorbent core 30. Such an arrangement requires that 
the containment flaps 10 be placed closer to one another than shown in the 
drawings. 
Another embodiment of the invention is illustrated in FIG. 6. In this 
embodiment, the reservoir wall 16 is attached only to the containment flap 
10. This arrangement may be more simply constructed than the earlier 
embodiments. A first surface of the upper edge 35 of reservoir wall 16 is 
sewn, bonded or otherwise attached near the distal edge 26 of the 
containment flap 10. The opposing surface of the lower edge 36 of the 
reservoir wall 16 is attached near the base 23 of the containment flap 10. 
While the opposing surface of the reservoir wall 16 is shown attached to 
the base of the flap in FIG. 6, either the same or the opposing surface of 
the reservoir wall 16 may provide the attachment which forms reservoir 34. 
Loci on the ends of the reservoir wall 16 are attached to the containment 
flap 10 to form a reservoir 34 sealed except for the passageways 12. 
Those skilled in the art will now see that certain modifications can be 
made to the apparatus and methods herein disclosed with respect to the 
illustrated embodiments, without departing from the spirit of the instant 
invention. And while the invention has been described above with respect 
to the preferred embodiments, it will be understood that the invention is 
adapted to numerous rearrangements, modifications, and alterations, and 
all such arrangements, modifications, and alterations are intended to be 
within the scope of the appended claims.