Abstract:
A disposable absorbent article, and a method of manufacture of the disposable absorbent article, which better contains fecal material within the article, and which prevents leakage of fecal material out of the article, and/or prevents movement of fecal material from the anal region to the genital region is described herein. The absorbent article utilizes barrier cuffs, an absorbent core, and a topsheet with at least one cut in the intermediate region of the absorbent article such that part of the intermediate region of the topsheet is lifted out of the plane of the rest of the topsheet by the barrier cuffs. The lifted portion forms a transverse barrier and a pocket between the topsheet and the absorbent core.

Description:
The present invention relates to absorbent articles such as disposable diapers, and more particularly to absorbent articles having barrier means for the containment of fecal matter. The invention also relates to methods of manufacture of the absorbent articles having barrier means for the containment of fecal matter. 
     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 into 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&#39;s leg or waist. Fecal material that is not absorbed by the absorbent article can work its way past the gaps in the article in the legs or waist of the wearer. 
     Contemporary disposable diapers have a front waist region, a rear waist region and an intermediate region between the front and rear waist regions; these regions being located within a front waist edge, a rear waist edge, and two longitudinal edges. Contemporary diapers comprise a liquid pervious topsheet, a liquid-impervious backsheet, and an absorbent core positioned between the topsheet and the backsheet. 
     Disposable diapers may also be provided with barrier cuffs which inhibit fecal material or gushes of urine or liquids from soiling the wearer&#39;s clothing The barrier cuffs restrain the free flow of this material to hold such material within the diaper. U.S. Pat. No. 4,743,246, issued on May 10 th  1988, discloses an absorbent article having barrier cuffs. 
     Various prior art patent applications have disclosed a cut-out hole in the top sheet to provide a means for fecal material to be held within the disposable diaper, behind the topsheet and out of contact with the wearer&#39;s skin. In some of these patent applications an elastic strip is used to apply tension to a region around the cut-out hole in order to maintain an open aperture. Usually the elastic strips are attached directly to the topsheet, usually to the side of the topsheet which faces away from the body of the wearer. For example U.S. Pat. No. 4,662,877, published on May 5 th  1987 discloses a topsheet with an aperture in the central crotch region of the diaper with zones of elastication in the topsheet tending to apply tensioning forces to the topsheet for urging it away from the underlying absorbent core. EP-A-0 357 298, published on 7 th  Mar. 1990; EP-A-0 486 006, published on 20 th  May 1992; and GB-A-2 328 158, published on 17 th  Feb. 1999, also teach various means of applying elastic tensioning forces to the topsheet in order to maintain an open aperture. 
     It is an object of the present invention to provide a disposable absorbent article, and a method of manufacture of the disposable absorbent article, which better contains fecal material within the article, and which prevents leakage of fecal material out of the article, and/or prevents movement of fecal material from the anal region to the genital region. The absorbent article comprises a barrier cuff adjacent to the longitudinal edges of the disposable absorbent article, each barrier cuff having a proximal edge and a distal edge; and spacing means associated with each barrier cuff distal edge so that the distal edge is spaced away from the top surface of the topsheet. 
     SUMMARY OF THE INVENTION 
     The object of the present invention is achieved by means of a top sheet comprising at least one cut in the intermediate region, each cut extending from a first cut end to a second cut end between barrier cuffs, wherein the topsheet adjacent to each of the cut ends is attached to the barrier cuff between the proximal edge and the distal edge, so that a part of the intermediate region of the topsheet is lifted out of the plane of the rest of the topsheet by means of the barrier cuffs to form at least one transverse barrier and a pocket between the topsheet and the absorbent core. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of a disposable absorbent article in a flat-out state, with a cutaway view, made according to the present invention. 
     FIG. 2 is a cross-section of a barrier cuff suitable for use in the absorbent article shown in FIG.  1 . 
     FIG. 3 is a perspective view of a disposable absorbent article of FIG. 1 which is no longer in a flat-out state. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As used herein, the term “disposable 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, and 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 term refers to sanitary products including catamenial products, but in particular the term refers to diapers and adult incontinent pants. As used herein the term “diaper” refers to a garment generally worn by infants and incontinent persons that is worn about the lower torso of the wearer, and this term is used to exemplify most preferred disposable absorbent articles. Whilst the term “diaper” is used to exemplify the invention, it is not intended to be limiting. 
     A diaper  20  according to the invention is shown in FIG. 1 in a flat-out state, with portions of the structure being cut-away to more clearly show the construction of the diaper  20 . The portion of the diaper  20  which faces the wearer is oriented towards the viewer. As shown in FIG. 1, the diaper comprises a liquid pervious topsheet  24 , the top surface of the topsheet  24  being designated  25 ; a liquid impervious backsheet  26 ; an absorbent core  28 , which is preferably positioned between at least a portion of the topsheet  24  and the backsheet  26 ; a fastening system generally designated  40 ; gasketing cuffs each comprising a side flap  58  and flap elastic members  32 . The diaper further comprises barrier cuffs  62  each having a proximal edge  64 , a distal edge  66 , and spacing means  76  (shown in FIG. 2) such as a spacing elastic member  77  for spacing the distal edge  66  away from the topsheet top surface  25 . The barrier cuffs  62  further comprise, as shown in FIG. 2, an inboard surface  68  and an outboard surface  70 . The diaper may further comprise a liquid handling structure  29  which is preferably positioned between the topsheet  24  and the absorbent core  28 . 
     The diaper  20  is shown in FIG. 1 to have a front waist region  36 , a rear waist region  38  opposed to the front waist region  36  and an intermediate region  37  located between the front waist region and the rear waist region. The diaper  20  further has a first region  81  juxtaposed with the front of the wearer while the diaper  20  is being worn and a second region  82  opposed to the first region  81  and juxtaposed with the back of the wearer while the diaper  20  is being worn. The periphery of the diaper  20  is defined by the outer edges of the diaper  20  in which the longitudinal edges  50  run generally parallel to the longitudinal centerline  100  of the diaper  20  and the end edges  52  run between the longitudinal edges  50  generally parallel to the transverse centerline  110  of the diaper  20 . In FIG. 1 the first region  81  is shown as extending from one end edge  52  to the transverse centerline  110  and the second region  82  is shown as extending from the opposing end edge  52  to the transverse centerline  110 . For purposes of discussion, the transverse centerline  110  is shown as the boundary between the first region  81  and the second region  82  in FIG.  1 . However, the boundary between the first region  81  and the second region  82  may be positioned at other locations, for example closer to one of the respective end edges  52 . The first region  81  being juxtaposed with the front of the wearer should be superior in the handling of urine. The second region being juxtaposed with the back of the wearer should be superior in the handling of faecal material, in particular low-viscosity faecal material. 
     The chassis  22  of the diaper  20  comprises the main body of the diaper  20 . The chassis  22  comprises at least a portion of the absorbent core  28  and preferably an outer covering layer including the topsheet  24  and the backsheet  26 . If the absorbent article comprises a separate holder and a liner, the chassis  22  generally comprises the holder and the liner. (For example, the holder may comprise one or more layers of material to form the outer cover of the article and the liner may comprise an absorbent assembly including a topsheet, a backsheet, and an absorbent core. In such cases, the holder and/or the liner may include a fastening element which is used to hold the liner in place throughout the time of use). For unitary absorbent articles, the chassis  22  comprises the main structure of the diaper with other features added to form the composite diaper structure. 
     FIG. 1 shows an embodiment of the diaper  20  in which the topsheet  24  and the backsheet  26  have length and width dimensions generally larger than those of the absorbent core  28  and the liquid handling structure  29 . The topsheet  24  and the backsheet  26  extend beyond the edges of the absorbent core  28  to thereby form the periphery of the diaper  20 . 
     While the topsheet  24 , the backsheet  26 , and the chassis  22  may be assembled in a variety of well known configurations, preferred diaper configurations are described generally in U.S. Pat. No. 3,860,003 entitled “Contractible Side Portions for Disposable Diaper” which issued to Kenneth B. Buell on Jan. 14, 1975; and U.S. Pat. No. 5,151,092 issued to Buell on Sep. 9, 1992; and U.S. Pat. No. 5,221,274 issued to Buell on Jun. 22, 1993. Other suitable diaper chassis designs, are disclosed in U.S. Pat. No. 5,569,232 entitled “Absorbent Article With Multiple Zone Structural Elastic-Like Film Web Extensible Waist Feature” which issued to Roe et al. on Oct. 29, 1996; U.S. Pat. No. 5,554,144 entitled “Absorbent Article With Multiple Zone Structural Elastic-Like Film Web Extensible Waist Feature” which issued to Roe et al. on Sep. 10, 1996; U.S. Pat No. 5,554,143 entitled “Absorbent Article With Multiple Zone Structural Elastic-Like Film Web Extensible Waist Feature” which issued to Roe et al. on Sep. 10, 1996; U.S. Pat. No. 5,554,145 entitled “Absorbent Article With Multiple Zone Structural Elastic-Like Film Web Extensible Waist Feature” which issued to Roe et al. on Sep. 10, 1996; U.S. Pat. No. 5,556,394 entitled “Absorbent Article With Multiple Zone Structural Elastic-Like Film Web Extensible Waist Feature” which issued to Roe et al. on Sep. 17, 1996. Each of these references is hereby incorporated by reference herein. 
     The inner surface of the diaper  20  comprises that portion of the diaper  20  which is adjacent to the wearer&#39;s body during use (i.e. the inner surface generally is formed by at least a portion of the topsheet  24  and other components joined to the topsheet  24 ). The outer surface comprises that portion of the diaper  20  which is positioned away from the wearer&#39;s body (i.e., the outer surface generally is formed by at least a portion of the backsheet  26  and other components joined to the backsheet  26 ) during use. 
     The barrier cuff  62  is preferably formed by fixing portions of a barrier cuff member to the backsheet  26  or topsheet  24  adjacent the longitudinal edge  50  of the diaper  20  with attachment means  88  such as adhesive or by pressure bonding; a leakage resistant seal being formed by the attachment means  88 , the barrier cuff  62  and the backsheet  26  or topsheet  24 . The barrier cuff comprises a proximal edge  64  and a distal edge  66 . The proximal edge  64  is preferably formed inboard of the elasticised leg cuff  32 , preferably between the elasticised leg cuff  32  and the side edge of the absorbent core  28 , by adjoining a segment of the barrier cuff to the backsheet  26  or topsheet  24  by edge attachment means such as an adhesive bead so as to form a leakage resistant seal along the proximal edge  64 . The distal edge  66  is disposed inboard of the proximal edge  64  and is not secured to any underlying elements of the diaper  20 . As shown in FIG. 2, the distal edge  66  can be formed by folding the end of the barrier cuff member back upon itself and securing it to another segment of the barrier cuff member by the distal attachment means to form a tunnel. A spacing means  76  such as a spacing elastic member  77  is enclosed in the tunnel that is formed when the end of the barrier cuff member is folded back upon itself; the spacing elastic member  77  being secured in the barrier cuff by the spacing elastic attachment means. The distal edge  66  is thus spaced away from the top surface  25  of the topsheet by the elastic gathering action of the spacing elastic members  77 ; a channel thereby being formed by at least the first proximal edge  64 , the first distal edge  66  and the inboard surface  68  of the barrier cuff  62 . 
     FIG. 1 shows two cuts  90  extending transversely across the topsheet  24  between barrier cuffs  62  (only part of the barrier cuffs  62  are shown for clarity). In this embodiment the cuts  90  extend beyond the first and second ends by means of oblique cuts extending generally in the direction of the respective end edges  52 . 
     FIG. 3 shows a pocket  94  between the topsheet  24  and a liquid handling component  29 , such as an acquisition layer. The pocket  94  is formed by cutting in the transverse direction across the top sheet  24  between the barrier cuffs  62  to form first and second cut ends  91 ,  92 . The first and second cut ends  91 ,  92  are then attached to the adjacent barrier cuffs  62 . In use, the barrier cuffs  62  cause a part of the topsheet  24  which is adjacent to the cut  90  to be lifted out of the plane of the rest of the topsheet  24 . This creates a transverse barrier and an adjacent aperture in the top sheet  24  promoting the passage of fecal material through the aperture and into the pocket  94  formed between the topsheet  24  and the acquisition layer  29 . 
     The topsheet comprises at least one cut in the intermediate region, and in preferred embodiments, the topsheet comprises two cuts in the intermediate region. When two cuts are used they are preferably substantially parallel and spaced from 2 mm to 150 mm apart, preferably from 30 mm to 80 mm apart. 
     In a preferred embodiment of the present invention the first and second cut ends lie at opposite ends of an essentially straight cut oriented transversely across the absorbent article. Alternatively, additional cuts at the first and second cut ends may be used to form at least one U-shaped cut (as shown in FIG.  1 ), or even at least one H-shaped cut. These additional cuts may be oriented obliquely, or substantially longitudinally. In still another alternative a hole may be cut-out of the topsheet, although preferably no material is cut out of the topsheet in order to avoid waste of material. In still another alternative embodiment the topsheet may be assembled from at least two separate components which are assembled adjacent to each other, or with a gap between them so that the two edges of adjacent topsheet components form the cut or hole. 
     According to various different embodiments of the present invention the barrier cuffs can, for example, be straight and mutually parallel, straight and mutually non-parallel (i.e. at an angle relative to each other), the barrier cuffs can be either straight or curved; either continuous or intermittent. 
     The topsheet adjacent to each of the first and second cut ends is attached adjacent to the distal edge of the barrier cuff by any convenient attachment means, for example, by gluing, ultrasonic welding, pressure bonding, thermal bonding (such as hot air seaming). 
     Preferably, the absorbent article further comprises a means for preventing the absorbent core, or elements of the absorbent core, from passing through the top sheet cut; more preferably the means comprises a liquid handling structure positioned between the topsheet and the absorbent core. Most preferably the web of absorbent material is an acquisition layer. 
     A pocket is formed between the topsheet and the acquisition layer of the absorbent core. Furthermore, the barrier leg cuff and the top sheet are separate components which are cooperatively attached in order to lift a part of the topsheet out of the plane of the topsheet so as to form the transverse barrier. Additional means may also be used to give the pocket a desired shape, and also to keep the pocket open in order to receive fecal material. For example swelling materials may be disposed along the sides of the pocket which, when wetted, absorb and retain liquid. Suitable swelling materials are absorbent gelling materials. These materials, optionally blended with other materials such as cellulose fluff, may be retained in “bags” which are suitably disposed within, or adjacent to, the pocket. When the swelling materials are wetted, for example by urine, the absorbent gelling materials absorb and retain the liquid making the “bag” more rigid. The rigidity of the “bag” comprising the swelling material contributes to holding the pocket open.