Patent Description:
Disposable absorbent articles are known in the prior art and have many uses. Whether intended for infants, children, adults or the elderly, disposable pads, napkins, diapers, training pants, briefs, underwear, incontinence articles, hygienic articles and the like are intended to absorb and retain voids, exudate or other body discharges. As used herein, "absorbent article" will refer to these or other examples.

Active adults appreciate the freedom afforded to them by incontinence absorbent articles. Such disposable articles can alleviate some of the emotional and physical discomfort of incontinence by absorbing and containing body discharges. Problems arise, however, when there is a need to carry multiple articles for use over an extended period of time. Multiple such articles can be bulky and require space or be carried in ways that are inconvenient or embarrassing.

While there are variations in the specific structural features of disposable absorbent articles, they are frequently presented to the consumer in the same manner. Essentially, the disposable absorbent article, irrespective of specific structural features, is packaged in a box, bag or carton with a plurality of disposable absorbent articles from which the consumer withdraws the ready-to-use article as needed. When traveling or attending to the activities of daily life, bulk packages as described above are indiscreet and impractical.

Given these and other shortcomings of existing absorbent articles, embodiments of the present invention include an absorbent article, which may particularly include an incontinence pad, that allows the use of a single pad to be used multiple times. Advantages of this embodiment include extending the duration for which the pad may be used and reducing the number and bulk of pads that an individual may need to carry.

<CIT> discloses a disposable absorbent product that includes first and second absorbent assemblies. The first absorbent assembly has a fluid- pervious first topsheet and a fluid- impervious first backsheet in overlaying relationship with one another. The second absorbent assembly is releasably coupled to the first absorbent assembly, and includes a second topsheet and a fluid-impervious second backsheet in overlaying relationship with one another. The second backsheet is adjacent the first topsheet and the second topsheet is configured to face toward the wearer of the product during use. The second topsheet has a fluid-pervious first region and an adjacent fluid-impervious second region that at least hinders the passage of fluid secreted by the wearer of the product there through.

According to an aspect of the invention, there is provided an absorbent article as defined in claim <NUM> hereinafter.

The various aspects, features and advantages of the disclosure will become more fully apparent to those having ordinary skill in the art upon careful consideration of the following Detailed Description thereof with the accompanying drawings described below.

While embodiments of the invention are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood however, that the invention is not intended to be limited to the particular forms disclosed.

Embodiments of the invention are now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims, the following terms take the meanings explicitly associated herein, unless the context clearly indicates otherwise: the meaning of "a," "an," and "the" includes plural reference, the meaning of "in" includes "in" and "on. " Relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.

"Attach" and its derivatives refer to the joining, adhering, connecting, bonding, sewing together, or the like, of two elements. Two elements will be considered to be attached together when they are integral with one another or attached directly to one another or indirectly to one another, such as when each is directly attached to intermediate elements. "Attach" and its derivatives include permanent, releasable, or refastenable attachment. In addition, the attachment can be completed either during the manufacturing process or by the end user.

"Bond" and its derivatives refer to the joining, adhering, connecting, attaching, sewing together, or the like, of two elements. Two elements will be considered to be bonded together when they are bonded directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements. "Bond" and its derivatives include permanent, releasable, or refastenable bonding.

"Connect" and its derivatives refer to the joining, adhering, bonding, attaching, sewing together, or the like, of two elements. Two elements will be considered to be connected together when they are connected directly to one another or indirectly to one another, such as when each is directly connected to intermediate elements. "Connect" and its derivatives include permanent, releasable, or refastenable connection. In addition, the connecting can be completed either during the manufacturing process or by the end user.

"Integral" is used to refer to various portions of a single unitary element rather than separate structures bonded to or placed with or placed near one another.

"Extensible" refers to materials which elongate or increase in at least one dimension when subject to an external pulling force.

"Elastomeric" refers to a material or composite which can be elongated by a percent of its relaxed length and which will recover, upon release of the applied force by a percent of its elongation. In certain embodiments, an elastomeric material or composite may be capable of being elongated by at least <NUM> percent, in further embodiments by at least <NUM> percent of its relaxed length. Embodiments of the elastic material or composite may recover, upon release of an applied force, at least <NUM> percent of its elongation.

These terms may be defined with additional language elsewhere in the specification.

Although the remainder of the description will be specifically directed to adult incontinence articles, including specifically, absorbent pads for placement in a user's undergarment(whether intended for men or women) to absorb bladder leakage, it is understood that the embodiments may also be implemented on other absorbent articles, whether intended for infants, children, adults or the elderly. As would be understood by one of ordinary skill in the art, such non-limiting examples include: disposable pads, napkins, diapers, training pants, and the like which are intended to absorb and retain body discharges.

Referring first to <FIG>, embodiments of the absorbent pad <NUM> comprise a first layer <NUM>, a second layer <NUM>, and a third layer <NUM>. Embodiments of the pad will be described herein having three layers. However, it should be understood that the pad may have more layers.

Each layer of the pad comprises a liquid impervious back sheet <NUM>. The backsheet or outer layer, which faces away from the wearer when the absorbent article is secured to the wearer, is composed of a moisture-impervious, flexible material. Accordingly, backsheet <NUM> may be made of any material suitable to minimize or prevent fluids and other discharge from escaping the pad. Non-limiting examples of suitable materials for the backsheet include polyethylene and/or breathable poly. According to some embodiments, the outer layer can be a thin film such as, for example, polyethylene film. The outer layer may be formed from a plastic resin of any of the above-referenced materials.

In addition, each layer comprises an absorbent core <NUM>. The absorbent core is positioned adjacent the backsheet proximal the wearer. The absorbent core may comprise a single layer or multiple layers. Embodiments of the absorbent core may comprise super absorbent fiber ("SAF"). Alternatively, the absorbent core may comprise super absorbent polymer ("SAP") or a combination of SAF and SAP. Embodiments of the absorbent core <NUM> may further comprise other materials suitable for absorbing the fluids and discharge such as a fibrous material (e.g., fluffed wood pulp). The SAP can be natural or synthetic and may be biodegradable. Non-limiting examples of SAP include polymers based on acrylate(s) such as sodium acrylate, potassium acrylate, and/or an alkyl acrylate(s) (e.g., methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, and hexyl acrylate). The absorbency of the core may vary depending upon whether it is intended for use by infants, children and/or adults. The absorbent core for each layer <NUM>, <NUM>, <NUM>, may vary from layer to layer. For example, the first layer absorbent core may be a thinner SAP, while the second absorbent core may be thicker and SAF.

Embodiments of the core may include an embossed top and/or an embossed bottom. In this manner, the core <NUM> provides increased longitudinal movement of fluid on both the embossed top and embossed bottom of the core <NUM>, and reduced lateral flow, decreasing the potential for leaks from the side of the absorbent article <NUM>.

Each layer may further comprise an inner layer. The inner layer faces a wearer and contacts the skin of the wearer when the absorbent pad <NUM> is secured to the wearer. The inner layer may comprise a topsheet <NUM> that is composed of a moisture pervious fabric suitable to allow bodily discharge to pass through the inner layer and be absorbed by the absorbent layer. Non-limiting examples of materials suitable to form the topsheet <NUM> include polypropylene, polyethylene, polyester, materials having hydrophobic properties, combinations thereof and/or the like. Additionally, the topsheet can be treated with a hydrophilic finish to improve pass through of liquids to diaper layers beneath the inner layer. Non-limiting examples of suitable hydrophilic finishes include stearic acid, melamine-based chemicals, fluorocarbon chemicals, and silicon-based chemicals.

In embodiments of the absorbent pad, tabs <NUM>, <NUM> may extend from, and be coupled to, an edge of the inner layers <NUM>, <NUM>. The tabs <NUM>, <NUM> may be made from the same material that is used for the backsheet, such as, for example, polyethylene and/or breathable poly. The tabs <NUM>, <NUM> can also be a polyethylene film or any soft, pliable material. It will also be appreciated that the tabs may be of any adequate material known in the prior art. The tabs <NUM>, <NUM> may be in similar locations, in line, as shown in <FIG>. Alternatively, the tabs <NUM>, <NUM> may be placed, as shown in <FIG>, with tab <NUM> on the side of third layer <NUM> and tab <NUM> on second layer <NUM> at a distance away from tab <NUM> (not overlaying each other). This can help prevent the wearer from trying to remove the wrong layer. Additionally, the tabs <NUM>, <NUM> may be color coded, such as red and green, to assist the wearer in removing the soiled layers. Not only can color and distance of the tabs <NUM>, <NUM> vary, but the size and shape may also vary. As shown in <FIG>, the tabs <NUM>, <NUM>, have a generally square shape. However, the tabs <NUM>, <NUM> may also be circular, triangular, or any other non-limiting example. The tabs may also be narrower or wider than depicted in <FIG>.

As illustrated in <FIG>, each tab assists the user in removing a single layer from the absorbent pad. For example, as shown in <FIG>, once the top inner layer <NUM> has become soiled or is otherwise in need of replacement, the tab <NUM> may be grasped and the layer <NUM> may be pulled upward, separating it from the underlying layer <NUM>. The underlying layer <NUM> is now exposed for use while remaining attached to the layer <NUM> below. In this manner, each layer may be used successively until the final layer, in this example outer layer <NUM>, is used and finally discarded.

The layers may be attached to one another by various means, such as an adhesive layer. For example, each layer may be adhered to the adjacent layer, such that an outside surface of layer <NUM> is attached to an inside surface of layer <NUM> and an outside surface of layer <NUM> is attached to an inside surface of layer <NUM>. Such adhesion may be accomplished by the adhesive layer positioned between the layers. Such adhesive layer may be a pattern of adhesive dots <NUM> positioned around the perimeter of the layer (<FIG>) or, over some portion or all of the surface of the layer (<FIG>). For example, as illustrated in <FIG>, a series of adhesive dots <NUM> may be applied to the outer surface of the inner layer <NUM> in a spaced apart pattern around the periphery of the layer. These adhesive dots may then attach layer <NUM> to the underlying layer <NUM>. Alternatively, the adhesive layer may be a pattern of adhesive lines <NUM>, as shown in <FIG>, positioned around the perimeter of the layer or cover some portion or all of the surface of the layer. Further, as shown in <FIG>, a continuous adhesive layer <NUM> may be positioned in a continuous fashion around the perimeter of the absorbent pad <NUM> or may cover all of the surface of the layer. In addition, the layers may be attached by ultrasonic welding, hook and loop, or other fastening means.

Further, in an alternate embodiment, the outside surface of the first layer <NUM> may be attached to a wearer's undergarment by various means. For example, a release liner <NUM> (<FIG>) or backing may be adhered to the outside surface of the first layer <NUM>. When a user desires to use the absorbent pad <NUM>, the user would remove the release liner and adhere the absorbent pad to the desired location on their undergarment. It will be appreciated that having an adhesive layer on the outside surface of first layer <NUM> will prevent the absorbent pad from repositioning while a wearer is being active. It can also allow a wearer to remove each layer with only one hand, instead of having to hold the absorbent pad <NUM> with a hand while removing the soiled layer with the other. The adhesive may be applied to the outside surface of the first layer <NUM> in a similar fashion to the outside surface of the second and third layers <NUM>, <NUM>. Specifically, such adhesive may be positioned around the perimeter of the layer, in a pattern of lines or dots, over some portion or all of the outside surface of the first layer <NUM>.

In alternative embodiments, each inner layer may be independently attached to the outer layer. For example, an outer surface of layer <NUM> may be attached to an inner surface of layer <NUM>, and an outer surface of layer <NUM> may be attached to an inner surface of layer <NUM> outside a periphery of layer <NUM> such that layer <NUM> is not directly adhered to layer <NUM>.

Referring back to <FIG>, the layers of the absorbent pad <NUM> are arranged in decreasing size, such that inner layer <NUM> has a smaller area than outer layer <NUM> and innermost layer <NUM> has a smaller area than layer <NUM>. Alternatively, but not in accordance with the invention the layers may progress from smaller to larger in the opposite directions, such that the innermost layer is larger than subsequent outer layers. In a further alternative not in accordance with the invention, the size of the layers may alternate. For example, the middle layer <NUM> may be smaller in diameter than the outer layer <NUM> and inner layer <NUM>. In this manner, the periphery of the inner layer <NUM> could be directly attached to the outer layer <NUM> as described above.

Claim 1:
An absorbent article comprising:
a first layer (<NUM>) comprising:
a first liquid impervious backsheet (<NUM>);
a first absorbent core (<NUM>) positioned adjacent the backsheet (<NUM>) and proximal the wearer; and
a first moisture pervious topsheet (<NUM>);
a second layer (<NUM>) comprising:
a second liquid impervious backsheet (<NUM>);
a second absorbent core (<NUM>) positioned adjacent the backsheet and proximal the wearer;
a second moisture pervious topsheet (<NUM>); and
a second-layer tab (<NUM>) coupled to and protruding from a peripheral edge of the second layer (<NUM>);
a third layer (<NUM>) comprising:
a third liquid impervious backsheet (<NUM>);
a third absorbent core (<NUM>) positioned adjacent the backsheet (<NUM>) and proximal the wearer;
a third moisture pervious topsheet (<NUM>); and
a third-layer tab (<NUM>) coupled to and protruding from a peripheral edge of the third layer (<NUM>);
wherein the second layer (<NUM>) is removably adhered to the first layer (<NUM>) such that the second backsheet contacts the first topsheet;
wherein the third layer (<NUM>) is removably adhered to the second layer (<NUM>) such that the third backsheet contacts the second topsheet;
wherein the second layer (<NUM>) has a smaller area than the first layer (<NUM>); and
wherein the third layer (<NUM>) has a smaller area than the second layer (<NUM>).