U.S. patent number 3,927,673 [Application Number 05/496,492] was granted by the patent office on 1975-12-23 for quilted diaper.
This patent grant is currently assigned to Colgate-Palmolive Company. Invention is credited to Glenn N. Taylor.
United States Patent |
3,927,673 |
Taylor |
December 23, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
Quilted diaper
Abstract
Improved absorbent article for diapers and the like comprising
an outer backing sheet of a water impervious or repellant material,
an optional inner top sheet having fluid passing properties, an
absorbent pad therebetween, and a second water impervious or
repellant interlayer sheet disposed between the top sheet and the
absorbent pad. The interlayer has a plurality of spaced small holes
therethrough. The interlayer and/or inner sheet are bonded directly
to the outer sheet through the large holes in the absorbent pad.
The outer margins of the layers may be sealed together. The
construction shows improved penetration of fluid, substantially
one-way transmission through the interlayer, and permits excellent
spreading by the backing sheet. The bonding through the pad holes
prevents pad shifting and balling in use without requiring a
wadding sheet, and the edge margins around the holes provide added
wicking surface for improved rate of absorption and retention. The
inner sheet is preferably a non-woven material that minimizes skin
contact with the plastic interlayer, providing a smooth hand
surface.
Inventors: |
Taylor; Glenn N. (Cary,
IL) |
Assignee: |
Colgate-Palmolive Company (New
York, NY)
|
Family
ID: |
23972883 |
Appl.
No.: |
05/496,492 |
Filed: |
August 12, 1974 |
Current U.S.
Class: |
604/366; 604/360;
604/370; 604/374; 604/365; 604/372 |
Current CPC
Class: |
A61F
13/537 (20130101); A61F 13/51305 (20130101); A61F
13/539 (20130101); A61F 13/5323 (20130101); B32B
7/12 (20130101); A61F 13/512 (20130101); B32B
27/12 (20130101); B32B 27/08 (20130101); B32B
2307/7265 (20130101); A61F 2013/53908 (20130101); A61F
2013/5395 (20130101); A61F 2013/586 (20130101); A61F
13/8405 (20130101); A61F 2013/15073 (20130101); A61F
2013/53721 (20130101); B32B 2555/02 (20130101); A61F
2013/530131 (20130101); A61F 13/58 (20130101); A61F
2013/53782 (20130101) |
Current International
Class: |
A61F
13/15 (20060101); A61F 13/56 (20060101); A61F
013/16 () |
Field of
Search: |
;128/132D,149,155-156,280,284,286-287,29R,296 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Michell; Robert W.
Assistant Examiner: Opitz; Rick
Attorney, Agent or Firm: Dulin, Esq.; Jacques M. Sprunger,
Esq.; Powell L.
Claims
I claim:
1. An absorbent article for use as a diaper or the like comprising
in operative combination:
a. a first backing sheet of generally fluid resistant material,
having marginal edges,
b. a second sheet of generally fluid resistant material,
c. said second sheet having a plurality of apertures therein,
d. an absorbent pad structure disposed between said first and said
second sheets,
e. said absorbent pad having a plurality of apertures therein, said
apertures being larger than the apertures in said second sheet,
f. said first and said second sheets being secured to each other in
registry with said pad apertures in at least a part of the area
defined by said pad apertures, and
g. the marginal edges of said first and second sheets being secured
to each other to make a unitary absorbent article.
2. An absorbent article as in claim 1 wherein said first and second
sheets are generally water impervious, and said aperttures in said
second sheet are disposed in a lateral area smaller than the area
of said pad.
3. An absorbent article as in claim 2 wherein said pad is smaller
in size than said first sheet.
4. An absorbent article as in claim 3 wherein said pad is adapted
for use as a diaper.
5. An absorbent article as in claim 4 wherein said diaper
adaptation includes relieved portions of said pad along at least
two opposed margins defining leg-fitting portions.
6. An absorbent article as in claim 5 which includes a third sheet
of fibrous material disposed adjacent to and outwardly from said
second sheet, said third sheet being secured to at least one of
said first and said second sheets.
7. An absorbent article as in claim 6 wherein said first and second
sheets are of plastic material and said secured area is selected
from heat bonding, solvent bonding and adhesive bonding.
8. An absorbent article as in claim 6 wherein two opposed pad
margins have relieved portions defining leg-fitting areas.
9. An absorbent article as in claim 8 wherein said margins having
relieved portions are pleated, and said pleats are secured by
adhesive.
10. An absorbent article as in claim 1 which includes a third sheet
of fibrous material disposed adjacent to and outwardly from said
second sheet, said third sheet being secured to at least one of
said first and said second sheets.
11. An absorbent article as in claim 1 including a plurality of
longitudinal folds defining a box-pleat configuration of the
article adapted for use as a diaper.
12. A disposable diaper, comprising: a fluid impervious backing
sheet, a fluid transmitting cover sheet, and an absorbent pad
intermediate said cover and backing sheets, said pad having a
plurality of apertures extending therethrough, and said cover sheet
being secured to said backing sheet through a plurality of said pad
apertures the area of securing being less than the area of the
apertures in said pad.
13. The diaper as in claim 12 wherein the apertures in said pad are
spaced inwardly from marginal edges of the pad.
14. The diaper as in claim 12 wherein said pad includes a pair of
side edges, and a pair of cut-out portions along said side edges in
the crotch region of the diaper.
15. The diaper as in claim 12 wherein said cover sheet comproses a
fluid pervious top sheet.
16. The diaper an in claim 12 wherein said cover sheet comprises a
fluid impervious sheet having a plurality of apertures extending
through said sheet and overlying said pad.
17. The diaper as in claim 16 including a fluid pervious top sheet
overlying said fluid impervious cover sheet.
18. The diaper as in claim 17 wherein said fluid impervious cover
sheet and fluid pervious top sheet are secured through said
apertures to said backing sheet.
19. The diaper as in claim 16 wherein the apertures of the fluid
impervious cover sheet are smaller in size than the apertures in
said pad.
20. The diaper as in claim 16 wherein said pad has marginal side
and end edges, and the apertures in said fluid impervious cover
sheet are spaced from said marginal edges throughout a substantial
areal extent of said pad.
21. The diaper as in claim 16 wherein said fluid impervious cover
sheet and backing sheet are secured together defining marginal side
and end edges of the diaper, and said apertures in the fluid
impervious cover sheet are spaced from said marginal edges of the
diaper to provide a fluid barrier adjacent the marginal edges of
the diaper.
22. The diaper as in claim 12 including a plurality of
longitudinally extending folds defining a box-pleat configuration
of the diaper.
23. A disposable diaper, comprising:
a. a pair of side edges;
b. a pair of end edges connecting said side edges;
c. a fluid impervious backing sheet;
d. a fluid pervious top sheet;
e. an absorbent pad intermediate said top and backing sheets;
f. said pad having marginal edges and a plurality of apertures
extending through the pad generally in a first (the crotch) region
of the diaper, said first region being adapted for placement
adjacent the crotch area of an infant;
g. a fluid impervious interlayer intermediate said top sheet and
pad and secured to said backing sheet through a plurality of said
pad apertures;
h. said interlayer having a plurality of apertures of smaller size
than the apertures in said pad;
i. said interlayer apertures being spaced from the diaper side and
end edges and the marginal edges of the pad throughout a
substantial areal extent of the pad;
j. said top and backing sheets and said interlayer being secured
together along the side and end edges of the diaper; and
k. a plurality of longitudinally extending folds defining a
box-pleat configuration of the diaper.
Description
FIELD
This application relates to improvements in fluid absorbent and
retentive articles, including diapers, catamenial pads, fluid
absorbent bed sheets, surgical or medicinal absorbent pads or
drapes, surgical or medicinal dressing pads or bandages, and the
like. More particularly the inventions herein relate to improved
diapers having apertured absorbent pads retained in combination
with a plurality of sheets in a manner that provides improved
performance.
BACKGROUND
Currently available absorbent pad systems have numerous
disadvantages, particularly complexity of manufacture and use
effectiveness. For example, pulverized wood pulp pads tend to have
low wet strength integrity resulting in pulling apart and balling
when contacted by fluid. Unless they have a special sheet, called a
wadding sheet, they also disintegrate and shift in position when
disposed between plastic sheets. Typically, they must be glued
across one entire surface to retain them in position, with
consequent loss of absorbency, use of large quantities of adhesive,
and extra layers of material. The wicking action of the pad is
reduced and the spreading action of backing sheets are also
hindered. The requirement of additional layers makes for a bulky
product, uncomfortable and ill fitting in use, and the rate of
liquid penetration is reduced with each additional layer required,
and particularly by the wadding sheet. Not only does the wadding
sheet reduce the rate of fluid penetration, it also significantly
adds to the cost of the diaper. Likewise, there is no way to
prevent or reduce reverse fluid flow and excessive urine contact on
the skin.
There is thus a substantial need for absorbent articles that have
improved use properties, are simple to construct, and overcome such
disadvantages of currently available articles.
OBJECTS
It is an object of this invention to provide an improved absorbent
article having utility for diapers, bandages, sheets, drapes,
catamenial pads and the like.
It is another object to provide an improved absorbent article
having an absorbent pad retained between a plurality of sheets.
It is another object to provide an improved absorbent aritcle, such
as a diaper, having an apertured absorbent pad disposed between
differently functioning inner and outer sheets, which sheets are
secured to each other through the apertures in the pad.
It is another object of this invention to provide an absorbent
article which has improved use characteristics including positive
location and retention of an absorbent pad without use of a special
retention-type wadding sheet.
It is another object to provide improved absorbent articles which
are simpler and cheaper to make than prior types of absorbent
systems.
It is another object to provide an improved absorbent article
having an apertured pad, which pad is retained between the
interlayer and an outer sheet in a manner to provide for improved
fluid transmission, one-way penetration, excellent fluid spreading,
added wicking edges, and improved absorbency rates and
retention.
It is a further object to provide a discontinuous front surface for
contacting an infant's skin.
Still other objects will be evident from the description which
follows. By way of example and not by way of limitation, specific
reference will be had to diaper system, but the principles
disclosed herein are equally applicable to the other aforementioned
types and uses of articles.
FIGURES
The description refers to the drawing in which:
FIG. 1 shows in plan view a diaper system illustrating one
embodiment of the instant invention, parts of which are broken away
to show the several layers of the system;
FIG. 2 is a section view along line 2-2 of FIG. 1;
FIG. 3 shows in perspective the embodiment of FIG. 1 folded in a
box pleat form ready for use; and
FIG. 4 is a fragmentary sectional view of another embodiment of the
diaper of the present invention.
SUMMARY
By way of example, an absorbent article useful as a diaper in
accord with the inventions comprises an outer or backing sheet and
an apertured interlayer sheet having disposed therebetween an
apertured absorbent pad, and, optionally, an inner or top sheet
overlying the interlayer. The top and/or interlayer sheets serve as
one or more cover sheets for the absorbent pad. The apertures of
the pad are relatively large and permit direct bonding of the
interlayer and/or inner sheet to the outerlayer therethrough
without bonding to the pad. This retains the pad in the use
position without need for a special wadding type retainer sheet,
which would normally define the front surface of the pad, and
without glue to position and retain the pad in place. The apertures
also provide additional wicking surface for rapid absorption of
fluid passing through the interlayer and/or inner sheets.
The interlayer has a plurality of smaller apertures which function
to pass fluid one way from the inner sheet to the pad. The holes
are preferably restricted in area to less than the areal extent of
the pad to reduce the tendency for back-wicking from the pad
through the inner sheet. The outer sheet and interlayer are
preferably of a thermoplastic material to keep the outer surface of
the diaper dry, to promote fluid spreading, and permit bonding
without need for adhesives. The marginal edges of the sheets are
preferably bonded to prevent fluid escape. The inner sheet is
preferably a non-woven fibrous material that minimizes direct skin
contact with plastic and has a suitable feel or "hand."
A portion of the pad may be removed in generally arcuate areas
disposed along the mid-points of two opposed sides or in the diaper
crotch region to provide for a better leg fit. The diaper
conveniently is folded in a box pleat with one or more adherent
tabs provided for removably retaining the diaper in a use position
on the child. A diaper of this invention shows improved rate of
fluid absorbency, improved penetration, excellent one-way fluid
transmission through the interlayer, excellent spreading by the
backing sheet and improved wicking into the pad and fluid
retention. The diaper is simple to construct, permitting omission
of a wadding sheet, yet having improved pad location and retention
without balling in use.
DETAILED DESCRIPTION
Referring to FIG. 1, absorbent article 1, such as a disposable
diaper, comprises an outer backing sheet 2 and an optional inner
sheet 3 having disposed therebetween an absorbent pad 4, and an
interlayer sheet 5. These sheets are shown for purposes of
illustration as generally rectangular, each having a pair of
lateral side edges 6, 7 and a pair of end edges 8, 9 connecting the
side edges 6, 7, the edges being substantially in registry.
However, other shapes, depending on use and preference, such as
square, triangular, polygonal, arcuate or combinations thereof may
be employed for the sheets.
The outer backing sheet is of a fluid impervious (preferred) or
resistant material, typically thermoplastic or thermosetting
plastic, such as a polyolefin (polyethylene, polypropylene), a
polystyrene, a polyvinyl plastic, such as polyvinylchloride, and
the like. Mixed polymers, laminates, co- and ter-polymers may also
be used. This sheet may be made by a continuous extrusion, casting,
or other operation, and is preferably a homogenous web. Where the
desired fluid imperviousness is achievable, the sheet may be woven,
non-woven, or felted. Sheet thickness may vary and typically is in
the range of from about 0.1 to 3.0 mils, with lighter thickness on
the order of 1.0 mils being used for diapering, with heavier sheets
being used for heavy duty applications such as surgical pads or
draping. The interlayer is preferably of the same material,
impervious properties and gauge. The sheets, particularly the outer
backing sheet and interlayer sheet, may be differently colored, for
coding purposes in manufacture, to insure proper orientation in
use, for sales appeal, and aesthetic reasons. For example, the
outer backing sheet may be white while the interlayer is blue; the
semi-translucent inner sheet takes on the blue color of the
interlayer and the absorbent article thus has differently
color-coded sides that can be referred to in manufacturing and use
instructions. Other colors, patterns and designs may be used.
The absorbent pad may be any suitable absorbent material, such as
pulverized wood pulp, cellulose wadding, or any woven, non-woven or
felted, natural or synthetic, fibrous or non-fibrous (such as open
or closed cell-sponge of foam-type) material. The pad, as best
shown in FIGS. 1 and 2, has end margins 10, 11, and side margins
12, 13 when it is generally rectangular. These margins are
generally spaced inwardly of margins 6, 7, 8 and 9, as shown. As
noted above, the pad may have a variety of shapes and sizes. One
diaper configuration is shown in FIGS. 1 and 3, wherein arcuate
portions 14, 15 are removed from side margins 12, 13 in registry
with the leg positions. As best shown in FIG. 3, this prevents
excess bulk in the baby's crotch area, provides a better fit, and
permits collection and spreading of fluid without loss to the
exterior by means of the outer backing sheet, interlayer, and
optional inner layer, which are not removed at that area.
Pad 4 also has a plurality of relatively large apertures 16 spaced
inwardly from the outer margins 10, 11, 12, 13 of the pad. These
apertures permit direct bonding of the interlayer 5 (and optionally
inner sheet 3) to the outer backing sheet 2 in zones 17, in the
manner shown best in the upper half of FIG. 2. The bonding may be
by any suitable means, heat sealing (preferred), solvent sealing,
adhesive and the like. The bonding zones occupy only a portion of
the entire area defined by the aperture size 16. The bonds
effectively retain the pad between the outer backing sheet 2 and
interlayer 5 in proper use position, without adhesive being applied
to the pad and present a generally quilted effect. The pad does not
shift in position during transport or use, and does not pill, wad
or ball upon contact with fluid. The lower portion of FIG. 2 shows
an alternative embodiment wherein the inner sheet is not bonded to
the interlayer and/or backing sheet in zone 17.
Further, this construction permits omitting the typical single or
multi-layer wadding sheet, pad wrapper or pouch, with consequent
improved rate of liquid permeability and reduced cost of the diaper
to the consumer. The pad apertures have edges 18 which provide
additional wicking surfaces for rapid absorption of fluid by the
pad. Absorption by exposed fibrous ends, such as presented by edges
18, is generally faster than through the inner surface 19 or the
pad.
The inner surface 20 of the outer backing sheet 2 serves to spread
fluid passing through the optional inner sheet 3, and the
interlayer 5 into contact with wicking edges 10, 11, 12, 13 and 18
facilitating absorption and into contact with the back surface of
the pad 4 intermediate the pad apertures 16. Since no glue is
requred to retain the pad in place, better fluid spreading is
obtained. Between interlayer 5 and outer backing sheet 2 in the
region of the apertures 16 are defined generally annular spaces 21,
seen best in FIG. 2. These spaces serve as reserviors for fluid
passing rapidly through apertures 22 in the interlayer 5. Thus, the
penetration rate limiting factor is the speed of transfer through
the interlayer apertures 22, rather than the absolute rate of
absorption through the pad surface 19. Fluid does not tend to
puddle on the inner surface 23 of the interlayer 5 while awaiting
the relatively slow sorption through the surface of the pad.
Rather, the fluid can run quickly through apertures 22 into
reservoirs 21 and then wick through edges 18. Urine contact on skin
is minimized.
The interlayer apertures 22 are generally smaller and more numerous
than the pad apertures 16. As an example, apertures 16 in the pad
may be 3/4 (1.9 cm) in diameter, while apertures 22 may be 1/8 (0.3
cm) in diameter. This provides a flow gradient effect permitting a
large number of access ports for fluid to pad 4 or reservoirs 21,
and minimizing back flow to the surface 23 and contact with skin.
Further, the larger number of apertures 22 statistically insures
registry with the apertures 16 and annular spaces 21. The small
apertures 22 are limited in lateral extent (both horizontally and
vertically as shown in FIG. 1) to an area generally smaller than
the area of the underlying pad 4 (except as may optionally occur in
the relieved areas 14 and 15) to eliminate leakage or backwicking
from edges 10, 11, 12 and 13. Thus, the fluid impervious interlayer
and backing sheets 5 and 2 provide a seal to prevent leakage at the
side and end edges of the diaper.
The inner sheet 3 is optional but preferred to minimize skin
contact with the plastic of the interlayer 5, and provide a smooth
feel or hand. The inner sheet is preferably of a woven or
non-woven, fibrous, natural (e.g., cellulosic) or synthetic
material. It may be a paper-process type of non-woven material,
felted, or randomly intertangled to form a self-supporting sheet.
The sheet also helps provide fluid transfer to the interlayer and
skin protection. As with pad 4, the inner sheet may be treated with
medicaments, chemical agents, deodorants, emollients, powders
(e.g., baby powder), surfactants, wetting agents, salves, perfumes,
bactericides, germicides, and the like, as desired.
FIG. 3 shows the pad of FIG. 1 folded into a conventional box pleat
configuration, having adhesive faced securing tabs 24, 24' with
release sheets 25, 25' thereover. In use the baby is laid on the
diaper, front end A brought up, the release sheets 25, 25' are
removed, and the tabs 24, 24' are secured to the outer surface 26
of backing sheet 2. To form the box pleat, adhesive 27, 27' may be
applied to spots C and D of the inner sheet (see FIG. 1) and the
pleats 28, 29 formed and retained in place by the folds and
adhesive. For packaging and shipping, the diaper may be folded
along fold line F-F'. The relieved areas 14, 15 prevent bulking
along the fold line, and permit better diaper fit.
Another embodiment of the present invention is illustrated in FIG.
4. In this embodiment, the interlayer is omitted and the inner top
sheet 3 is secured directly to the backing sheet 2 through the pad
apertures 16. The bonded top and backing sheets prevent shifting of
the absorbent pad, as previously described in connection with the
diaper of FIGS. 1-3.
As apparent from the drawings, the quilted diaper of the present
invention has a plurality of raised and recessed surface portions
32 and 34, respectively, defining an undulating front and rear
surface of the diaper which is aesthetically pleasing to the eye.
When the diaper is placed on an infant, the tape strips are secured
in place, the backing sheet is pulled somewhat taut, tending to
accenturate the depressed front surface portions and the undulating
front surface of the diaper. Accordingly, the diaper presents a
discontinuous front surface with the raised portions contacting the
infant's skin, and the depressed portions providing air pockets
promoting the circulation of air within the placed diaper. To the
extent that the inner top sheet becomes moist, the discontinuous
front surface minimizes the wet front surface area which contact
the infant. The discontinuous front surface also minimizes clinging
of the top sheet against the infant's skin, which otherwise might
be present in a continuous front surface.
It should be understood that various modifications within the scope
of this invention can be made by one of ordinary skill in the art
without departing from the spirit thereof. I therefore wish my
invention to be defined by the scope of the appended claims as
broadly as the prior art will permit, and in view of the
specification if need be.
* * * * *