阅读说明：本技术 一次性吸收制品 (Disposable absorbent article ) 是由 C·W·科尔曼 F·P·阿布托 J·L·戴 S·兰加纳坦 于 2017-05-31 设计创作，主要内容包括：一种一次性吸收制品包括：身体侧衬里、外覆层、设置在所述身体侧衬里与所述外覆层之间的吸收主体,以及设置在所述身体侧衬里与所述吸收主体之间的涌流层,所述涌流层具有X-Y平面、Z方向和纵向方向,以及在所述Z方向上基本延伸穿过涌流材料的屏障,其中所述屏障被构造成阻挡至少一个线性纵向流体流动路径。所述涌流层可替代地具有多个屏障,所述多个屏障在所述Z方向上基本延伸穿过所述涌流材料,其中所述多个阻挡层被构造成阻挡多个线性纵向流体流动路径或所有线性纵向流体流动路径,同时允许在所述纵向方向上的非线性流体流动路径。(A disposable absorbent article comprising: a bodyside liner, an outer cover, an absorbent body disposed between the bodyside liner and the outer cover, and a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a barrier extending substantially through the surge material in the Z direction, wherein the barrier is configured to block at least one linear longitudinal fluid flow path. The surge layer may alternatively have a plurality of barriers that extend substantially through the surge material in the Z-direction, wherein the plurality of barrier layers are configured to block a plurality of linear longitudinal fluid flow paths or all linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.)

1. An absorbent article comprising:

a bodyside liner;

an outer cover;

an absorbent body disposed between the bodyside liner and the outer cover; and

a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a barrier extending substantially across the surge material in the Z direction, wherein the barrier is configured to block at least one linear longitudinal fluid flow path.

2. The article of claim 1, the surge layer further comprising a plurality of barriers that are staggered to block a plurality of linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

3. The article of claim 2, wherein the plurality of barriers comprise barriers in the form of parallel lines.

4. The article of claim 3, wherein the parallel lines are perpendicular to the longitudinal direction.

5. The article of claim 2, wherein the plurality of barriers comprise barriers in the form of lines disposed at a non-orthogonal angle to the longitudinal direction.

6. The article of claim 2, wherein the plurality of barriers comprise a combination of barriers in the form of parallel lines, arcuate lines, and/or geometric shapes.

7. The article of claim 2, wherein the plurality of barriers comprises a plurality of embossments.

8. The article of claim 1, wherein the article is a diaper, training pant, adult incontinence garment, or catamenial pad.

9. The article of claim 1, wherein the surge layer comprises thermoplastic fibers.

10. The article of claim 1, the surge layer further comprising a plurality of barriers that are staggered to block all linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

11. The article of claim 1, wherein the barrier is an embossing, a barrier filler, a chemical treatment, a slit, a film fragment, a polymeric material, an adhesive, a lotion, an ointment, and combinations thereof.

12. The article of claim 1, wherein the barrier is an embossment.

13. An absorbent article comprising:

a bodyside liner;

an outer cover;

an absorbent body disposed between the bodyside liner and the outer cover; and

a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a plurality of barriers extending substantially through the surge material in the Z direction, wherein the plurality of barriers are configured to block a plurality of linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

14. The article of claim 13, wherein the plurality of barriers comprise barriers in the form of parallel lines.

15. The article of claim 13, wherein the plurality of barriers comprise barriers in the form of a plurality of lines disposed at a non-orthogonal angle to the longitudinal direction.

16. The article of claim 13, wherein the article is a diaper, training pant, adult incontinence garment, or catamenial pad.

17. The article of claim 13, wherein the plurality of barriers comprises a plurality of embossments.

18. The article of claim 13, wherein the plurality of barriers comprise embossments, barrier fillers, chemical treatments, slits, film fragments, polymeric materials, adhesives, lotions, ointments, and combinations thereof.

19. An absorbent article comprising:

a bodyside liner;

an outer cover;

an absorbent body disposed between the bodyside liner and the outer cover; and

a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a plurality of barriers extending substantially across the surge material in the Z direction, wherein the plurality of barriers are configured to block all linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

20. The article of claim 19, wherein the article is a diaper, training pant, adult incontinence garment, or catamenial pad.

Background

The present disclosure relates to disposable absorbent articles, such as disposable absorbent articles used as personal care products, which contain released bodily waste liquids in the article.

Disposable absorbent articles are widely used as personal care products such as diapers, child toilet training pants and other infant care products, adult incontinence garments and other adult care products, sanitary napkins and other feminine care products, and the like, as well as surgical bandages and sponges. These articles absorb and contain bodily waste and are intended to be discarded after a limited period of use; that is, these articles are not intended to be laundered or otherwise restored for reuse. A conventional disposable absorbent article includes an absorbent body disposed between an inner layer adapted to be in contact with the skin of a wearer and an outer layer for inhibiting leakage of waste liquid absorbed by the absorbent body from the article. The inner layer of the absorbent article is typically liquid permeable to allow body waste to pass through the inner layer for absorption by the absorbent body.

For example, a wearer's toilet training pants serve as a training aid when a child transitions from diaper to pant. Conventional toilet training pants are three-dimensional articles that resemble underwear in appearance, but are constructed with a liquid permeable inner layer and an absorbent body to provide the absorbent function of a disposable absorbent article. The inner layer of the training pants remains dry and comfortable to the skin of the child with the training pants quickly and efficiently drawing urine away from the skin and retaining it in the absorbent body. If the liquid is deposited in the article faster than it is sucked away from the skin, the liquid will accumulate in the lowest part of the article, resulting in leakage.

Thus, despite improvements in the construction of disposable absorbent articles, there remains a need for a relatively easily constructed disposable absorbent article capable of absorbing accumulated or leaked liquid insults.

Disclosure of Invention

In one aspect, a disposable absorbent article includes a bodyside liner, an outer cover, and an absorbent body disposed between the bodyside liner and the outer cover. The disposable absorbent article further includes a surge layer disposed between the body-side liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a barrier extending substantially through the surge material in the Z direction, wherein the barrier is configured to block at least one linear longitudinal fluid flow path.

In another aspect, a disposable absorbent article includes a bodyside liner, an outer cover, and an absorbent body disposed between the bodyside liner and the outer cover. The disposable absorbent article further includes a surge layer disposed between the body-side liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a plurality of barriers extending substantially through the surge material in the Z direction, wherein the plurality of barriers are configured to block a plurality of linear longitudinal fluid flow paths while allowing for non-linear fluid flow paths in the longitudinal direction.

In yet another aspect, a disposable absorbent article includes a bodyside liner, an outer cover, and an absorbent body disposed between the bodyside liner and the outer cover. The disposable absorbent article further includes a surge layer disposed between the body-side liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a plurality of barriers extending substantially through the surge material in the Z direction, wherein the plurality of barriers are configured to block all linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

Other aspects and features of the present disclosure will be in part apparent and in part pointed out hereinafter.

Drawings

The foregoing and other features and aspects of the present disclosure and the manner of attaining them will become more apparent, and the disclosure itself will be better understood by reference to the following description, appended claims, and accompanying drawings, wherein:

FIG. 1 is a side view of a wearer toilet training pant of the present disclosure;

FIG. 2 is a top plan view of the training pant of FIG. 1 shown unfastened and laid flat with portions of the training pant broken away to show its internal structure;

FIG. 3 is a schematic representation of an embossing pattern in the surge layer of the article shown in FIG. 1;

FIG. 4 is a schematic view of an alternative embossing pattern in the surge layer of the article shown in FIG. 1; and is

FIG. 5 is a schematic representation of another alternative embossing pattern in the surge layer of the article shown in FIG. 1.

Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the disclosure. The figures are representational and are not necessarily drawn to scale. Some proportions within the figures may be exaggerated, while other parts may be minimized.

Detailed Description

In the context of this specification, each term or phrase below will include the following meaning or meanings:

"joined" refers to the joining, adhering, connecting, attaching, etc., of two elements. Two elements will be considered to be bonded together when they are bonded directly to each other or to each other, such as when each is directly bonded to intermediate elements.

"film" refers to a thermoplastic film prepared using a film extrusion and/or shaping process such as a cast film or blown film extrusion process. The term includes apertured films, slit films and other porous films that constitute liquid transfer films, as well as films that do not transfer liquid.

"hydrophilic" describes fibers or surfaces of fibers that are wetted by an aqueous liquid in contact with the fibers. The degree of wetting of a material can in turn be described in terms of the contact angles and surface tensions of the liquids and materials involved. Apparatus and techniques suitable for measuring the wettability of a particular fibrous material or blend of fibrous materials can be provided by a Cahn SFA-222 Surface Force analysis System (Cahn SFA-222 Surface Force Analyzer System) or a substantially equivalent System. Fibers having contact angles less than 90 are considered "wettable" or hydrophilic and fibers having contact angles greater than 90 are considered "nonwettable" or hydrophobic when measured using this system.

When used in the singular, the "layer" can have the dual meaning of a single element or a plurality of elements.

"liquid impermeable" when used to describe a layer or laminate means that bodily waste liquids (such as urine) will not pass through the layer or laminate upon liquid contact, in a direction generally perpendicular to the plane of the layer or laminate, under typical use conditions.

"liquid permeable" refers to any material that is not liquid impermeable.

"meltblown" refers to fibers formed by: molten thermoplastic material is extruded through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity heated gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al. Meltblown fibers are microfibers which may be continuous or discontinuous, are generally smaller than about 0.6 denier, and are generally self bonding when deposited onto a collecting surface. Meltblown fibers used in the present disclosure are preferably substantially continuous in length.

"nonwoven" and "nonwoven web" refer to a material or web of material that is formed without the aid of a fabric weaving or knitting process.

"flexible" refers to a material that is compliant and will readily conform to the general shape and contours of a wearer's body.

"spunbond fibers" refers to small diameter fibers formed by: molten thermoplastic material is extruded as filaments from a plurality of fine capillaries of a spinneret having a circular or other configuration, and the diameter of the extruded filaments is then rapidly reduced by conventional processes such as those described in the following patents: U.S. Pat. No. 4,340,563 to Appel et al, U.S. Pat. No. 3,692,618 to Dorschner et al, U.S. Pat. No. 3,802,817 to Matsuki et al, U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No. 3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dobo et al, each of which is incorporated herein by reference in its entirety. Spunbond fibers are generally continuous and typically have an average denier of greater than about 0.3, more particularly between about 0.6 and about 10.

"superabsorbent" refers to a water-swellable, water-insoluble organic or inorganic material capable of absorbing at least about 15 times its weight, and more preferably at least about 30 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride under most favorable conditions. Superabsorbent materials can be natural, synthetic, and modified natural polymers and materials. Further, the superabsorbent materials can be inorganic materials such as silica gels or organic compounds such as crosslinked polymers.

"surge layer" is defined herein as a layer that is capable of rapidly receiving and temporarily retaining bodily waste to decelerate and diffuse surges or surges of bodily waste and subsequently release bodily waste therefrom into another layer or layers.

"thermoplastic" describes a material that softens when exposed to heat and returns substantially to an unsoftened condition when cooled to room temperature.

"three-dimensional" refers to a garment similar to underwear, shorts, or pants having continuous leg and waist openings defined by the material from which the garment is made. The garment may have a seam that is manually tearable.

"tortuosity" refers to the indirection of a path between two points. For example, a detour from point a to point B has a higher degree of curvature than a straight line between points a and B. The linear path is a straight path from point a to point B.

Referring now to the drawings and in particular to FIG. 1, a disposable absorbent article of the present disclosure is shown in the form of a toilet training pant for a wearer and is generally indicated by reference numeral 21. As used herein, "disposable absorbent article" refers to an article that: may be placed against or in close proximity to (i.e., adjacent to) the body of the wearer to absorb and contain the various waste fluids discharged from the body. Such articles are intended to be discarded after a limited period of use rather than being laundered or otherwise restored for reuse. It is to be understood that the present disclosure is applicable to a variety of other disposable absorbent articles, such as diapers and other infant care products, adult incontinence garments and other adult care products, sanitary napkins and other feminine care products, and the like, as well as surgical bandages and sponges, without departing from the scope of the present disclosure.

By way of example only, a variety of materials and methods for constructing the training pants 21 are disclosed in the following documents: PCT patent application WO 00/37009 published on 29/6/2000 by fletcher et al, U.S. patent 4,940,464 issued on 10/7/1990 to Van Gompel et al, and U.S. patent 5,766,389 issued on 16/6/1998 to Brandon et al, all of which are incorporated herein by reference.

The training pants 21 of the illustrated embodiment generally include a central absorbent assembly 23 extending longitudinally from the front region 25 of the training pants through the crotch region 27 to the back region 29 of the training pants. As shown in FIG. 2, the central absorbent assembly 23 is generally rectangular and has laterally opposing side edges 31 and longitudinally opposing front and back waist edges, respectively designated 33 and 35. Front and back side panels, respectively designated 37 and 39, are secured to the central absorbent assembly 23 as will be described later herein, and extend laterally outward at the front and back regions 25 and 29, respectively, of the training pants 21.

To form the three-dimensional training pant 21, the corresponding front and back side panels 37, 39 (e.g., front and back left side panels) are refastenably secured together using the fastening components 41. Alternatively, the front and back side panels 37, 39 may be permanently secured together, such as by ultrasonic bonding, or they may be integrally formed with each other and with the central absorbent assembly 23. Securing the side panels 37, 39 together provides a central waist opening 45 and a pair of laterally spaced leg openings 47 of the training pants 21. The training pants 21 are worn by the following steps: passing the wearer's feet through the waist opening 45 and the respective leg openings 47; gripping the training pants near the waist opening; the training pants are then pulled up the legs of the wearer until the crotch region 27 of the training pants is snug against the crotch of the wearer.

Referring to FIG. 2, the central absorbent assembly 23 of the training pants 21 includes an outer cover, generally indicated at 49, a bodyside liner 51, and an absorbent body 57 disposed between the outer cover and the liner. The outer cover 49 can be elastic, stretchable or non-stretchable, and desirably is a liquid impermeable multi-layer laminate structure of at least one of the layers. For example, the outer cover 49 of the illustrated embodiment is a two-layer structure including an outer layer and an inner layer joined together by a laminating adhesive, wherein the outer layer is composed of a liquid permeable material and the inner layer is composed of a liquid impermeable material. Suitable laminating Adhesives are available from Findley Adhesives, inc., of Wauwatosa, Wisconsin, u.s.a. or from National Starch and Chemical Company, Bridgewater, New Jersey, u.s.a. It should be understood that the outer cover 49 could alternatively be constructed of a single layer of impermeable material without departing from the scope of this disclosure.

The liquid permeable outer layer of the outer cover 49 can be any suitable material, and desirably is a material that provides a generally cloth-like texture. One example of such a material is a 20gsm (grams per square meter) spunbond polypropylene nonwoven web. The outer layer may also be constructed of the same materials as the bodyside liner 51 described later herein. Moreover, while the outer layer of the outer cover 49 need not be liquid permeable, it desirably provides the wearer with a relatively cloth-like texture.

The liquid impermeable inner layer of the outer cover 49 can be vapor permeable (i.e., "breathable") or vapor impermeable. The inner layer is desirably made of a thin plastic film, although other flexible liquid impermeable materials may also be used. The liquid impermeable inner layer (or the liquid impermeable outer cover 49 in the case of an outer cover having a single layer construction) inhibits leakage of bodily waste liquids from the training pants and wetting articles such as bed sheets and clothing, as well as the wearer and caregiver. A suitable liquid impermeable material for such use is a 0.02 millimeter polyethylene film commercially available from Huntsman Packaging of Newport News, Virginia, u.s.a.

Where the outer cover 49 has a single layer construction, it may be embossed and/or matte finished to provide a more cloth-like appearance. As previously mentioned, the liquid impermeable layer of the outer cover 49 can allow vapors to escape from the training pants 21 while preventing liquids from passing through the training pants. Suitable liquid impermeable, vapor permeable materials are comprised of a microporous polymeric film or a nonwoven fabric that has been coated or otherwise treated to impart a desired level of liquid impermeability. Suitable microporous membranes are PMP-1 membrane materials commercially available from Mitsui Toatsu Chemicals, Inc., Tokyo, Japan, or XKO-8044 polyolefin membranes commercially available from 3M Company, Minneapolis, Minnesota, U.S. A.

The leg elastic members 61 are secured between the outer and inner layers of the outer cover 49, such as by being bonded therebetween by a laminating adhesive, generally adjacent the lateral outer edges of the inner layer of the outer cover. Alternatively, the leg elastic members 61 may be disposed between the outer cover 49 and the bodyside liner 51 or between other layers of the training pants 21. A wide variety of elastic materials may be used for the leg elastic members 61. Suitable elastic materials include sheets, strands or ribbons of natural rubber, synthetic rubber or thermoplastic elastomeric polymers, as is well known to those skilled in the art. The elastic material may be stretched and secured to a substrate, secured to a gathered substrate, or secured to a substrate and then elasticized or shrunk, for example by the application of heat, such that elastic retractive forces are applied to the substrate. For example, one suitable elastic material is dry-spun coalesced multifilament spandex yarn sold under the trade name LYCRA and available from e.i. du Pont de Nemours and Company, Wilmington, Delaware, u.s.a.

The absorbent body 57 is somewhat rectangular in shape and desirably is configured to be generally compressible, flexible, non-irritating to the wearer's skin, and capable of absorbing and retaining body waste liquids, such as urine. The absorption body 57 includes an inner layer desirably composed of hydrophilic fibers and an outer layer desirably composed at least partially of a high-absorbency material commonly known as superabsorbent material. More specifically, the inner layer of the absorbent body 57 is desirably composed of cellulose fluff such as wood pulp fluff, and the outer layer is desirably composed of superabsorbent hydrogel-forming particles or a mixture of cellulose fluff and superabsorbent hydrogel-forming particles. Thus, the inner layer has a lower absorption capacity per unit weight than the outer layer. The inner layer may alternatively be composed of a mixture of hydrophilic fibers and superabsorbent material, provided that the concentration of superabsorbent material present in the inner layer is substantially lower than the concentration of superabsorbent material present in the outer layer, such that the inner layer may have a lower absorbent capacity per unit weight than the outer layer. It is also contemplated that the outer layer may be composed solely of superabsorbent material without departing from the scope of this disclosure.

The cellulosic fluff making up the inner layer desirably has a density of about 0.15-0.20g/cc (grams per cubic centimeter) and constitutes from about 20% to 80% by weight of the absorbent body. One suitable type of wood pulp fluff is identified under the trade designation CR1654, available from u.s.alliance, Childersburg, Alabama, u.s.a., and is a bleached, highly absorbent kraft wood pulp containing predominantly softwood fibers. However, the wood pulp fluff may be exchanged with other hydrophilic fibrous materials, such as synthetic, polymeric, or meltblown fibers, or a combination of meltblown fibers and natural fibers.

Suitable superabsorbent materials can be selected from natural, synthetic, and modified natural polymers and materials. The superabsorbent materials can be inorganic materials such as silica gels or organic compounds such as crosslinked polymers. Suitable superabsorbent materials are available from a variety of commercial suppliers, such as Dow Chemical Company and Stockhausen GmbH & Co.KG, D-47805Krefeld, Federal Republic of Germany, located in Midland, Michigan, U.S.A.

The surge layer 53 is disposed between the bodyside liner 51 and the absorbent body 57 to help decelerate and diffuse surges or gushes of bodily waste fluid that have permeated the liner 51. The surge layer 53 is similar to the surge layers disclosed in U.S. Pat. Nos. 5,490,846 and 5,562,650, the entire disclosures of which are incorporated herein by reference to the extent they do not conflict herewith. The surge layer 53 rapidly absorbs the surge of bodily waste fluid permeating the liner 51 and then slowly releases the bodily waste fluid to the absorbent body 57. The width and length of the surge layer 53 are substantially the same as the width and length of the absorbent body 57. However, it should be understood that the surge layer 53 may be narrower and/or shorter than the absorbent body 57, or wider and/or longer than the absorbent body 57, without departing from the scope of this disclosure.

Desirably, the surge layer 53 can quickly receive and temporarily contain bodily waste fluids before slowly releasing them to flow to the absorbent body 57. The surge layer 53 may include various types of fabrics such as spunbond fabrics, meltblown fabrics, bonded carded webs, through-air bonded carded webs, knitted fabrics, woven fabrics, air-formed fabrics, and the like, as well as combinations thereof. The fabric may be composed of various types of fibers, such as polyolefin fibers, polyester fibers, bicomponent fibers, composite fibers, and the like, as well as combinations thereof.

For example, one suitable material from which the surge layer 53 may be constructed has a basis weight of about 50gsm and comprises an air-through bonded carded web of a uniform blend of 60% 3 denier bicomponent fibers comprising a polyester core/polyethylene sheath commercially available from KoSa Corporation of Salisbury, North Carolina, u.s.a., and 40% 6 denier polyester fibers also commercially available from KoSa Corporation. Other examples of suitable surge layers 167 are described in U.S. Pat. nos. 5,486,166, 5,490,846, 5,562,650, and 5,364,382, the entire disclosures of which are incorporated herein by reference in a manner consistent herewith.

The surge layer 53 desirably has a thickness equal to or greater than about 1.5mm and a permeability in the range of about 2000-4000 darcies. The liner 51 is secured to the surge layer 53, such as by bonding to the surge layer using a suitable adhesive, and to the absorbent body 57, such as by bonding to the absorbent body by another adhesive. It should be understood that the liner 51 may not be secured to the surge layer 53 and/or the absorption body 57 without departing from the scope of this disclosure.

The absorbent body 57 may be wrapped or enclosed by a suitable wrap (not shown) that maintains the integrity and/or shape of the absorbent body. The absorbent body 57 covers the outer cover 49, extends laterally between the leg elastic members 61, and is secured to the inner layer, such as by being bonded thereto with an adhesive. However, it should be understood that the absorbent body 57 may not be secured to the outer cover 49 and remain within the scope of this disclosure.

The bodyside liner 51 covers the absorbent body 57 to isolate the wearer's skin from bodily waste liquid retained by the absorbent body, and is secured to at least a portion of the absorbent body, such as by being bonded to at least a portion of the absorbent body with an adhesive. The liner 51 further extends beyond the absorbent body 57 to cover a portion of the inner layer of the outer cover 49 (particularly in the crotch region 27 of the training pants 21), and the liner is secured to a portion of the inner layer of the outer cover, such as by being bonded to a portion of the inner layer of the outer cover by an adhesive, to enclose the absorbent body 57 between the outer cover 49 and the liner 51 about the periphery of the absorbent body 57. While the bodyside liner 51 is slightly narrower than the outer cover 49, it should be understood that the liner 51 and outer cover 49 may be the same size, or the liner 51 may be larger in size than the outer cover 49, without departing from the scope of this disclosure. It is also contemplated that the liner 51 does not extend beyond the absorbent body 57 and is not secured to the outer cover 49 and/or the absorbent body 57. The bodyside liner 51 is desirably conformable, soft, comfortable, and non-irritating to the wearer's skin, and may be less hydrophilic than the absorbent body 57, so as to present a relatively dry surface to the wearer and permit bodily waste liquids to readily penetrate through its thickness.

The bodyside liner 51 may be manufactured from various types of web materials, such as synthetic fibers (e.g., polyester or polypropylene fibers), natural fibers (e.g., wood or cotton fibers), a combination of natural and synthetic fibers, porous foams, reticulated foams, apertured plastic films, and the like. Various woven and nonwoven fabrics can be used for the bodyside liner 51. For example, the body liner 51 may be constructed from a meltblown or spunbond web of polyolefin fibers. Alternatively, the liner 51 may be a bonded carded web composed of natural and/or synthetic fibers. The bodyside liner 51 can also be composed of a substantially hydrophobic material, and the hydrophobic material can optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. For example, the material may be surface treated with about 0.45% by weight of a surfactant mixture comprising AHCOVEL.N-62 available from Uniqema, Inc., a department of ICI, New Castle, Delaware, U.S.A, and GLUCOPON.220 UP available from Cognis Corporation, Ambler, Pennsylvania, U.S.A, in an effective ratio of 3: 1. The surfactant can be applied by any conventional means such as spraying, printing, brushing, and the like. The surfactant may be applied to the entire liner 51, or may be selectively applied to specific sections of the liner.

A particularly suitable bodyside liner 51 is composed of a nonwoven bicomponent web having a basis weight of about 27 gsm. The nonwoven bicomponent web can be a spunbond bicomponent web or a bonded carded bicomponent web. Suitable bicomponent staple fibers include polyethylene/polypropylene bicomponent fibers available from CHISSO Corporation, Osaka, Japan. In this particular bicomponent fiber, the polypropylene forms the core and the polyethylene forms the sheath of the fiber. Fibers having other orientations (such as multi-lobed, side-by-side, and end-to-end) may be used without departing from the scope of the present disclosure. Moreover, while the outer cover 49 and bodyside liner 51 of the central absorbent assembly 23 can comprise elastomeric materials, it is contemplated that the central absorbent assembly can alternatively be generally inelastic, with the outer cover 49, bodyside liner 51 and absorbent body 57 being constructed of generally inelastic materials.

The front and back side panels 37, 39 of the training pants 21 are bonded to the central absorbent assembly 23 at the respective front and back regions 25, 29 of the training pants and extend outwardly beyond the laterally opposite edges 31 of the assembly. For example, the front side panels 37 of the illustrated embodiment are secured to an inner layer of the outer cover 49, such as by adhesive (not shown), by thermal bonding, or by ultrasonic bonding. These side panels 37 may also be secured to the outer layer of the outer cover 49, such as by adhesive (not shown), by thermal bonding, or by ultrasonic bonding. The back side panels 39 are secured to the outer cover 49 at the back region 29 of the training pants 21 in substantially the same manner as the front side panels 37. Alternatively, the side panels 37, 39 may be integrally formed with the central absorbent assembly 23, such as by being integrally formed with the outer cover 49, bodyside liner 51, or other layers of the training pants 21.

To improve fit and appearance, the side panels 37, 39 desirably have an average length measured parallel to the longitudinal axis of the training pants 21 that is about 20% or greater, more desirably about 25% or greater, of the total length of the training pants (also measured parallel to the longitudinal axis). For example, for training pants 21 having an overall length of about 54 centimeters, the side panels 37, 39 desirably have an average length of about 10 centimeters or greater, and more desirably an average length of about 15 centimeters. Each of the side panels 37, 39 may be constructed of one or more separate pieces of different material. For example, each side panel 37, 39 may include a first side panel portion and a second side panel portion (not shown) joined at a seam (not shown), wherein at least one of the portions includes an elastomeric material. Alternatively, each individual side panel 37, 39 may be constructed from a single sheet of material folded upon itself along an intermediate fold line (not shown).

The side panels 37, 39 desirably comprise an elastic material capable of lateral stretching. Suitable elastic materials and one method of describing the incorporation of the elastic side panels 37, 39 into the training pants 21 are described in the following U.S. patents: 4,940,464 published on 7/10 of 1990 to Van Gompel et al; 5,224,405 published on 7/6/1993 to Pohjola; 5,104,116 published on month 4 and 14 1992, to Pohjola; and 5,046,272 published on month 9 and day 10 1991 to Vogt et al; all of these patents are incorporated herein by reference. For example, suitable elastic materials include stretch-heat laminate (STL), neck-bonded laminate (NBL), reversibly necked laminate, or stretch-bonded laminate (SBL) materials. Methods for preparing such materials are well known to those skilled in the art and are described in the following patents: U.S. Pat. No. 4,663,220 issued on 5.5.1987 to Wisneski et al; U.S. Pat. No. 5,226,992 issued on 7/13/1993 to Morman; and European patent application No. EP 0217032, published 4/8 1987 in the name of Taylor et al; all of these patents are incorporated herein by reference. Alternatively, the side panels 37, 39 may comprise other woven or nonwoven materials, such as those described above as being suitable for the outer cover 49 or bodyside liner 51, or stretchable but inelastic materials.

Containment flaps, generally indicated at 91, are secured to the bodyside liner 51 laterally inward from the leg openings in generally parallel spaced relation to one another to provide a barrier to the flow of urine toward the leg openings. The containment flaps 91 extend longitudinally from the front region 25 of the training pants 21 through the crotch region 27 to the back region 29 of the training pants. Each containment flap 91 includes a nonwoven layer and a film layer secured to the nonwoven layer, such as by being bonded to the nonwoven layer by an adhesive. The flap elastomer 99 is secured between the nonwoven layer and the film layer, typically by a suitable adhesive at the distal end 103 of the flap 91, with the nonwoven layer being folded over the flap elastomer 99 and the thin layer at the distal end 103. The flaps 91 are secured to the bodyside liner 51 by seams of adhesive to define the proximal ends of the flaps.

In use, when the wearer of the training pants 21 urinates in the training pants, urine penetrates the liner 51, where the surge layer 53 helps to decelerate and diffuse surges or gushes of bodily waste liquid that penetrate the liner 51 for absorption by the absorbent body 57. Unabsorbed urine may be retained within the surge layer 53. Eventually, the urine flows along the surge layer 53 and through the surge layer to the absorbent body 57. This typical arrangement does not always work in an ideal manner as described below.

All absorbent articles (regardless of configuration or number of layers) require several functional tasks to reduce garment leakage. These tasks include fluid intake, fluid distribution, and fluid lock-up. Typical personal care absorbent articles partially address these tasks by providing a surge layer 53 between the liner 51 and the absorbent body 57. The surge material may be a bonded carded web material. The surge layer 53 serves three purposes. 1) Since a typical superabsorbent material (SAM) in the absorbent body 57 cannot absorb fluid as quickly as it is delivered from the user, the surge layer 53 serves as a temporary holding location or reservoir for the fluid. Thus, the surge layer 53 should have a high permeability and a high void volume. 2) When the SAM in the infested area (typically the front area 25) is saturated with fluid, additional fluid must be transferred to the SAM unsaturated area via the surge layer 53. Thus, the surge layer 53 must move or allow fluid movement in the X-Y plane. 3) After infestation, the surge layer 53 must act as a barrier between the now-wetted absorbent layer and the user's skin. Thus, the surge layer 53 must not permanently retain or "absorb" fluid, meaning that the surge layer 53 is desirably made of thermoplastic fibers.

If a typical surge material: 1) higher permeability in the Z direction to allow fluid to pass; 2) temporarily holding the liquid; and 3) is thermoplastic so as not to permanently retain fluid or moisture, then the surge material will also have a higher permeability and lower capillary action in the X-Y plane. This means that once the SAM in the insult area (typically the front area 25) is fully saturated, fluid will flow along the surge layer 53 to the lowest point in the absorbent article 21, typically the crotch region 27. After two or three insults, the crotch region 27 becomes saturated and the surge layer 53, due to its low capillary action, does not have the ability to move fluid from the crotch region 27 against gravity. This results in fluid pooling in the crotch region 27 and fluid leakage from the absorbent article 21.

A typical solution to avoid pooling and leakage is to add more absorbent material in the crotch region 27, which also makes the article less comfortable for the user. In addition, since the user may be in multiple locations during an insult, additional absorbent material is added in other areas of the article; the absorbent material may not be used depending on the position of the user. The addition of additional absorbent material makes the article less comfortable for the user and increases the cost of the article.

Previous efforts to control the fluid in the surge material and increase the absorbent core utilization have focused primarily on increasing the capillary tension of the surge material by making two layers of surge material or by changing the surfactant treatment of the surge material. In addition, efforts have been made to increase the void volume of the surge material without increasing the cost. These efforts have not produced adequate results.

Another previously unused way to address pooling and leakage is to increase the utilization of the absorbent material in the manner described herein. In other words, optimizing fluid flow to use all absorbent material already present in the article would eliminate the need to add additional absorbent material. This may be accomplished by controlling the flow of fluid in the absorbent article 21 from the point of insult to the lowest point in the surge layer 53. Reducing the fluid permeability of the surge material in the X-Y plane slows the fluid flow to low points, but reducing the fluid permeability of the surge material in the X-Y plane changes the fluid permeability of the surge material in the Z direction, resulting in reduced fluid absorption in the absorbent body 57 and increased residual fluid content in the surge layer 53. Additionally, reducing the fluid permeability of the surge material in the X-Y plane may reduce the fluid flow rate below the infested flow rate, resulting in fluid backflow and leakage across the surge layer 53. Furthermore, simply reducing the fluid permeability of the surge material in the X-Y plane does not necessarily increase the contact area of the fluid with the unused absorbent.

The surge solution described herein both reduces the flow rate of fluid from the insult area (typically the front area 25) to low points in the absorbent article 21 and increases the contact of fluid with the absorbent body 57, thereby enabling a more uniform distribution of fluid absorption in the absorbent body 57. The surge solution described herein increases the tortuosity of the fluid flow path in the X-Y plane shown in fig. 3-5, while maintaining the fluid permeability of the surge material in the X-Y plane and the fluid permeability of the surge material in the Z direction (perpendicular to the X-Y plane). Forcing the fluid into a non-linear path effectively increases the path distance from the insult area, typically in the front region 25, to the crotch region 27 with the goal of slowing the fluid to the crotch region 27 or other lowest point, thereby allowing the fluid to be absorbed by the SAM in the absorbent body 53.

The most effective way to increase the tortuosity of the fluid flow path is to apply a barrier 90 to the X-Y plane linear fluid flow within the surge layer 53 itself. In one aspect, such a barrier 90 may be a physical barrier formed in the form of a fine line embossment that is disposed in the surge layer 53 in a variety of patterns. By using heat and pressure, a high density of fine lines of surge material can be created so that fluid is prevented from penetrating the lines. Such a wire can be produced at high speed in a commercial process. Since fluid cannot pass through the wire, fluid must flow around the wire. Any suitable pattern of such lines will slow the flow of fluid in the X-Y plane. The active pattern comprises a series of V-shaped lines or a series of lines with strategically placed line breaks.

In addition to embossing, barrier fillers, chemical (e.g., hydrophobic) treatments, slits, film fragments, polymeric materials, adhesives, lotions, ointments, or any other suitable means may be used to create a barrier to fluid flow.

Three exemplary patterns are shown in fig. 3-5, which are plan views of the surge layer 53. Figure 3 shows the pattern of embossing lines 92 through the cross-sectional thickness or Z-direction of the surge. The embossing lines 92 are staggered to eliminate any linear flow path in the longitudinal direction 44. Fig. 4 shows a pattern of embossing lines in a V-shaped pattern 94 that is also staggered to eliminate any linear flow path in the longitudinal direction 44. Fig. 5 shows a pattern of a combination of embossing lines 92 and embossing lines in a V-shaped pattern 94, which is also staggered to eliminate any linear flow path in the longitudinal direction 44. It should be noted that these are just three examples of suitable patterns. Other suitable patterns may employ arcuate lines, offset geometries, funnel-shaped patterns, single lines or shapes, or any other lines or shapes that reduce or eliminate linear flow paths in the longitudinal direction 44 (particularly toward the transverse center of the surge material).

Surge materials for disposable absorbent articles described herein have increased X-Y tortuosity and fluid flow path, but still maintain Z-direction permeability. The resulting fluid flow delay allows more fluid to be absorbed into the upper portion of the absorption body 57 rather than flowing down the surge layer 53 to the lowest point or crotch region 27 of the absorption body 57, thereby improving the utilization of the absorption body 57. The increase in the degree of X-Y bending reduces the amount of fluid in the lower part of the absorbent garment and improves the utilisation of the absorbent core.

In a first particular aspect, an absorbent article includes: a bodyside liner; an outer cover; an absorbent body disposed between the bodyside liner and the outer cover; and a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a barrier extending substantially through the surge material in the Z direction, wherein the barrier is configured to block at least one linear longitudinal fluid flow path.

A second particular aspect includes the first particular aspect, the surge layer further including a plurality of barriers that are staggered to block a plurality of linear longitudinal fluid flow paths while allowing for non-linear fluid flow paths in the longitudinal direction.

A third particular aspect includes the first aspect and/or the second aspect, wherein the plurality of barriers includes barriers in the form of parallel lines.

A fourth particular aspect includes one or more of aspects 1-3, wherein the parallel lines are perpendicular to the longitudinal direction.

A fifth particular aspect includes one or more of aspects 1-4, wherein the plurality of barriers includes barriers in the form of lines disposed at a non-orthogonal angle to the longitudinal direction.

A sixth particular aspect includes one or more of aspects 1-5, wherein the plurality of barriers comprises a combination of barriers in the form of parallel lines, arcuate lines, and/or geometric shapes.

A seventh particular aspect includes one or more of aspects 1-6, wherein the plurality of barriers comprises a plurality of embossments.

An eighth particular aspect includes one or more of aspects 1-7, wherein the article is a diaper, training pant, adult incontinence garment, or catamenial pad.

A ninth particular aspect includes one or more of aspects 1-8, wherein the surge layer includes thermoplastic fibers.

A tenth particular aspect includes one or more of aspects 1-9, the surge layer further including a plurality of barriers that are staggered to block all linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

An eleventh particular aspect includes one or more of aspects 1-10, wherein the barrier is an embossing, a barrier filler, a chemical treatment, a slit, a film fragment, a polymeric material, an adhesive, a lotion, an ointment, and combinations thereof.

A twelfth particular aspect includes one or more of aspects 1-11, wherein the barrier is an embossment.

In a thirteenth particular aspect, an absorbent article includes: a bodyside liner; an outer cover; an absorbent body disposed between the bodyside liner and the outer cover; and a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a plurality of barriers extending substantially through the surge material in the Z direction, wherein the plurality of barriers are configured to block a plurality of linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

A fourteenth particular aspect includes the thirteenth particular aspect, wherein the plurality of barriers includes barriers in the form of parallel lines.

A fifteenth particular aspect includes the thirteenth and/or fourteenth particular aspect, wherein the plurality of barriers includes barriers in the form of a plurality of lines arranged at a non-orthogonal angle to the longitudinal direction.

A sixteenth particular aspect includes one or more of aspects 13-15, wherein the article is a diaper, a training pant, an adult incontinence garment, or a catamenial pad.

A seventeenth particular aspect includes one or more of aspects 13-16, wherein the plurality of barriers comprises a plurality of embossments.

An eighteenth particular aspect includes one or more of aspects 13-17, wherein the plurality of barriers comprises embossments, barrier fillers, chemical treatments, slits, film fragments, polymeric materials, adhesives, lotions, ointments, and combinations thereof.

In a nineteenth particular aspect, an absorbent article includes: a bodyside liner; an outer cover; an absorbent body disposed between the bodyside liner and the outer cover; and a surge layer disposed between the bodyside liner and the absorbent body, the surge layer having an X-Y plane, a Z direction, and a longitudinal direction, and a plurality of barriers extending substantially across the surge material in the Z direction, wherein the plurality of barriers are configured to block all linear longitudinal fluid flow paths while allowing non-linear fluid flow paths in the longitudinal direction.

A twentieth particular aspect includes the nineteenth particular aspect, wherein the article is a diaper, a training pant, an adult incontinence garment, or a catamenial pad.

When introducing elements of the present disclosure or the preferred embodiments thereof, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

As various changes could be made in the above constructions without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.