Disposable diaper having pocket containments and a method for manufacturing the same

• US 6,494,872 B1
• Filed: 01/03/1996
• Issued: 12/17/2002
• Est. Priority Date: 06/01/1992
• Status: Expired due to Term

• Current Assignee: Paragon Trade Brands, LLC
• Original Assignee: Paragon Trade Brands Inc. (Johnson Controls International plc)
• Inventors: Suzuki, Migaku, Fukui, Hiroaki
• Primary Examiner(s): Weiss, John G.
• Assistant Examiner(s): REICHLE, KARIN M
• Application Number:
  US08/613,427
• Time in Patent Office: 2,540 Days
• Field of Search: 156/163-164, 156/229, 156/494, 604/385.26, 604/385.19, 604/385.1, 604/385.2, 604/392-398
• US Class Current: 604/385.26
• CPC Class Codes: A61F 13/15699 Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
• CPC Class Codes: A61F 13/49413 the edge leakage prevention means being an upstanding barrier
• CPC Class Codes: A61F 13/495 with faecal cavity

Abstract

The present invention is directed to provide a diaper having a pocket structure which includes a breakage-resistant hydrophobic topsheet and an apertured portion of proper size which is surrounded by a strengthened inner periphery and provides an improved leakage protection effect. The present invention is further directed to a method of manufacturing such diaper which enables economical and simplified process operation. A diaper is,provided wherein an absorbent body is interposed between a liquid impermeable backsheet and an apertured hydrophobic topsheet to form side, front and rear end portions of the diaper. The hydrophobic topsheet includes two separate sheets each having alternating concave portion and convex portions defined by a wavy side edge. The two sheets are arranged to face to each,other so that the convex portions thereof partially overlay each other at front and rear end portions of the diaper to form pocket portions. The concave portions each have a flap portion which is folded over a predetermined width to enclose an elastic member and the flap portions face each other to bound an apertured portion therebetween.

Claims

1. A diaper having a liquid impermeable backsheet, a hydrophobic topsheet, and an absorbent body interposed between said backsheet said topsheet to form sides and front and rear end portions of said diaper, said hydrophobic topsheet comprising two separate sheets each having a concave portion between spaced convex portions, said two sheets being arranged to face each other so that said convex portions thereof partially overlay each other at said front and rear end portions of the diaper to form pocket portions, said concave portions each having a pair of spaced transverse cuts therein to define a flap portion which is folded over by a predetermined width to enclose an elastic member whereby said folded-over flap portions face each other to define an apertured portion therebetween.

2. The diaper of claim 1, wherein:

said overlaying convex portions are secured so that said convex portions are movable with respect to each other to accommodate movement of a wearer.

3. A method for manufacturing a diaper having pocket portions comprising the steps of:

providing an elongate continuous expanse of hydrophobic topsheet material;

cutting said topsheet material along a wavy line extending longitudinally of the topsheet material to provide first and second continuous sheet members each having alternating convex portions and concave portions;

producing a pair of spaced transverse cuts in each of said concave portions of said topsheet material of a predetermined length which extend into each of said concave portions to form flap portions;

positioning an elongate elastic member on a topsheet member in the region of said concave portion adjacent a flap portion;

folding over said flap portion to enclose said elastic member;

longitudinally offsetting said first and second continuous sheet members with respect to each other so that said convex portions thereof partially overlay each other and said concave portions thereof face each other and are spaced from each other to define an apertured portion therebetween;

interposing absorbent bodies between a backsheet and said offset first and second continuous sheet members;

bonding said backsheet with said first and second continuous sheet members at sides and front and rear portions of an individual diaper section intended to be cut out therefrom so that pocket portions are provided by said hydrophobic topsheet material and said apertured portion is defined between said folded-over flap portions of said concave portions; and

producing transverse cuts at said front and rear end portions to separate an individual diaper section.

4. The method of claim 3, wherein:

said overlaying convex portions are secured so that said convex portions are moveable with respect to each other to accommodate movement of a wearer.

5. A disposable diaper comprising

a liquid impermeable backsheet,

an absorbent body overlying said backsheet,

an elongate hydrophobic topsheet overlying said absorbent body, said topsheet comprising two separate sheets each having longitudinally spaced-apart convex portions and a concave portion therebetween, said two sheets being disposed adjacent opposite sides of said absorbent body and in facing relation, with the convex portions at one set of ends of said sheets overlapping and the convex portions at another set of ends of said sheets opposite said one set of ends overlapping, and the concave portions facing and spaced from each other to pocket portions, said concave portions each having a flap portion defined by a pair of spaced-apart cuts extending outwardly from said pocket portions, and

each of said sheets having an elastic member extending longitudinally of said sheet secured to said concave portion of the sheet adjacent said pocket portions, said flap portion of the sheet being folded over by a predetermined width outwardly from said pocket portions and secured over said elastic member to enclose said elastic member whereby said folded-over flap portion bounds [one] a side of said pocket portions.

6. The diaper of claim 5, wherein said elastic member is contractible to define an inner gather to provide formed fit for a wearer.

7. The diaper of claim 6, wherein the concave portion has a first predetermined length and wherein said elastic member has a length substantially equivalent to said first predetermined length.

8. The diaper of claim 6, wherein the topsheet has a second predetermined length and wherein said elastic member has a length substantially equivalent to said second predetermined length.

9. A method for manufacturing a disposable diaper having pocket portions comprising the steps of:

providing an elongate continuous expanse of hydrophobic topsheet material,

cutting said topsheet material along a wavy line extending longitudinally of the topsheet material to provide first and second continuous sheet members each having alternating convex portions and concave portions,

producing longitudinally spaced-apart transverse cuts in each of said concave portions of said topsheet material of a predetermined length which extend into each of said concave portions to form flap portions,

securing an elongate elastic member on a topsheet member adjacent a flap portion, folding over said flap portion to enclose said elastic member and securing said flap portion in its folded-over position,

longitudinally offsetting said first and second continuous sheet members with respect to each other so that said convex portions thereof partially overlay each other and said concave portions face each other and are spaced from each other to define an apertured portion therebetween,

providing a substantially continuous expanse of backsheet material adjacent and in facing relation to said first and second sheet members,

interposing absorbent bodies between said overlapping first and second continuous sheet members and said backsheet material,

bonding said backsheet with said first and second continuous sheet members at sides and front and rear end portions of an individual diaper section intended to be cut out therefrom so that pocket portions are provided by said hydrophobic topsheet material and said apertured portion is defined between the folded-over flap portions of said concave portions, and

producing transverse cuts at said front and rear end portions to separate an individual diaper section.

10. The method of claim 9, which further comprises the step of securing an elongate member to said flap portion intermediate an inner edge of said concave portion and said elastic member, and using said elongate member to fold said flap portion over said elastic member.

11. The method of claim 9, wherein said elastic member has a length substantially equivalent to a distance by which said spaced apart transverse cuts in each of said concave portions are separated, said elastic member also being positioned between said transverse cuts.

12. The method of claim 9, wherein at least one of said continuous topsheet members has a third predetermined length and wherein said elastic member has a length substantially equivalent to said third predetermined length and extends substantially the full length of said at least one of said continuous topsheet members.

13. A method for manufacturing a disposable diaper having pocket portions comprising the steps of:

providing an elongate continuous expanse of hydrophobic topsheet material,

cutting said topsheet material along a wavy line extending longitudinally of the topsheet material to provide first and second continuous sheet members each having alternating convex portions and concave portions,

producing longitudinally spaced-apart secondary transverse cuts in each of said concave portions of said topsheet material of a predetermined length which extend into each of said concave portions to form flap portions,

securing an elongate elastic member on a topsheet member adjacent a flap portion,

securing an elongate member to said flap portion intermediate an inner edge of said concave portion and said elastic member, and using said elongate member to fold said flap portion over said elastic member and securing said flap portion in its folded-over position,

longitudinally offsetting said first and second continuous sheet members with respect to each other so that said convex portions thereof partially overlay each other and said concave portions face each other and are spaced from each other to define an apertured portion therebetween,

providing a substantially continuous expanse of backsheet material adjacent and in facing relation to said partially overlaying first and second continuous sheet members,

interposing absorbent bodies between said first and second continuous sheet members and said backsheet material,

bonding said backsheet with said first and second continuous sheet members at sides and front and rear end portions of an individual diaper section intended to be cut out therefrom so that pocket portions are provided by said hydrophobic topsheet material and said apertured portion is defined between the folded-over flap portions of said concave portions, and

producing transverse cuts at said front and rear end portions to separate an individual