AN ABSORBENT ARTICLE THAT HAS BARRIER DOUBLESINTEGRALS AND PROCESS TO DO THE SAMEFIELD OF THE INVENTIONThe present invention relates to absorbent articles such as disposable diapers, and more particularly, to absorbent articles having integral barrier folds formed of portions of the weft, from which the article is cut which had been previously removed to form an absorbent article. the openings or notches of leg, and discarded as waste.
BACKGROUND OF THE INVENTIONThe primary function of absorbent articles such as disposable diapers and underwear for incontinence, is to absorb and contain body exudates. These articles are thus intended to prevent body exudates from staining, moistening or otherwise contaminating clothing or other items, such as sheets, which come into contact with the wearer. The most common mode of failure for such products, occurs when the body exudates are rotted out of the openings between the article and the user's leg or waist adjacent to the clothing, because they are not immediately absorbed into the article or article. The absorbent is not capable of sustaining a good fit in the user, such that crevices are created that allow the exudates to drain out of the absorbent article. For example, the urine tends to be deposited on the top sheet in discharges such that the urine migrates towards the cracks in the frame more rapidly than what can be absorbed, and such that it may come into contact with clothing or other articles. and be absorbed by these items. Additionally, loose or watery fecal material that is not readily absorbed by the absorbent articles, tends to "float" on the liquid receiving surface and function in such a manner that it passes between the spaces in the article on the user's legs or waist. Contemporary disposable diapers have a fluid-permeable upper sheet, an impenetrable fluid back sheet, an absorbent core and elasticized leg fins generally formed from an elastic member that is encased in the continuous upper sheet and the back sheet, which it extends beyond the edges of the absorbent core. These elasticized leg fins show efficiency generally to avoid the effect of wick or fluid passage and the overflow of the fluid-laden diaper towards the clothing that comes into contact with the diaper edges, since the elasticized leg fins present a barrier fluid impervious between the diaper edge and the clothing, and in addition, provides a seal action around the user's legs to maintain a seal around the leg and minimize cupping. However, leaks along the perimeter of the diaper can still occur. As the diaper is worn for longer periods of time, the forces tend to act on the diaper to degrade the initial fit on the wearer. Large spaces and warping of the diaper on the legs and waist results in the degradation of the fit. In this way, as the liquids are deposited on the upper sheet, some of the liquids are not immediately absorbed through the upper sheet and migrate towards the edges of the diaper, where it can drain through or pass the spaces in. the diaper, and get to come into contact with clothing or undergarments where it can be absorbed by and impregnated in such garments. Disposable diapers with separately joined barrier folds have been provided, which inhibit the faecal matter being washed away or the discharge of urine or liquids from staining the wearer's clothing. The barrier folds restrict the free flow of this material and provide a structure that holds said material inside the diaper, such that said material floats freely or flows on the upper sheet of the diaper, it is contained inside the diaper. Typically, the barrier folds are formed by joining an independent weft of the doubles material to the weft of the upper sheet, or the upper sheet of a complete frame. For example, commonly assigned U.S. Patent 4,695,278 to Lawson teaches a dual bending configuration in which the barrier doubles is a separate element attached to the topsheet. When the barrier fold is attached to the top sheet as a separate element, special machinery is required to join the barrier folds, and, consequently, the additional machinery increases the cost of the finished article. In addition when conventional diapers are manufactured, the notches or slits are cut on the sides of the article to provide a contour to the legs of the person who will use the article. For example, leg samples account for approximately 15 to 20% of the area of an absorbent article. The portion removed from the article to create the notches or leg slits has no further use in the manufacturing process and is discarded. In this way, current diaper manufacturing methods produce a large amount of unnecessary waste.
BRIEF DESCRIPTION OF THE INVENTIONThe present invention relates to a disposable absorbent article having barrier folds and to a method of making this article. The folds are integral with the diaper, that is, they are not formed separately and then attached to the article. The article includes a frame consisting of a fluid-permeable top sheet, a fluid-impermeable back sheet, and an absorbent core disposed between the top sheet and the back sheet. In a first embodiment, the barrier folds are formed from an extension of the top sheet and the back sheet, beyond the longitudinal edges of the absorbent core and having a first and second ends that are attached to the top sheet. another underlying layer of the diaper. The barrier folds are formed from a fold area defined by the cuts in the diaper weft. The barrier folds are formed by folding the fold area towards the longitudinal center line of the absorbent article, and joining at least a portion of the fold area adjacent the ends of the fold area to the top sheet. The barrier folds further include a separating means for separating the folds away from the frame, at least in the crotch region of the article. As a modification to this embodiment, the article may further include seal folds that are also formed from the material of the upper sheet and the extended back sheet. In a second embodiment, the article includes barrier folds each of which consists of a top sheet layer and a back sheet layer, and the stamp folds which each consist of two layers of the sandwich top sheet between two layers of the backsheet material. The barrier folds and the seal folds are formed from a fold area defined by the cuts in the diaper weft. The folds are formed by one of the fold patterns described below.
The barrier folds of this invention also preferably include a separating means, which is preferably elastic, to separate the folds away from the frame, and, preferably, the folds of the seal will include an elasticized member. The process, by which the absorbent articles of the present invention are made, begins with a weft having longitudinal edges consisting of the topsheet, the backsheet, and the absorbent cores disposed between the topsheet and the backsheet. The web is finally cut laterally at separate spaced intervals to form individual absorbent articles. Each absorbent article has a first waist region, a second waist region, a crotch region located between the first and second waist regions, longitudinal and lateral centerlines, longitudinal edges and end edges. To define the barrier folds and seal folds, the frame is first cut at spaced apart intervals along each longitudinal edge to define a fold area having internal, external and medial longitudinal portions. The fold area is then bent to form the leg folds, as described below. The cuts are provided in either the first waist region, the second waist region, or both of the first and second waist regions. The articles are preferably folded according to one of the following three fold patterns. In a first fold pattern according to the present invention, the cuts are provided in both the first waist region, such as the second waist region, on each side of the article. These cuts define a fold area that bends toward the longitudinal center line of the absorbent article to form a barrier fold and a seal fold. Once the fold areas have been folded, a portion of the fold area adjacent to each end of the fold area, they are attached to the upper sheet or to a layer that lies on the upper sheet of the article in both of the first and second waist regions, to complete the barrier folds and the seal folds. In a second bending pattern according to the invention, the cuts are provided as described above, joining means are provided to the longitudinally adjacent bending areas either side of a line connecting to the closed ends of the cuts (ie say, that end of the cut closest to the longitudinal centerline of the absorbent article). The fold area is bent towards the longitudinal center line. The attachment means makes a portion of the fold area to the top sheet, or to a layer that lies on the top sheet in at least the crotch region of the resulting article. Once secured, the fold is then folded away from the longitudinal center line to produce the barrier fold. The ends of the barrier folds are attached to the upper sheet or a layer that lies on the upper sheet in the first and second waist regions of the article, such that a barrier fold results that has a distant edge that is free. of the top sheet in at least the crotch region. The portion of the fold areas longitudinally adjacent to the longitudinal edges forms a seal fold. Each of the resulting barrier folds consists of one layer of the upper sheet and one layer of the back sheet and the outer seal fold comprises two layers of the backsheet and two layers of the material of the upper sheet. In a third bending pattern, a first means of attaching to the topsheet in the first and second waist regions is provided. The fold area is first unfolded towards the longitudinal center line and attached to the underlying elements in the first and second waist regions. After the fold area is bent towards the longitudinal center line, a second means of attachment to the garment facing surface of the fold area is provided, preferably in its medial longitudinal portion and a third attachment means is provided to the garment. surface facing the body of the fold area in the first and second waist regions of the article along the cutting lines. The fold area is then bent away from the longitudinal centerline, such that the fold area becomes joined equally in its medial longitudinal portion. The fold is then joined to the top sheet in the first and second waist regions to produce a barrier fold having two layers of the backsheet and two layers of the top sheet material, and a fold having a single layer of the material of top sheet and back sheet.
BRIEF DESCRIPTION OF THE DRAWINGSSince the specification concludes with the claims particularly pointing and indistinctly claiming the subject matter that is considered as the formation of the present invention, it is believed that the invention is better understood from the following description, which is taken together with the drawings annexes in which similar designations are used to assign substantially identical elements, and in which: Figure 1 is a plan view of an absorbent article having integral barrier folds formed by the process of this invention; Figure 2 presents a partial cross section of the fold area to illustrate one of the fold patterns of this invention; Figure 3 presents a partial cross section of the fold area to illustrate an alternate bend pattern of the absorbent article shown in Figure 1; Figure 4 presents an illustration of the article of an alternate modality before the doubling process takes place; Figure 5A and 5B present a partial cross-section of the fold area to illustrate one of the fold patterns of this invention; Figures 6A and 6B present a partial cross-section of the fold area to illustrate another of the fold patterns of this invention; Figure 7 shows an illustration of an alternative embodiment of the article of this invention; and Figure 8 presents an illustration of one embodiment of the process of this invention, in which the fold area is created by continuous cuts from one article to the next; and Figure 9 presents an illustration of an embodiment of this invention that includes a cavity in the second waist region of the article.
DETAILED DESCRIPTION OF THE INVENTIONThe Product: As used herein, the term "absorbent article" refers to articles that absorb and contain body exudates, and more specifically refers to articles that are placed against or close to the user's body to absorb and contain the various body discharges. The absorbent articles are typically differentiated in case they are reusable or disposable. Disposable absorbent articles are those items that are intended to be discarded after a single use (ie, they are not intended to be washed or otherwise restored or reused). The absorbent articles of the present invention are preferably disposable absorbent articles. The absorbent articles may also be defined in terms of whether they are "unitary" such that they do not require separate handling parts, or if they comprise a disengaged member of a diaper system such as a fastener and separate liners. The absorbent articles of the present invention are preferably unitary. One embodiment of the present invention, in diaper 20, is shown in Figure 1. As used herein the term "diaper" refers to a garment generally worn by infants and incontinent persons that is worn around the wearer's lower torso. . However, it should be understood that the present invention is also applicable to other disposable absorbent articles such as incontinence briefs or undergarments, disposable training pants, diaper bras, sanitary napkins and the like. Figure 1 is a plan view of an absorbent article, diaper 20 of the present invention in its non-contracted, flat state, (i.e., with the contraction induced by the elastic pulled outward) with portions of the structure being cut out for show more clearly the construction of the diaper 20, and with the portion of the diaper 20 that contacts the wearer facing the viewer. The diaper 20 is shown in Figure 1, having a first waist region 22, a second waist region 24, a crotch region 26, and a periphery 28 that is defined by the outer edges of the diaper 20, in which the longitudinal edges are designated 30 and the end edges are designated 32.
The diaper 20 further has a lateral centerline, which is designated 34, and a longitudinal center line, which is designated 36. The diaper 20 comprises a liquid-permeable upper sheet 38, a generally-facing surface 40 by the upper sheet 38; a backsheet impermeable to liquid 42; a garment facing surface 58 generally defined by the backsheet 42, an absorbent core 44; fastener means 54 for securing the diaper 20 to the wearer such as the pair of tape tab fasteners 56; barrier folds 62 each having a proximal edge 64, a distant edge 66, a first end 72, and a second end 74; separating means 76 such as elastic members 77 for separating the distant edge 76 away from the surface facing the body40; ear panels 88; and an elastic waist feature 90. Figure 1 shows a modality of the diaper 20, in which the top sheet 38 and the back sheet 42 have length and width dimensions generally greater than those of the absorbent core 44. The top sheet 38 and the backsheet 42 extend beyond the edges of the absorbent core 44 to thereby form the periphery 28 of the diaper 20. The periphery 28 comprises the longitudinal edges 30 and the end edges 32. As shown in Figure 1, the upper sheet 38 is generally coextensive with the backsheet 42 along at least the end edges 32, and preferably the longitudinal edges 30. Although the upper sheet 38 as the backsheet 42 and the absorbent core 44 can be assembled into a variety of well-known configurations, preferred diaper configurations are generally described in U.S. Patent No. 3,860,003 entitled "Contractible Sid e Portions for Disposable Diaper "(Collapsible side portions for disposable diaper) by Kenneth Buell; and U.S. Patent No. 5,151,092 entitled "Absorbent Article with Dynamic Elastic Waist Feature Having a Predisposed Resilient Flexural Hinge" (absorbent article with dynamic elastic waist feature having a predisposed elastic hinge) by Buell et al .; each of which is incorporated herein by reference. The diaper 20 has two longitudinally opposite waist regions, first waist region 22 and a second waist region 24 extending, respectively from the end edges 32 of the periphery of the diaper 28 towards the lateral centerline of the diaper 20. The regions waist 22 and 24 generally comprise those portions of the diaper 20 which, when worn, enclose the wearer's waist. The crotch region 26 is that portion of the diaper 20 placed between the first waist region 22 and the second waist region 24, and comprises that region of the diaper 20, which, when worn, is placed between the legs of the wearer and covers the lower torso of the user. The absorbent core 44 can be any of the means that are generally compressible, conformable, non-irritating to the wearer's skin and capable of absorbing and retaining liquids and certain body exudates. The absorbent core has longitudinal sides 50 and side ends 52. The absorbent core 44 can be manufactured in a wide variety of sizes and shapes (e.g., rectangular, hourglass, asymmetric, etc.,) and from a wide variety of liquid absorbent materials commonly used in disposable diapers and other absorbent articles, such as crushed wood pulp which is generally referred to as an air filter. Examples of other suitable materials include crepe cellulose wadding, absorbent foams, absorbent sponges, super absorbent polymers, gelling absorbent materials, or any equivalent materials or combinations of materials. The configuration and construction of the absorbent core can also be varied. For example, the absorbent core may have zones of varying gauge, a hydrophilic gradient, a super absorbent gradient, or acquisition zones of lower average basis weight and lower average density.; or may comprise one or more layers or structures). The total absorbent capacity of the absorbent core 44 must, however, be compatible with the design load and intended use of the diaper 20. In addition, the size and absorbent capacity of the absorbent core 44 may be varied to suit varying users. in size from babies to adults. Exemplary absorbent structures for use as the absorbent core 44 are described in U.S. Patent No. 4,610,678 entitled "High-Density Absorbent Structures" issued to Weisman et al. On September 9, 1986, U.S. Patent No. 4,673,402 entitled "Absorbent Articles With Dual-Layered Cores" (Absorbent articles with double layer cores), issued to Weisman et al. on June 16, 1987; United States patentNo. 4,888,231 entitled "Abosrbent Core Having a Dusting Layer", issued to Angstadt on December 19, 1989; U.S. Patent No. 4,834,735 entitled "High Density Absorbing Members Having Lower Density and Lower Basis Weight Acquisition Zones" (High Density Absorbing Members Having Low Basis Weight and Low Density Acquisition Zones), issued to Alemany et al. May 30, 1989; and U.S. Patent No. 5,318,554 to Young et al. issued June 7, 1994. Each of these patents is incorporated herein by reference. The backsheet 42 is positioned adjacent the absorbent core 44 and is preferably secured by core bonding (not shown) such as those well known in the art. For example, the backsheet 42 can be secured to the absorbent core 44 by a uniform, continuous adhesive layer, a patterned adhesive layer, or an array of separate lines or spots of adhesives. The adhesives that have been found to be satisfactory are manufactured by H.B. Fuller Company of St. Paul, Minnesota and are marketed as HL-1258. The joining means will preferably comprise an open-pattern network of filaments of adhesive as described in United States Patent No. 4,573,986 entitled "Disposable Waste-Containment Garment", which was issued. to Minetola, et al. on March 4, 1986, most preferably various lines of adhesive filaments twisted in a spiral pattern as illustrated by the apparatus and methods shown in United States Patent No. 3,911, 173 issued to Sprague. , Jr. on October 7, 1975; U.S. Patent No. 4,785,996 issued to Ziecker et al. on November 22, 1978; and U.S. Patent No. 4,842,666 issued to Werenicz on June 27, 1989. Each of these patents is incorporated herein by reference. Alternatively, the joining means may comprise heat bonds, pressure joints, ultrasonic joints, dynamic mechanical joints or any other suitable joining means or combination of these appropriate joining means or combination of these joining means as is known in The technique. The backsheet 42 is impermeable to liquid and is preferably manufactured from a thin plastic film, although other flexible liquid impervious materials may also be used. As used herein, the term "flexible" refers to materials which are docile and readily conform to the shape and general contour of the human body. The backsheet 42 prevents the exudates absorbed and contained in the absorbent core 44 from wetting the articles that come into contact with the diaper 20 such as the sheets and clothes. The backsheet 42 can thus comprise a woven or non-woven material, polymeric films such as polyethylene or polypropylene thermoplastic films, or mixed materials such as a film-coated nonwoven material. Preferably, the backsheet is a thermoplastic film having a thickness of from about 0.012 mm to about 0.051 mm. Particularly preferred materials for the backsheet include the RR8220 blown films and the RR5475 cast films as manufactured by Tredegar Industries, Inc. of Terre Haute, IN and P18-1401 available from Clopay Corp. of Cincinnati, OH. The backsheet 42 is preferably finished in relief or cylindrical to provide an appearance more similar to the fabric. In addition, the backsheet 42 can allow the vapors to escape from the absorbent core 44, (i.e., breathable, while still preventing the exudates from passing through the backsheet 26. The size of the backsheet 42 is dictated by the size of the absorbent core 44 and the exact design of the selected diaper.The topsheet 38 is positioned adjacent to the superette facing the body of the absorbent core 44, and is preferably attached to it and to the backsheet 42 by the joining means (not shown) such as those well known in the art. The appropriate attachment means are described with respect to the attachment of the backsheet 42 to the absorbent core 44. As used herein, the term "attached" encompasses configurations with which one element is directly secured to the other element by securing the element. directly to the other element, and configurations with which the element is indirectly secured to the other element by fixing the element to a member or intermediate members, which in turn, are fixed to another element. In a preferred embodiment of the present invention, the topsheet 38 and the backsheet 42 are directly bonded together at the periphery of the diaper 42, and are indirectly joined together by attaching them directly to the absorbent core 44 by the attachment means (not shown) . The topsheet 38 is docile, soft to the touch, and non-irritating to the wearer's skin.
The topsheet 38 is perezable to the liquid in at least those portions that lie on the absorbent core 44, allowing liquids (eg, urine) to easily penetrate through its thickness. An appropriate top sheet can be made from a wide range of materials, such as porous foams, cross-linked foams, plastic films with openings, natural fibers (e.g., wood or cotton fibers).(synthetic fibers) for example polyester or polypropylene fibers or from a combination of natural and synthetic fibers. Without the upper sheet 38 it is made of a hydrophilic material, at least the upper surface of the sheet 38 is treated to be hydrophilic in that portion of the upper sheet that is intended to receive the liquids, in such a way that the liquids will transfer through the top sheet more quickly. This decreases the likelihood that the exudates will flow out of the topsheet 38 instead of being directed through the sheet 38 and be absorbed by the absorbent core 44. Preferred modes of the topsheet 38 are also hydrophobic in at least the fold area 102, preferably, all portions of the topsheet 38 that lie outwardly from the center laterally of the longitudinal edge of the absorbent core 44 are hydrophobic. As used herein, the term "hydrophobic" is intended to imply that the topsheet 48 is not wetted by aqueous liquids. There are a number of fabrication techniques that can be used to manufacture the topsheet 38. For example, the topsheet 38 can be woven, non-woven, spunbonded, carded, or the like. A preferred top sheet 38 is carded, and thermally bonded by means well known to those skilled in the art of fabrics. Alternatively, the topsheet 38 may be of a film formed with openings as described in U.S. Patent 4,463,405 to Ahr and others "Macroscopically Expanded Three-Dimensional Plástic Web Exhibiting Non-Glossy Visible Surface and Cloth-Like Tactile Impression "(macroscopically expanded, three-dimensional plastic screen, which exhibits a non-glossy visible surface and a fabric-like impression to the touch); U.S. Patent 4,432,312 to Radel et al entitled "Resilient Plástic Web Exhibiting Fiber-Like Properties" (Elastic plastic weave exhibiting cloth-like properties); and US Pat. No. 3,929, 135 to Thompson entitled "Absorptibe Structure Having Tapared Capillaries" (Absorbent structure having used capillaries); all of which are incorporated herein by reference. A preferred top sheet comprises a short length polyethylene fiber web as manufactured by Veratec, Inc., a division of the International Paper Company of Walpole, Massachusetts under the product designation P 8. Preferably, the top sheet 38 has a weight from about 14 to about 25 grams per square meter, a minimum dry strength strength of at least 400 grams per centimeter in the longitudinal direction and a wet tensile strength of at least 55 grams per centimeter in the lateral direction. The diaper 20 preferably includes ear panels 88 which are those portions of the diaper 20 that extend laterally outward from a line parallel to the longitudinal edge of the absorbent core 44 toward the lateral edge of the diaper 20 in at least one of the regions of the diaper 20. waist 22 to 24. The ear panels 88 generally extend longitudinally from the end 32 of the diaper 20 towards the absorbent core, in at least one of the waist regions 22, 24. In the embodiment shown in Figure 1, the ear panels 88 are located in the second waist region 24. The ear panels 88 are formed from the portion of the topsheet 38 and the backsheet 42 that extend laterally laterally from the side edges of the absorbent core 44 in the second waist region 24. Preferably, the ear panels 88 further comprise an elastic member (not shown) disposed between the extended topsheet and the backsheet, and are mechanically pre-stretched as described in the aforementioned U.S. Patent 5,151,092, which it is incorporated herein by reference. The diaper 20 further preferably comprises a waist feature 90 that provides improved fit and containment. The characteristic of elastic waist 90 is that portion or area of the diaper 20 that is intended to expand and contract elastically to dynamically adjust to the wearer's waist. The elastic waist feature extends longitudinally outwardly from at least one of the end edges of the absorbent core 44, and generally forms at least a portion of the end edge 32 of the diaper 20. Disposable diapers are often constructed to have two. elastic waist features, one positioned in the first waist region 22 and one positioned in the second waist region 24, although diapers can be constructed with a single elastic waist feature located in either the first waist region or the second region of waist 24. In the embodiment shown in Figure 1, the characteristic of elastic waist 90 is operatively associated with the ear panels 88 in the second waist region 24. In addition, although the characteristic of elastic waist 90 or any of its constituent elements can comprise a separate element fixed to the diaper 20, preferably the characteristic is constructed elastic waist 90 as an extension of other diaper elements such as the backsheet 42 or the topsheet 38, preferably both the topsheet 42 and the topsheet 38. The elastic waist feature 90 can be constructed in a non-elastic number of different configurations, including those described in U.S. Pat. no. 4,515,595 issued Kievit et al. On May 7, 1985 and the aforementioned United States Patent No. 5,151, 092; each of these references being incorporated herein by reference. Alternatively the ear panels 88 and / or the waist feature 90 may comprise a weft of elastic structural film (SELF) a weft of elastic structural film is an extensible material exhibiting a behavior similar to elastic in an elongation direction without the use of additional elastic materials. The SELF frame includes a stretchable network having at least two contiguous, distinct and unlike regions. One of the regions is configured in such a way that it will exhibit resistance forces in response to an axial elongation applied in a direction parallel to the predetermined axis, in the presence of a substantial portion of the other region that develops significant resistance forces to the applied elongation. At least one of the regions has a surface path length that is greater than that of the other region as measured substantially parallel to the predetermined axis, while the material is in an unstressed condition. The region exhibiting the greatest surface path length includes one or more deformations that extend beyond the plane of the other region. The SELF frame exhibits at least one predetermined axis when subjected to an elongation applied in a direction parallel to the predetermined axis. The SELF screen exhibits the first applied resistance to elongation resistance until the elongation of the weft is sufficient to cause a substantial portion of the region having the greatest surface path length between the plane of elongation applied, after which the SELF screen exhibits second strengths of additional elongation resistance. The total resistance forces of the elongation are greater than the first elongation resistance forces provided by the first region. SELF frames suitable for the present invention are more fully described in copending, commonly assigned US Patent Application Serial No. 08 / 203,456, entitled "Absorbent Article with Multiple Zone Structural Elastíc-Like Film Web Extensible Waist Feature "(Absorptive article with extensible belt characteristic of film in the form of structural elastic, multi-zone) filed by Donald C. Roe, et al. On February 24, 1994, which is incorporated herein by reference . The diaper 20 is preferably provided with a fastening means 54 to form a lateral closure on the diaper 20. In this manner, the first waist region 22 and the second waist region 24 are maintained in an overlapping configuration, when worn. the diaper 20. The fastener means 54 may comprise any of a number of fastener systems as are known in the art such as belts, internal fastener members, tape tabs, hook and loop fastener or other mechanical fasteners. The barrier folds 62 provide a structure for restricting the free flow of body exudates along the surface facing body 40, and for maintaining and containing such exudates within diaper 20, and to help provide a sealing action around of the user. Each barrier fold 62 is a flexible member having a proximal edge 64 and a distal edge 66. In addition, the barrier fold 62 may be provided with a spacer means 76 to separate the distant edges 76 away from the surface facing the body. 40 to form a channel (not shown). The spacer means 76 may comprise one or more elastic members 77. As shown in Figure 1, the barrier fold 62, and more particularly, the proximal edge 64, includes a longitudinal edge 30 of the diaper 20. The proximal edge 64 is juxtaposed on the longitudinal edge 30 in such a way that the exudates, especially the watery fecal matter, which is not easily absorbed and tends to float along the surface facing the body 40, will contact the barrier fold 62 before it can flow out of the diaper 20. It should be emphasized that if the bending area is elasticized by one or more elastic members to create an elasticized seal fold, then the proximal edge 64 preferably extends upwardly from the elasticized portion of the seal dolbez in at least the crotch region 26. The proximal edges 64 and the distal edges 66 are in a spaced relation to each other, and define an effective height of the barrier fold 62. The proximal edge 64 may be separated from the distal edge 66 in a parallel and rectilinear relationship. The effective height of the barrier fold 62 is an important parameter in reducing leakage of body exudates out of the diaper 20. If the effective height of the barrier fold 62 is too small, then gaps will form between the user's leg and the Distant edge 66, such that liquids can flow on the distant edge 66 towards the periphery 28 of the diaper 20. The effective height of the barrier fold 62 depends on the specific design chosen for the diaper 20. The effective height of the barrier folds 62 is defined as the distance between the longitudinal edge of the core 50 and the distant edge of the barrier fold 66. For example, for the embodiment shown in Figure 1, the effective height is at least greater than about 7.6 cm and preferably greater than approximately 8.9 cm. The portion of the adjacent bending area of the bending ends (122, 124 in Figure 4) are attached to the topsheet 38 or other underlying structure in the first and second waist regions 22, 24. The distal edge 66 of each barrier fold 62 is preferably unsecured to any underlying element of diaper 20, in at least crotch region 26 such that it can be separated away from the surface facing body 40. Distant edge 66 is separated away from the surface facing the body 40, such that the barrier fold 62 can form a channel to increase the containment of the diaper 20. As used herein "spacing" includes embodiments wherein the distant edges 66 can assume one or more positions in relation to the surface facing the body 40, sometimes including its same position adjacent to the surface facing the body 40. A channel (not shown) is preferably formed between the proximal edge 64 and the distant edge 66 of the barrier fold62, in at least the crotch region 26. The channel forms a barrier to the flow of exudates as they tend to move or float across the topsheet 38. The channel also contains and maintains exudates within the diaper. 20, until the diaper 20 can be removed. A separation means 76 for separating the distant edge 66 away from the surface facing the body 40 can be any member that collects, contracts, stiffens, shortens or otherwise acts on the barrier fold 62, to cause the barrier folds 62 to rise to provide a channel along the barrier fold 62 that acts as a restriction against leakage of exudates. As shown in Figure 1, the separator means 76 preferably comprises at least one elastic member 77 operatively associated with each of the barrier folds 62 adjacent the distant edge 66. A second elastic member 84 may also be provided or adjacent to the longitudinal edge 30 to form a seal fold 80. The elastic members 77 are preferably secured to the fold area 102, in an elastically contractible condition such that when the barrier folds 62 have been formed, the members elastics 77 effectively contract or collect the distant edge 66 of the barrier fold 62. The elastic members 77 can be secured to the fold areas 102 in an elastically contractible condition in at least two ways, as discussed in the patent United States No. 3,860,003, incorporated by reference above, and United States Patent No. 4,695,278 issued to Lawson intitu "Absorbent Article Having Dual Cuffs" (Absorbent article having dual folds), which is incorporated herein by reference. In addition, the length of the elastic member 77 is generally dictated by the design of the diaper. As shown in Figures 1, 5B, 6B and 7, the diaper 20 may also include seal folds 80. The seal folds 80 provide a structure for restricting the free flow of body exudates away from the edges of the diaper 20; which make contact with the legs of the user. As shown in Figures 5A and 6B each seal fold 80 is a flexible member having a proximal edge 86 and a distal edge 82. The seal folds 80 preferably include elastic elements 84 at their distal edges 82 to increase the action sealing of the seal folds 80. A preferred embodiment of the diaper 20 shown in Figure 1 has a backsheet 42 having a smaller lateral width (i.e., narrower), than the upper sheet 38 such that the sheet upper 38 extends laterally beyond the backsheet in at least fold area 102. In addition, spacer means 76, comprises a longitudinally extending elastic member that is wrapped by the upper sheet extended in a fold of C, to form the distant edge 66 of the barrier fold 62. The fold area 102 is bent toward the longitudinal center line 36, and the first and second ends of the fold area are joined to the top sheet 38 or to another underlying structure in the first and second waist regions 22, 24 as described above. This embodiment is shown in partial cross-section in Figure 2. In still another embodiment of the diaper 20 shown in Figure 1, the fold area 102 bends toward the longitudinal centerline 36 in a first fold of C and the ends of the area of bending are attached to the topsheet or to another underlying structure in the first and second waist regions as described above. However, in this embodiment, the ends of the fold area are joined to the first and second waist areas inward of the center of the distant edge 66 leaving a portion of the fold area 102 unjoined. This unjoined portion bends away from the longitudinal centerline 36 in a second fold of C, and the first and second ends of this portion without joining the fold area 102 join the underlying structure in the first and second waist region. 22, 24, respectively. This modality is shown in partial cross section in theFigure 3. This embodiment has the advantage of providing a greater effective bending height without the high risk of blocking those portions of the diaper 20 intended to receive the body exudates. In the embodiment of this invention shown in Figure 1, the barrier folds 62 are formed by making cuts in the first waist region 22, and in the second waist region 24. The cuts in the first waist region 22, are made preferably coextensive with the lateral edge 32 of the diaper 20 in this waist region. In this embodiment, the cuts in the second waist region 24 can also comprise a line of weakness such as the landing area of a piercing pattern. The cuts define a fold area 102, which is bent toward the longitudinal centerline 36 to form the barrier fold 62. As described above, at least the distant edge 66 and preferably that portion of the fold area 102 in the first and second waist regions 22 and 24, it is to the upper sheet 38 or to an underlying layer of the upper sheet 38 in the first waist region 22 and in the second waist region 24. The barrier fold 62 includes a spacer means holding the distal edge 66 of the fold 62 away from the diaper 20 in at least the crotch region 26. Preferably, the spacer means 76 is elastic. In an alternate embodiment of the diaper 20, as shown in Figure 4, the fold area 102 is formed by making 2 cuts on each longitudinal side 30 of the diaper 20. The fold area 102 is then folded using one of the fold patterns described forward to produce a barrier fold 62 and a seal fold 80. The fold areas 102 of this embodiment can be bent in a variety of ways. In a bend pattern shown in Figures 5A and 5B, the bending area is formed as shown and joining means 112 is provided for attaching the inner longitudinal portion 106 to the topsheet 38u to other underlying layers. The resulting barrier fold 62 comprises a layer of the topsheet 38 and a layer of the backsheet 42, and the resulting seal fold 80 comprises two layers of the topsheet 38 sandwiched between two layers of the backsheet 42. second fold pattern shown in Figures 6A and 6B the middle longitudinal portion is divided into two sub-portions by a fold line and the attachment means 112 joins the garment-facing surfaces 58 of these sub-portions with each other. The resulting barrier fold 62 comprises two layers of the backsheet 42 sandwiched between two layers of the topsheet 38, and the resulting seal fold 80 comprises a layer of the backsheet 42 and a layer of the topsheet 38. The portion of the fold area 102 adjacent to each of the first and second ends of the fold area, 122, 124 is attached to the topsheet 38 or to an underlying structure for a diaper 20 using either of the two fold patterns discussed above. In a preferred embodiment of both of these fold patterns, the barrier fold 62 will include a separation means 76, which is preferably an elasticized member and the seal fold 80 will preferably include an elasticized member 84. In another embodiment of this article, shown in Figure 9, when the upper sheet 38 is associated with the back sheet 42, and the absorbent core 44 in a frame, the upper sheet 38 remains disjoint or unjoined to the underlying layers, except at the periphery of at least the second waist region 24. The barrier folds 62 are formed by any of the fold patterns described above, and attached to the underlying layers, for example, the top sheet 38. In this embodiment, at least the folds 62 are elastified or include elastic-like elements at their distant edges, the contraction forces of the elastic members cause the upper sheet 38 to collect and form a cavity in the second waist region 24, which acts to inhibit the flow of a bowel movement out of the second waist region 24 of the diaper 20. The diaper 20 is preferably applied to a wearer by placing the second waist region 24 behind the wearer's back, and directing or pulling the rest of the diaper 20 between the legs of the wearer such that the first waist region 22 is placed across the front of the wearer. The ends of the tape tab fasteners 56 are then preferably secured to the outward facing areas of the diaper 20. In this manner, the barrier folds 62 must be disposed in the "non-moving" area of the user of the barrier. crotch region 26.
The procedure Having described the product in detail, the process of this invention by which the product is manufactured should be discussed. In a method of this invention, a web including a top sheet 38, a back sheet 42 and an absorbent core 44, are associated to form the diaper 20 using any conventional manner. The topsheet 38 and backsheet 42 are associated together in any appropriate manner as is well known in the diaper manufacturing art. As used herein the term "associated" encompasses configurations in which diaper components are directly bonded together by attaching one component directly to another component and configurations with which one component indirectly joins another component by attaching a member component intermediates, which, in turn, are fixed to other components. The topsheet 38 and the backsheet 42 can be directly bonded together at the periphery of the diaper 20, by an adhesive or any other means of attachment as is known in the art. Thus, for example, a continuous, uniform adhesive layer, a patterned adhesive layer, an array of separate lines or dots of adhesives or a network of adhesive filaments can be used. After the weft has been formed, it is cut into separate locations along its longitudinal edges to create a fold area 102 on each side of the diaper 20. As used herein the word "cut" implies a mechanically disposed line of weakness having an open end point and a closed end point, and includes cutting, in whole or in part (eg, a pattern of perforations), the weft between the open and closed ends. As shown in Figure 4, the cuts 104 can be provided in the first waist region 22 of the diaper at approximately the transition point between the crotch region 26 and the first waist region 22. The cuts 104 can be made in the area of the diaper 20, which notches or side slits are typically made in the current art. The cuts 104 are positioned in such a way that the angle formed by the cuts 104, which define the folding area 102, with the lateral centerline 34 is at least about 0o and not more than about 70 °. Preferably, the cuts 104 in the second waist region 24 will have an angle of about 25 ° to about 50 ° with the side center line 34. One skilled in the art will appreciate that the angular relationship between the cuts and the lateral centerline 34 , will depend on the size of the article being manufactured and the length of elastic member 77 desired in the resulting barrier fold 62 and seal fold 70. One skilled in the art will also appreciate that the length of the cuts 104 also depends on the effective height of the desired barrier folds 72, and of the article that is manufactured. One skilled in the art will further appreciate that the cuts 104 do not necessarily have to be straight and that they can also be curved or arched. One skilled in the art will further recognize that the cuts 104 may also comprise a line of weakness in the pattern, such as the landing areas of a perforation pattern. Alternatively, one of the cuts may be adjacent to the side edge 32 in the first waist region 22, to produce a diaper 20 similar to that shown in Figure 1. This cut may also serve to cut a finished diaper 20 from of a plot, if the process of cutting, bending, cutting described later is used. For this modality of diaper 20, the cuts are provided in the second waist region 24 of the diaper 20 at approximately the transition point between the crotch region 26 and the second waist region 24. The cuts 104 define two areas of laterally bending opposite 102, a fold area 102 on each side of the diaper 20 as shown in Figure 4. Each fold area 102 may have a generally trapezoidal shape with the longer side of the trapezoidal shape being farther from the longitudinal center line 36 of the diaper 20. Each fold area 102 can be divided into an internal longitudinal portion 106., an external longitudinal portion 108 and an average longitudinal portion 110. The specific ratio of the sizes of the portions 106, 108 and 110, determines the size of both the barrier folds of 62 and the seal folds 80. The internal longitudinal portion 106 is that portion closest to the longitudinal centerline 36 and coextensive with the closed ends of the cuts 104. The outer longitudinal portion 108 is adjacent the outer longitudinal edge 30 of the weft. The medial longitudinal portion 110 is located between the internal longitudinal portion 106 and the external longitudinal portion 108. Additionally, each fold area 102 terminates at a first end 122 and a second end 124. After the fold areas have been cut 102 , the fold areas 102 are bent to create the barrier folds 62 and the seal folds 80. To form the barrier folds 62 of the diaper 20 shown in Figure 1, the fold areas 102 are bent inward toward the line longitudinal central 36 of the diaper 20 and secured to the upper sheet 38, or to another underlying layer of the upper sheet, by a joining means 112. The barrier folds are preferably secured to the first and second ends of the fold area 122 and 124. The resulting folds 62 will be erect in the crotch region 26 when the diaper 20 is applied to the wearer. A separating means 76 may optionally be placed in the fold area 102 before the cuts are made. Preferably, this spacer means 786 is an elastically extensible member and can be placed in one of the longitudinal portions 106, 108 and 110 of the doubles area 102, depending on the desired configuration of the resulting folds 62 and 80. Alternatively, the spacer means may comprise a hardening member or other member that will cause the barrier folds 62 to rise when the diaper 20 is applied. If spacing means 76 is included in the external longitudinal portion 110, then the resulting barrier fold 62 will be separated from the liquid receiving surface of the diaper 20. If an elastically extensible element 84 is placed in the internal longitudinal portion 106 or portion longitudinal 108 of fold area 102, a fold of shrinkable seal 70 will also be formed. Preferably, the diaper 20 includes two elastic elements, a separating means 76 and an elastically extensible member 84. When the separating means 76 and the elastically extensible member 84 are employed, both a separate barrier fold 62 and a shrinkable seal fold will result. 80. In a second fold pattern for the diaper mode 20 shown in Figure 1, the longitudinal edges of the weft are folded around the spacing means 76 in a first fold of C which also defines the distant edge 66 of the edge of the diaphragm. barrier 62. The fold area 102 is then bent toward the longitudinal center line 36, and attached to the topsheet or other underlying structure as described above. For this folding pattern, the backsheet 42 is preferably narrower than the top sheet 38 such that, the longitudinal edges of the web are folded around the separating means 76, the portion of the web that is folded around the web. the separating means comprises only the upper sheet 38. This process can be used to produce the modality of the diaper 20 having the fold pattern shown in Figure 2. The diaper 20 having the fold pattern shown in Figure 3 can be produced with the following variations of the process described above. The fold area 102 is bent towards the longitudinal center line 36 in a first fold of C and the first and second ends of the area 122, 124 are attached to the topsheet 38 or to another underlying structure in the first and second waist regions as it was describedabove. However, in this embodiment, the ends of the fold area are joined to the first and second waist areas inward of the distant edges 66, leaving a portion of the fold of the area 102 disengaged. This disjoint portion is bent away from the line longitudinal central 36 in a second fold of C, and the first and second ends of this disconnected portion of fold area 102 are then attached to the structureunderlying the first and second waist regions 22, 24. Preferably, a cutting, bending cut process is used to produce the diaper 20 shown in Figure 1. This process allows for improved processing comfort by providing a diaper 20 that can be easily opened by a consumer. In this process, two first laterally opposite cuts are made in theplot. In this embodiment of the process, the first cuts 104 comprise a perforation pattern and define the junction between the second waist region 24 and the crotch region 26. Preferably, the perforation pattern comprises at least two landing areas that have a minimum length of 1 mm. The web is then folded towards the longitudinal center line and attached to the top sheet or other underlying layers as described: > ? previously. A second cut 104 is then made which is juxtaposed with the end of the state 34 that is in the first waist region 22. This second cut both completes the definition of the fold area 102 as separates the individual diaper 20 from the weft. In a third bending pattern of this invention as shown in Figures 5A and 5B, the weft is provided and cuts 104 are made as described above. After the cuts 104 are made, a joining means 112 adjacent to the line connecting the closed ends of the cuts is used to join the outer longitudinal portion 106 to the underlying layers as shown in Figure 5A. The attachment means 112 may be any means for securing the fold area 102 to the top sheet 38 such as adhesives, heat and pressure sealants, ultrasonic bonding or any other means or methods as is known in the art. For example, adhesives may be applied to the top sheet 38, or any layer underlying the top sheet 38, adjacent to and on the inward side of a line extending between the ends of the cuts 104. The fold area 102 is then folded inward, towards the longitudinal centerline 36 of the diaper 20, and is attached to the topsheet 30 or to another underlying layer of the topsheet 38. The fold area 102 is folded along the line between the cuts 104. in such a way that the internal longitudinal portion 106 comes to join the upper sheet 38 or another underlying layer of the upper sheet 38 of the diaper 20. The middle longitudinal portion 110 and the longitudinal portion 108 are then folded away from the center line 36 of the diaper 20 to form the barrier folds 62. After the folds have been formed, the portion of the fold area 102 adjacent to the cuts, i.e. adjacent the ends of the fold area 122, 124, is a is attached to the underlying portions in the first and second waist regions 22 and 24. This creates a barrier fold 62, which is unattached to the diaper 20 in the crotch region 26, and which will lift in the crotch region. 26 when the diaper 20 is applied to a user. The resulting diaper 20 will have a barrier fold 62 consisting of a single fold of both the top sheet and the back sheet, and a seal fold 80 consisting of two layers of both the top sheet and the back sheet, as shown. in Figure 5B. One skilled in the art will appreciate that the dimensions of both the barrier fold 62 and the seal fold 80 can be varied depending on what proportion the fold area is bent inward toward the longitudinal center line and the depth at which the cuts are made in the diaper 20. In the embodiment shown in Figure 7, the ends of the barrier folds 62 are fixed to the upper sheet 38 with the distant edge 66 of each barrier fold directed inward, towards the longitudinal centerline of the diaper 20. In an alternate embodiment, the ends of the folds of barrier 62 can be attached to the topsheet 38 with the distal edge 66 of each fold 62 directed outward from the centerline 36 in both of the first and second waist regions 22 and 24 of the diaper 20. The barrier folds 62 also they may be "twisted", i.e. one end may be attached to underlying layers, such as, for example, the topsheet 38, up to the longitudinal center line 36 and the other end may be attached to the topsheet 38 away from the proximal edge 64 of the fold 62. As shown in Figures 6A and 6B, in a fourth fold pattern, the topsheet 38, as the backsheet 42 and the absorbent core 44 are associated in a diaper weave as described above . The diaper weave is then cut, also as described above, to form the fold areas 102. The fold area 102 is first bent toward the longitudinal center line 36 along a line extending between the inner ends of the diagonal line. the cuts 104. The fold area 102 is then bent longitudinally in the medial longitudinal portion 110, away from the longitudinal center line 36 to form two sub-portions. The garment facing surfaces 58 of these sub-portions are then joined using attachment means 112. For example, as shown in Figure 6A, a joining means 112 adjacent the fold of the medial longitudinal portion 110 on the surface is used. gives towards the garment of the fold area 102, to join the fold over the portions to each other. As seen in Figure 6A, this method creates a barrier fold 62 consisting of two folds of each of the upper sheet material and the backsheet material, and a seal fold 80 having a fold of the upper sheet material and the material of the back sheet. The ends of the external longitudinal portion 108 of the fold area 102 are then attached to the top sheet 38 by a joining means 112, as described above, to complete the construction of the seal folds 80. In an alternate embodiment of the The process described above, shown in Figure 7, employs a back sheet 42, which is narrower laterally than the top sheet 38. This creates a web in which the top sheet 38 extends beyond the edges of the sheet rear 42, preferably at an equal distance, on each side of the frame. For example, the backsheet 42 can have a side width that is approximately1 to 5 inches smaller than the lateral width of the upper sheet 38. The barrier folds 62 can be formed by any of the fold patterns described above. However, the folding pattern as described in Figure 6A and 6B is preferred, because, depending on the width of the backsheet 42 it results in a barrier fold 62 having external folds of the top sheet and at least one only inner fold of the backsheet which helps to prevent leakage through the barrier dolbez, and a seal fold 80 comprising only the top sheet. This produces a diaper that has soft seal folds 80. If the back sheet is folded according to the fold pattern shown in Figures 5A and 5B, a seal fold 80 having an outer fold and an inner fold of the upper sheet material and an outer fold of the backsheet material would result. This second embodiment would provide a fold of moisture permeable barrier 80. However, this fold pattern would produce a barrier fold 62 that would be permeable to liquids, thereby increasing the risk of runoff. To prevent the barrier folds 62 formed by the second mode from running off, the barrier fold must be impermeable to liquids. For example, depending on the wetting capacity of the upper sheet material, a treatment may be necessary to make those portions of the upper sheet covering the hydrophilic absorbent core, and those portions that are laterally outwardly of the hydrophobic absorbent core. Such treatments may be applied by a supply of the top sheet material or as an additional step in the manufacturing process to make the resulting barrier cuffs 62 impermeable to liquids. In the alternate embodiment of the process described above, the topsheet 38 is secured to the backsheet 42 only at the periphery of the diaper in the second waist region 24. The diaper weave is formed as described above except that the upper sheet 38 to absorbent core 44 in second waist region 24, wherein the end edges 32 and longitudinal sides 30 are secured in the second waist region 24. The fold area 102 is then cut and attached to the body of the diaper 20 in any of the manners described above. In this embodiment, it is preferred that the distant edges 66 of the resulting barrier folds 62 are elastified and directed inward toward the longitudinal centerline 36. A diaper 20 resulting from this alternating process is shown in Figure 9. As shown in Figure 9, the retraction forces of the elastic elements 77 of the leg bends 62, acts to form a cavity 120 in the second waist region 24 by raising the top sheet 38 out of the underlying layers. This process results in a barrier, which restricts the flow of soft bowel evacuations out of the second waist region 24 of the diaper 20. For any of the embodiments described above, the cuts 204 may also be continuous from a portion of the weft. to the next, as shown in Figure 8. Although the diaper weft is not cut into individual diapers until the process is completed, the weft can be divided into separate items for illustration purposes. By "continuous", it is implied that the cut 204 begins in the first waist region 222 of a first diaper 220 and continues to the second waist region 224 of the next diaper 220 in the weft. In this cutting process, no cuts are made in the crotch region 226 of the articles. If the cuts 204 are made continuously from a diaper 220 thus follows, the resulting fold area 202 will have a first pendant end232 and a second end 234 in the first end 222 and at the second end 224 respectively. The fold area 202 is then bent to form a barrier fold (not shown) in any of the manners described above. The first and second hanging ends 232 and 234 are secured to the top sheet to complete the formation of the barrier folds. One skilled in the art will appreciate that these first and second hanging ends 232 and 234 can be adjusted to any desired length before being fixed to the top sheet. Although embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended to cover all of the changes and modifications that are within the scope of this invention with the appended claims.