Title of Invention

DISPOSABLE DIAPER

Abstract Here is disclosed a disposable diaper improved so as to give the wearer no uncomfortable feeling to wear this diaper and to allow water vapor generated as a result of sweat evaporation to be let out from the diaper through the wings. A disposable diaper (1A) includes pair of second wings (14) attached to transversely opposite side edge portions (12) of a rear waist region (10) and extending outward in a transverse direction are formed from an elastically stretchable composite sheet (18). The composite sheet (18) comprises a breathable stretchy plastic film formed with a plurality of air passages each extending in a thickness direction from a first opening facing the wearer's skin toward a second opening facing away from the wearer's skin and breathable heat-sealable fibrous nonwoven fabric layers partially bonded to both surfaces of the plastic film and formed with a plurality of gathers rising and falling along surfaces of the nonwoven fabric layers.
Full Text SPECIFICATION
DISPOSABLE DIAPER
TECHNICAL FIELD OF THE INVENTION
[0001]
The present invention relates to a disposable diaper
adapted for absorption and containment of bodily discharges.
[0002]
There has already been proposed a disposable diaper
comprising a liquid-pervious topsheet, a liquid-impervious
backsheet and a liquid-absorbent core interposed between these
two sheets so as to defire, in a longitudinal direction, a front
waist region, a rear waist region and a crotch region extending
between these waist regions. The diaper is contoured by
longitudinally opposite ends extending in a transverse
direction outside longitudinally opposite ends of the core and
transversely opposite side edges extending in the longitudinal
direction outside transversely opposite ends of the core. The
front waist region is provided with a pair of first wings
extending outward from respective side edges of the front waist
region in the transverse direction and the rear waist region
is provided with a pain of second wings extending outward from

the respective side edges of the rear waist region in the
transverse direction (See Patent Document 1).
[0003]
In the diaper disclosed in Patent Document 1, the wings
of the rear waist region is provided with a pair of tape fasteners
and the front waist regior is provided on its outer surface with
a target tape on which the tape fasteners are releasably
anchored. Each of the second wings extending from the rear
waist region comprises an inner layer sheet and an outer layer
sheet both of which are elastically stretchable. These inner
layer sheet and outer layer sheet may be made of an elastically
stretchable fibrous nonwoven fabric, elastomer film or rubber
film. The inner layer sheet and the outer layer sheet are
overlapped and bonded together through the intermediary of
elastic material having a rubber-like elasticity and a stretch
stress higher than those of the inner layer sheet and the outer
layer sheet. Each of the tape fastener has a fixed side portion
which is permanently borded to the outer end of the associated
second wing and a free portion extending outward from the fixed
side portion in the transverse direction. A hook member of a
mechanical fastener is attached to the free portion of the tape
fastener and a loop member of the mechanical fastener is
attached to outer surface of the target tape.

[0004]
To put this diaper cm the wearer's body, the second wings
of the rear waist region are placed upon the outer side of the
front waist region and then the free portions of the respective
tape fasteners are anchored on the outer surface of the target
tape to connect the front end rear waist regions with each other.
Upon connection of the front and rear waist regions, the diaper
is formed with a waist-hole and a pair of leg-holes. This diaper
is characterized in that the inner layer sheet and the outer
layer sheet constituting the second wings are bonded together
in a non-stretched state through the intermediary of the elastic
material, so there is no possibility that the inner layer sheet
and the outer layer sheet might be formed with gathers which
might create a feeling of discomfort against the wearer.
Patent Document 1: Japanese Unexamined Patent
Application Publication No. 1998-328237
DISCLOSURE OF THE INVENTION
PROBLEM TO BE SOLVED BY THE INVENTION
[0005]
The diaper disclosed in Patent Document 1 uses an
elastically stretchable fibrous nonwoven fabric, elastomer
film or rubber film as stock materials for the inner layer sheet
and the outer layer sheet constituting the second wings of the

rear waist region. Disadvantageously, the wearer may
experience uncomfortable tackiness and sliminess peculiar to
elastomeric materials as these sheets formed from the elastomer,
or rubber film and the elastically stretchable fibrous nonwoven
fabric containing an elastomeric materials as these sheets
formed from the elastomer or rubber film and the elastically
stretchable fibrous nonwoven fabric containing an elastomeric
material come in contact with the wearer's skin. In addition,
these sheets may stick to the wearer's skin since these sheets
exhibit a relatively high fricticnal force and such factor also
may deteriorate a feeling to wear the diaper. When the
elastomer film or the rubber film is used as stock material for
the inner layer sheet and the outer layer sheet, a water vapor
permeability of the second wings extending from the rear waist
region will be significantly deteriorated and it will be
impossible to let water vapor generated due to evaporation of
sweat out from the diaper through the second wings.
Consequently, a stuffiness generated within the diaper can not
be eliminated.
[0006]
In view of the problems as have been described above, it
is an object of the present invention to provide a disposable
diaper improved so as to give the wearer no uncomfortable

feeling to wear this diaper, on one hand, and to allow water
vapor generated as a result of sweat evaporation to be let out
from the diaper through the wings, on the other hand.
MEASURE TO SOLVE THE PROBLEM
[0007]
The object set forth above is achieved, according to the
present invention, by a disposable diaper comprising a front
waist region, a rear waist region, a crotch region extending
between these two waist regions, a pair of first wings extending
outward from transversely opposite side edge portions of the
front waist region in a transverse direction and a pair of second
wings extending outward from transversely opposite side edge
portions of the rear waist region in the transverse direction.
[0008]
The diaper according to the present invention further
comprises, of the first and second wings, at least the second
wings being formed from an elastically stretchable composite
sheet which comprises, ir turn, a breathable stretchy plastic
film formed with a plurality of air passages extending through
the plastic film each having a first opening facing the wearer's
skin and a second opening facing away from the wearer's skin
and a pair of breathable, heat-sealable fibrous nonwoven fabric
layers partially bonded to both surfaces of the plastic film

at of heat-sealed spots and formed with a plurality of gathers
rising and falling along surfaces of the fibrous nonwoven fabric
layers. The wings are free from uncomfortable tackiness and
sliminess peculiar to rubber-based materials although the wings
are elastically stretchabLe as a whole, since one of the fibrous
nonwoven fabric layers comes in contact with the wearer's skin.
Furthermore, water vapor Generated due to sweat evaporation can
be let out from the diaper through the air passages.
[0009]
The diaper according to the present invention includes
the following preferred embodiments.
The plastic film is formed from an elastically
stretchable thermoplast LC elastomer film and a pair of
polyolefin-based thermoplastic synthetic resin film layers
bonded to both surfaces of the elastomer film, and the fibrous
nonwoven fabric is formed from polyolefin-based thermoplastic
synthetic resin fibers.
[0010]
The second opening has an area smaller than that of the
first opening so that the air passage is tapered from the first
opening toward the second opening. A surface tension is higher
in the vicinity of the second opening than in the vicinity of
the first opening.

[0011]
The number of the ait: passages formed through the plastic
film is in a range of 10 - 8O/cm2 of the plastic film and a total
area of the first openincs the plastic film is in a range of
10 - 20% of an area of the plastic film.
[0012]
Inside the air passage, the fibrous nonwoven fabric
layers are bonded together at the heat-sealed spots and the
number of the air passages inside which the fibrous nonwoven
fabric layers are bonded to each other is in a range of 1.5 -
10% of the total number of the air passages. This diaper allows
water vapor generated due to evaporation of the sweat having
transferred to the heat-sealed spots to be let out from the
diaper.
[0013]
The fibrous nonwoven fabric layers maintain a fibrous
state at the heat-sealed spots and have a fibrous density higher
at the heat-sealed spots than in the remaining region except
the heat-sealed spots. A capillary phenomenon occurs more
significantly at the heat-sealed spots than in the remaining
region and an amount of sweat having permeated a remaining
region of the nonwoven fabric layer rapidly transfers toward
the heat-sealed spots.

[0014]
Each of the wings formed from the elastically stretchable
composite sheet presents a transverse stretch stress in a range
of 1.5 - 7.0 N as the wing is stretched in the transverse
direction to a length dimension in the transverse direction
corresponding to 120% on the basis of its non-stretched
transverse length dimension set as 100% and presents a
transverse stretch stress in a range of 3. 0 - 10.0 N as the wing
is stretched to a length dimension in the transverse direction
corresponding to 150% of the non-stretched length dimension.
[0015]
The plastic film has a thickness of 0.3 - 1 mm, and the
fibrous nonwoven fabric layers each has a basic weight of 20
- 60 g/m2, a thickness of 0.1 - 0.5 mm and a density of 0.04
- 0.6 g/cm3.
EFFECT OF THE INVENTION
[0016]
The disposable diaper according to the present invention
is primarily characterized in that at least the second wings
of the first and second wings are formed from the elastically
stretchable composite sneet comprising the breathable and
stretchy plastic film and the breathable heat-sealable fibrous
nonwoven fabric layers partially bonded to both surfaces of the

plastic film wherein one cf the fibrous nonwoven fabric layers
comes in contact with the wearer's skin as the diaper is put
on. Such features are effective to eliminate the apprehension
that the wings might stick to the wearer's skin and the wearer
might experience uncomfortable feeling to wear the diaper
although the wings are elastically stretchable as a whole. On
the other important aspect of the present invention, the
stretchy plastic film is formed with a plurality of the air
passages allowing water vapor generated due to sweat
evaporation to be let out from the diaper through these air
passages and thereby allowing stuffiness possibly occurring
within the diaper to be prevented. Furthermore, the elasticity
of the wings may be utilized to tighten the diaper around the
wearer's waist and thereby may prevent the diaper once put on
the wearer's body from slipping down from its proper position.
[0017]
In the diaper wherein the fibrous nonwoven fabric made
of polyolefin-based thermoplastic synthetic resin fiber is used
as the constituent layers of the composite sheet, the wings are
free from uncomfortable tackiness and sliminess peculiar to the
rubber-based material and there is no anxiety that the wearer
might experience uncomfortable feeling as the wings come in
contact with skin.

[0018]
In the diaper where in each of the air passages formed
through the stretchy plastic film constituting the composite
sheet is tapered from the first opening toward the second
opening, a surface tension acting on the air passage is higher
in the vicinity of the second opening than in the vicinity of
the first opening. Consequently, sweat having flowed into the
first opening can be easily transferred toward the second
opening, i.e., toward the skin non-contacting side of the wing
under the surface tension. In this way, wetness on this side
of the wing can be rapidly eliminated.
[0019]
In the diaper wherein the fibrous nonwoven fabric layers
constituting the composite sheet are bonded to each other inside
the air passage at the heat-sealed spots, water vapor generated
due to evaporation of sweat having moved to the heat-sealed
spots can be let out from the diaper through these air passages
and the amount of sweat having permeated the nonwoven fabric
layer can be rapidly dried.
[0020]
In the diaper wherein the nonwoven fabric layers have
fiber densities higher in the heat-sealed spots than in the
respective remaining regions, a capillary phenomenon occurs

more significantly in the heat-sealed spots than in the
remaining regions. Such significant capillary phenomenon
allows any amount of sweat having permeated the remaining region
of the nonwoven fabric layer to be rapidly transferred to the
heat-sealed spots and thereby allows the remaining region to
be rapidly dried. In this way, uncomfortable tackiness and/or
sliminess due to sweat which would otherwise stay on the
remaining region of the nonwoven fabric layer destined to
contact with the wearer's skin can be effectively eliminated.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0021]
[FIG. 1] Fig. 1 is a partially cutaway perspective view
showing an open-type diaper, one of embodiments of the
invention.
[FIG. 2] Fig. 2 is a sectional view taken along the line
II-II in Fig. 1.
[FIG. 3] Fig. 3 is a sectional view taken along the line
III-III in Fig. 1.
[FIG. 4] Fig. 4 is a sectional view taken along the line
IV-IV in Fig. 1.
[FIG. 5] Fig. 5 is a partially cutaway perspective view
of a composite sheet.
[FIG. 6] Fig. 6 is a sectional view taken along the line

VI-VI in Fig. 5.
[FIG. 7] Fig. 7 is a perspective view showing the diaper
as put on the wearer's body.
[FIG. 8] Fig. 8 is a perspective view showing a pull-on
diaper as another embodiment of the invention.
[FIG. 9] Fig. 9 is a sectional view taken along the line
IX-IX in Fig. 8.
[FIG. 10] Fig. 10 is a developed and partially cutaway
view showing the diaper of Fig. 8 with the front and rear waist
regions having been disconnected from each other.
[FIG. 11] Fig. 11 Ls an end view showing the composite
sheet forming the first and second wings.
IDENTIFICATION OF REFERENCE NUMERALS USED IN THE DRAWINGS
[0022]
1A open-type diaper (disposable diaper)
IB pull-on diaper (disposable diaper)
2 liquid-pervious topsheet
3 liquid-impervious oacksheet
4 liquid-absorbent core
4a longitudinally opposite ends
4b transversely opposite side edges
8 front waist region
9 crotch region

10 rear waist region
11 longitudinally opposite end portions
12 transversely opposite side edge portions
13 first wings
13a transversely inner end portions
13b transversely outer end portions
14 first wings
14a transversely inner end portions
14b transversely outer end portions
18 elastically stretchable composite sheet
25 breathable and stretchable plastic film
26 breathable and heat-sealing fibrous nonwoven fabric
layers
27 heat-sealed spots
28 gathers
29 thermoplastic elastomer film layer
30 thermoplastic synthetic resin film layer
31 air passages

32 first opening
33 second opening
34 tubular wall
35 heat-sealed spots
DESCRIPTION OF THE BEST MODE FOR WORKING OF THE INVENTION

[0023]
Details of a disposable diaper according to the present
invention will be more fully understood from the description
of open-type and pull-on diapers as typical embodiments given
hereunder with reference to the accompanying drawings.
EMBODIMENT 1
[0024]
Fig. 1 is a partially cutaway perspective view showing
an open-type diaper 1A of the invention, Fig. 2 is a sectional
view taken along the line II-II in Fig. 1, Fig. 3 is a sectional
view taken along the line III-III in Fig. 1 and Fig. 4 is a
sectional view taken along the line IV-IV in Fig. 1. In Fig.
1, a transverse direction is indicated by an arrow L and a
longitudinal direction is indicated by an arrow M. As used
herein the term "inner sjrfaces" of top- and backsheets 2, 3
and leak-barrier sheets refers to surfaces thereof facing a
core 4 and as used herein the term "outer surfaces" of these
sheets 2, 3, 7 refers to surfaces thereof facing away from the
core 4. As used herein the term "skin contacting side" refers
to the side facing the weatrer's skin and expression used herein
"skin non-contacting side" refers to the side facing away from
the wearer's skin.
[0025]

The diaper 1A basically comprises the liquid-pervious
topsheet 2 lying on the skin contactable side, the
liquid-impervious backsheet 3 lying on the skin non-contactable
side and the liquid-absorbent core 4 interposed between the top-
and backsheets 2, 3. In addition to these constituting members,
the diaper 1A includes tape-like waist-surrounding elastic
members 5, a plurality of strand-like leg-surrounding elastic
members 6 and a pair of the leak-barrier sheets 7.
[0026]
The diaper 1A is corrposed, in the longitudinal direction,
a front waist region 8, a rear waist region 10 and a crotch region
9 extending between thes'2 waist regions 8, 10, and the diaper
1A is contoured by longitudinally opposite end portions 11
extending in the transverse direction outside longitudinally
opposite ends 4a of the core 4 a.nd transversely opposite side
edge portions 12 extending in the longitudinal direction
outside transversely opposite ends 4b of the core 4. The front
waist region 8 is provided with a pair of first wings 13 extending
outward from respective side edge portions 12 of the front waist
region 8 in the transverse direction. The rear waist region
10 is also provided with a pair of second wings 14 extending
outward from the respect ive side edge portions 12 of the rear
waist region 10 in the transverse direction. Thus, the diaper

1A has a generally hourglass-like planar shape.
[0027]
The topsheet 2 is formed from a breathable hydrophilic
fibrous nonwoven fabric 15. The backsheet 3 is formed from a
breathable liquid-impervious plastic film 16 lying on the lower
surface of the core 4 and a breathable hydrophobic fibrous
nonwoven fabric 17 placed on the lower surface of the film 16.
Respective surfaces of the film 16 and the nonwoven fabric 17
opposed to each other are intermittently bonded by means of
adhesive (not shown) . The core 4 extends between the front and
rear waist regions 8, 10 and is permanently bonded to at least
one of inner surfaces of the topsheet 2 and the film 16 of the
backsheet 3.
[0028]
The core 4 comprises a mixture of particulate or fibrous
super-absorbent polymer and. fluff pulp or a mixture of
particulate or fibrous super-absorbent polymer, fluff pulp and
thermoplastic synthetic resin fiber, in any case, compressed
to a desired thickness. Preferably, the core 4 is entirely
wrapped with a liquid-pervious sheet such as a tissue paper or
hydrophilic fibrous nonwoven fabric in order to avoid a
possibility that the core 4 might get out of its initial shape
and/or the particulate polymer might fall off from the core 4.

The polymer may be seLected from the group consisting of
starch-based polymer, cellulose-based polymer and synthetic
polymer.
[0029]
The longitudinally opposite end portions 11 are formed
from longitudinally opposite end portions 2a of the topsheet
2 and longitudinally opposite end portions 3a of the backsheet
3 extending outward beyond longitudinally opposite ends 4a of
the core 4. The top- and backsheets 2, 3 are overlapped together
along the end portions 2a, 3a thereof and inner surfaces of these
sheets 2, 3 are permanently bonded together to form the
respective end portions 11. The waist surrounding elastic
members 5 are contraccibly attached to the respective end
portions 11 so as to extend in the transverse direction. More
specifically, the waist surrounding elastic members 5 are
interposed between the respective end portions 2a of the
topsheet 2 and the respective end portions 3a of the backsheet
3 and are permanently bonded to the inner surfaces of these
sheets 2, 3 while these elastic members 5 are stretched at a
given ratio.
[0030]
The transversely opposite side edge portions 12 are
formed from transversely opposite side edge portions 2b of the

topsheet 2 and transversely opposite side edge portions 3b of
the backsheet 3 extending outward in the transverse direction
beyond transversely opposite side edges 4b of the core 4. The
side edge portions 2b of the topsheet 2 extend outward in the
transverse direction slightly beyond the transversely opposite
side edges 4b of the core 4 and the side edge portions 3b of
the backsheet 3 as well as the side edge portions 7a of the
leak-barrier sheets 1 extend outward in the transverse
direction beyond the side edge portions 2b of the topsheet 2.
Along the side edge portions 12, the respective side edge
portions 2b, 3b, 7a are overlapped together and have inner and
outer surfaces thereof bonded together. The leg surrounding
elastic members 6 are contractibly attached to the respective
side edge portions 12 of the crotch region 9 so as to extend
in the longitudinal direction. More specifically, the leg
surrounding elastic members 6 are interposed between the
respective side edge portions 3b of the backsheet 3 and the
respective side edge portions 7a of the leak-barrier sheets 7
and are permanently bonded to the inner surfaces of these sheets
3, 7 while these elastic members 6 are stretched at a given ratio.
[0031]
The first wings 13 are defined by the side edge portions
3b of the backsheet 3 and the fixed side portions 7a of the

respective leak-barrier sheets 7 extending outward from the
side edge portions 12 of the front waist region 8 in the
transverse direction. These sheets 3, 7 are overlapped
together and have respective inner surfaces bonded together
along these side edge portions 3b, 7a of the sheets 3, 7.
[0032]
The second wings 14 are formed from an elastically
stretchable composite sheet 18, respectively, which are
elastically stretchable in the transverse direction. Each of
the second wings 14 has its transversely inner end portion 14a
interposed between the side edge portion 3b of the backsheet
3 and the fixed side edge portion 7a of the leak-barrier sheet
7 and permanently bonded to respective inner surfaces of these
sheets 3, 7 by means of adhesive (not shown). The transversely
outer end portions 14b of the respective second wings 14 are
provided with tape fasteners 19 extending in the transverse
direction.
[0033]
The leak-barrier sheets 7 are formed from a breathable
hydrophobic fibrous nonwoven fabric 20 and extend in the
longitudinal direction between the front and rear waist regions
8, 10. Each of the leak-barrier sheets 7 has the fixed side
portion 7a lying outside the associated side edge 4b of the core

4 and extending in the lor gitudinal direction, a movable portion
7b normally biased to rise up above the topsheet 2 and extending
in the longitudinal direction and longitudinally opposite f ix.ed
end portions 7c lying on the longitudinally opposite end
portions 11, respectively, and collapsed inward in the
transverse direction of the diaper 1A. An elastic member 21
extending in the longitudinal direction is contractibly
attached to the movable portion 7b in the vicinity of its distal
end wherein the elastic member 21 is wrapped with a part of the
movable portion 7b and permanently bonded to the movable portion
7b by means of adhesive (not shown). The fixed end portions
7c are permanently bonded to the outer surface of the respective
end portions 2a of the topsheet 2. In the leak-barrier sheets
7, the elastic members 21 contract as the diaper 1A is curved
in the longitudinal direction with the topsheet 2 inside and
a contractile force of these elastic members 21 causes the
movable portions 7b to rise above the topsheet 2 so as to form
barriers against bodily discharges.
[0034]
Each of the tape fasteners 19 has a fixed side portion
19a permanently bonded to the outer end portion 14b of the
associated second wing 14 by means of adhesive (not shown) and
a free portion 19b extending outward from the fixed side portion

19a in the transverse direction. Stock materials for the tape
fastener 19 may be selected from the group consisting of a
fibrous nonwoven fabric made of polyolefin-based thermoplastic
synthetic resin fiber and a film made of polyolef in-based
thermoplastic resin. The free portion 19b is provided with a
plurality of hooks 22 expending in a thickness direction of the
diaper 1A. These hooks 22 are made of polyolefin-based
thermoplastic synthetic resin. Alternatively, the free
portion 19b may be coated with pressure-sensitive adhesive,
instead of the hooks 22.
[0035]
The front waist region 8 is provided with a target tape
23 on which the free end portions 19b of the respective tape
fasteners 19 are releasably anchored. The target tape 23 has
a rectangular shape having its longer sides extending in the
transverse direction and is intermittently or continuously
bonded to the outer surface of the nonwoven fabric 17 of the
backsheet 3 by means of adhesive (not shown). Stock materials
for this target tape 23 may be selected from the group consisting
of a fibrous nonwoven fabric made of polyolefin-based
thermoplastic synthetic resin fiber and a film made of
polyolefin-based thermoplastic synthetic resin. The target
tape 23 is provided on its outer surface with a plurality of

loops 24 each describing a circular arc in the thickness
direction of the diaper 1A. These loops 24 are made of
polyolefin-based thermoplastic synthetic resin. When it is
desired to coat the free portions 19b of the respective tape
fasteners 19 with pressure-sensitive adhesive, the synthetic
resin film may be used as the target tape 23.
[0036]
Fig. 5 is a partially cutaway perspective view showing
a composite sheet 18 forming the second wings 14 and Fig. 6 is
a section view taken along the line VI-VI. In Figs. 5, 6, a
transverse direction is indicated by an arrow L, a longitudinal
direction is indicated by an arrow M and a thickness direction
is indicated by an arrow N. The composite sheet 18 comprises
a breathable and stretohable plastic film 25 and a pair of
breathable and heat-seal able fibrous nonwoven fabric layers 26A,
26B. The plastic film preferably has a thickness of 0.3 - 1
mm, the nonwoven fabric layers 26A, 26B preferably has a basic
weight of 20 - 60 g/m2, a thickness of 0.1 - 0.5 mm and a density
in a range of 0.04 - 0.6 g/cm3, respectively. The nonwoven
fabric layers 26A lies on the skin contactable side and the
nonwoven fabric layers 2 6B lies on the skin non-contactable side.
The plastic film 25 and the nonwoven fabric layers 26A, 26B have
respective surfaces ove rlapped and partially bonded together

by means of a plurality of heat-sealed spots 27 which are
distributed as evenly as possible. These nonwoven fabric
layers 26A, 26B are formed with a plurality of gathers 28 which
rise and fall along surfaces of the nonwoven fabric layers 26A,
26B. The nonwoven fabric layers 26A, 26B may be hydrophilic
or hydrophobic.
[0037]
The plastic film 25 is formed from an elastically
stretchable thermoplastic elastomer film 29 and thermoplastic
synthetic resin film layers 30 placed upon both surfaces of the
elastomer film 29. The elastomer film 29 and the synthetic
resin film layers 30 are overlapped and bonded together along
respective surfaces thereof opposed one to another. Each of
the thermoplastic synthetic resin film layers 30 comprises a
pair of two sub-layers overlapped and bonded together. The
plastic film 25 is formed with a plurality of air passages 31
extending from its upper surface toward its skin
non-contactable side (i.e., toward the nonwoven fabric layer
26B) in the thickness direction of the diaper 1A. Each of these
air passages 31 is defined by a first opening 32 facing the
wearer's skin, a second opening 33 facing away from the wearer's
skin and having a diameter smaller than that of the first opening
32 and a tubular wall 34 extending between the first and second

openings 32, 33 so as to be tapered from the first opening 32
toward the second opening 33.
[0038]
Inside some of the air passage 31, the nonwoven fabric
layers 26A, 26B have respective surfaces facing each other
bonded together by means of heat-sealed spots 35. Inside the
remaining air passages 31, however, these nonwoven fabric
layers 26A, 26B are not heat-sealed together. At the
heat-sealed spots 27, 35, these nonwoven fabric layers 26A, 26B
are not in a filmy state but maintain a fibrous state. In other
words, a fiber density of the nonwoven fabric layers 26A, 26B
is higher than a fiber density thereof in the remaining region
except the heat-sealed spots 27, 35.
[0039]
The elastomer film 29 is made of material selected from
the group consisting of styrene-based block copolymer,
polyurethane-based block copolymer, polyester-based block
copolymer, polyamide-based block copolymer and copolymer blend.
The styrene-based block copolymer may be selected from a group
consisting of styrene-butadiene-styrene (S-B-S) and
styrene-ethylene butadiene-styrene (S-EB-S). The copolymer
blend may be selected from a group consisting of
styrene-ethylene butadiene-styrene/polypropylene (S-EB-S/PP)

and polypropylene/ethylene-propylene (PP/-P).
[0040]
The synthetic resin film 30 is formed from
polyolefin-based thermoplastic synthetic resin. The fibrous
nonwoven fabric is formed from polyolefin-based thermoplastic
synthetic resin fiber. The polyolefin may be selected from the
group consisting of polyamide, polyester, polyvinyl chloride,
polyethylene, polypropylene and polystyrene.
[0041]
The plastic film 2b may be obtained, for example, by using
a process including the steps as follow. The elastomer film
29 and the synthetic resin film 30 are respectively extruded
from the associated extruders and placed upon each other before
cured so that respective; surfaces of these film layers 29, 30
opposed to each other may be heat-sealed so as to form the plastic
film 25. In this step, the plastic film 25 is not formed with
the air passages 31.
[0042]
In the softened state, the plastic film 25 runs to a rotary
suction drum and one surface of the plastic film 25 is held in
contact with a peripheral surface of the drum as the plastic
film 25 travels on the peripheral surface. The suction drum
is provided on its peripheral surface with a plurality of

openings distributed as evenly as possible and tubular walls
extending from peripheral edges of the respective openings
toward an axis of the drum. The suction drum is provided on
its peripheral surface vvith a suction station at which the air
is sucked by suction means toward the axis of the drum through
the respective openings. Regions of the plastic film 25 just
facing the respective openings of the drum are sucked and
stretched from the openings toward the axis of the drum as the
plastic film 25 traveling on the peripheral surface of the drum
reaches the suction station. In consequence, lower ends of the
respective regions of the plastic film 25 sucked and stretched
in this manner and exposed to "he internal space of the drum
are disrupted to form a plurality of air passages 31 extending
toward the axis of the dram. Then the plastic film 25 is cooled
and cured and taken up on a roll.
[0043]
The stretchable composite sheet 18 may be obtained, for
example, by using a process including the steps as follows. The
nonwoven fabric layers 2 5A, 26B substantially in non-stretched
state are placed upon both surfaces of the plastic film 25 being
stretched in the transverse direction. Then these film 25 and
the nonwoven fabric layers 26A, 26B are partially heated to bond
them together and, at the same time, to bond the nonwoven fabric

layers 26A, 26B to each other inside the air passages 31. Upon
relaxation of the plastic film 25, the film 25 contracts in the
transverse direction and the nonwoven fabric layers 26A, 26B
also contract in the transverse direction to form a plurality
of gathers 28. Bonding of the film 25 to the nonwoven fabric
layers 26A, 26B may te achieved using thermal embossing
technique or ultrasonic sealing technique. It should be noted
here that the nonwoven fabric layers 26A, 26B are bonded to each
other inside some of the air passages 31 but not bonded to each
other inside the remaining air passages 31.
[0044]
An example of the thermal embossing technique uses a
thermal embossing roll provided, on its peripheral surface with
a plurality of projections and a flat roll opposed to the
embossing roll so that the film 25 and the nonwoven fabric layers
26A, 26B placed one upon another may be guided into a nip of
these rolls. In the course of passing through the nip, the film
25 is stretched in a machine direction at a given ratio. The
nonwoven fabric layers 26A, 26B are under a tension in the
machine direction but not stretched. Passing through the nip
of these paired rolls, the film 25 and the nonwoven fabric layers
26A, 26B are wedged betveen the embossing projections and the
peripheral surface of the flat roll and heated by the embossing

projections. In this way, these film 25 and nonwoven fabric
layers 26A, 26B are partially heat sealed together.
[0045]
The ultrasonic sealing technique generally uses a horn
and an anvil opposed to each other so that the film 25 and the
nonwoven fabric layers 26A, 26B placed one upon another may be
guided through a gap between these horn and anvil. In the course
of passing through the gap, the film 25 is stretched in the
machine direction at a given ratio. The nonwoven fabric layers
26A, 26B are under a tension in the machine direction but not
elastically stretched. Frictional heat generated between the
horn and the anvil both oscillating under the effect of
ultrasonic waves causes the film 25 and the nonwoven fabric
layers 26A, 26B to be partially heat-sealed together.
[0046]
The film 25 and the nonwoven fabric layers 26A, 26B are
preferably formed from the same type of polyolefin-based
material. For example, when polyethylene-based synthetic resin
is used to form the film 25, it is preferred to use
polyethylene-based synthetic resin fiber as the component fiber
of the nonwoven fabric Layers 26A, 26B. The film 25 and the
nonwoven fabric layers 26A, 2 6B formed from the same type of
polyolefin-based material present respective melting points

which are substantially similar one to another and can be easily
bonded one to another. When the film 25 and the nonwoven fabric
layers 26A, 26B are formed from different types of
polyolef in-based material, respectively, it is preferred to use
the material having a melting point substantially the same as
or lower than that of the film 25 for the component fiber of
the nonwoven fabric layers 26A, 26B. This is because, if the
film 25 has a melting point higher than the melting point of
the nonwoven fabric layers 26A, 26B, the nonwoven fabric layers
26A, 26B will inevitably become filmy in the course of
heat-sealing them together with the film 25 and it will be
difficult for the nonwoven fabric layers 26A, 26B to maintain
their fibrous state at the heat-sealed spots 27, 35.
[0047]
Fig. 7 is a perspective view showing the diaper 1A as put
on the wearer's body. An example of the sequence in accordance
with which a parent or a care personnel puts the diaper 1A on
the wearer's body will be described. After the hip of the wearer
lying face up has been laid on the developed diaper 1A, the front
waist region 8 is held with the hand and folded back along the
crotch region 9 onto the wearer's belly. Then, with the tape
fasteners 19 gripped by the fingers, the second wings 14 are
folded back so that these wings 14 may be positioned above the

wearer's belly. The second wings 14 are placed on respective
outer sides of the end psrtion 11 and the first wings 13 of the
front waist region 8. Adjusting a tightness of the end portions
11 as well as of the wings 14 around the wearer's waist, the
free portions 19b of the respective tape fasteners 19 are
anchored on the outer surface of the target tape by means of
the hooks 22 and thereby the front and rear waist regions 8,
10 are connected to each other.
[0048]
To anchor the tape fasteners 19 on the target tape 23,
the free portions 19b of the respective tape fasteners 19 may
be pressed against the cuter surface of the target tape 23 and
thereby the hooks 22 may be engaged with the loops 24. Upon
connection of the front and rear waist regions 8, 10 to each
other, the diaper 1A is formed with a waist-hole 36 and a pair
of leg-holes 37. Excretion discharged on the diaper 1A put on
the wearer's body is absorbed by the core 4 through the topsheet
2 and retained therein.
[0049]
Of the composite sheet 18 forming each of the second wings
14, the fibrous nonwoven fabric layer 26A contacts the wearer's
skin during use of the daaper 1A, so it is not apprehended that
the wings 14 might uncomfortably stick to the wearer's skin in

spite of stretchable elasticity of the wings 14. Comfortable
feeling to wear the diaper 1A is further enhanced by forming
the nonwoven fabric layers 26A, 26B using polyolefin-based
synthetic resin fiber which is free from tackiness as well as
sliminess peculiar to ruober-based material. Tightness of the
diaper 1A around the wearer's waist can be appropriately
adjusted by utilizing the elasticity of the second wings 14 so
as to prevent the diaper 1A from slipping down from its proper
position.
[0050]
The stretchable plastic film 25 constituting the
composite sheet 18 is formed with a plurality of air passages
31 so that water vapor generated within the diaper 1A due to
sweat evaporation can be Let out from the diaper 1A through these
air passages 31 and thereby stuffiness possibly occurring
within the diaper 1A can be prevented. More specifically, each
of these air passages 31 extending through the plastic film 25
in its thickness direction is tapered from the first opening
32 toward the second opening 33 and a surface tension acting
on the air passage 31 is higher in the vicinity of the second
opening 33 than in the vicinity of the first opening 32.
Consequently, sweat having flowed into the first opening 32 can
be easily transferred toward the second opening 33, i.e., toward

the skin non-contactable side of the second wing 14 under the
surface tension. In this way, wetness on this side of the wing
14 can be rapidly eliminated.
[0051]
A total thickness of the film 25 and the nonwoven fabric
layers 26A, 26B in the heat-sealed spots 27 is smaller than that
of the film 25 and the nonwoven fabric layer 26A except the
heat-sealed spots 27, so the nonwoven fabric layer 25A except
the head-sealed spots 27 comes in contact with the wearer's skin
as the diaper 1A is put on. The nonwoven fabric layers 26A,
26B have fiber densities higher in the heat-sealed spots 27,
35 than in the respective remaining regions and therefore a
capillary phenomenon occurs more significantly in the
heat-sealed spots 27, 35 than in the remaining regions. Such
significant capillary phenomenon allows any amount of sweat
having permeated the regaining region of the nonwoven fabric
layer 26A to be rapidly transferred to the heat-sealed spots
27, 35 and thereby allots the remaining region to be rapidly
dried. In this way, uncomfortaible tackiness and/or sliminess
due to sweat which would otherwise stay on the remaining region
of the nonwoven fabric layer 26A contacting with the wearer's
skin can be effectively eliminated. Inside some of the air
passages 31, the nonwoven fabric layers 26A, 26B are bonded

together at the heat-sealed spots 35, so water vapor generated
as the amount of sweat having moved to the heat-sealed spots
35 is evaporated can be let out from the diaper 1A through these
air passages 31 and the amount of sweat having permeated the
nonwoven fabric layer 26A can be rapidly dried.
[0052]
The number of the air passages 31 formed through the
plastic film 25 is in a range of 10 - 80/cm2 of the plastic film
25 and a total area ratio of the first openings 32 of these air
passages 31 is in a range of 10 - 20% of the plastic film 25.
If the number of the air passages 31 is less than 10 and the
total area ratio of the first openings 32 of these air passages
31 is less than 10% of an area of the plastic film 25, the number
of the air passages 31 per square centimetre of the plastic film
25 as well as the opening area, of the first openings 32 will
be insufficient to let the water vapor out from the diaper 1A
and to transfer the sweat toward the skin non-contacting side
of the second wings 14. As a result, it would be impossible
to prevent a stuffiness from being generated within the diaper
1A. If the number of the air passages 31 exceeds 80/cm2 and
the total area ratio of the first openings 32 of these air
passages 31 exceeds 20% of the area of the plastic film 25, on
the contrary, the film 25 will be formed with a number of the

first openings 32 excess ively close one to another and the film
25 will be broken between each pair of the adjacent first
openings 31. Thereupon the second wings 14 will lose the
desired elasticity and no more contract again. The nonwoven
fabric layers 26A, 26B are bonded to each other inside the air
passages 31 formed through the film 25 by a range of 1.5 - 10%
with respect to the total number of the air passages 31. If
this percentage is less than 1.5%, it will be impossible to let
the water vapor generated due to evaporation of the sweat having
been transferred to the heat-sealed spots 35 out from the diaper
1A and therefore to dry the sweat having permeated the nonwoven
fabric layer 26A.
[0053]
Each of the second wings 14 formed from the elastic
composite sheet 18 presents a transverse stretch stress of 1.5
- 7.0 N as the wing 14 is stretched in the transverse direction
to a length dimension in the transverse direction corresponding
to 120% of its non-stretched length dimension set as 100% and
presents a transverse stretch stress of 3. 0 - 10. 0 N as the wing
14 is stretched to a length dimension in the transverse
direction corresponding to 150% of its non-stretched length
dimension. If the stretch stress of the second wing 14 exceeds
the above-mentioned higher limits, the wings 14 will needlessly

clinch the wearer's waist as the diaper 1A is put on and the
wearer will experience a feeling of oppression partially around
his or her waist. If the stretch stress of the second wing 14
is less than the above-mentioned lower limits, on the contrary,
a contractile force of the wing 14 will be substantially
ineffective and it will be impossible for the wings 14 to clinch
the wearer's waist appropriately. The stretch stress was
measured using a method as follows:
(1) The transversely opposite side edge portions 12 of
the rear waist region 10 are cut away from the diaper 1A to
prepare samples for measurement of stretch stress. Each sample
comprises a part of the side edge 12 and the complete second
wing 14 (including the tape fastener 19). INSTRON 5543 or
AUTOGRAPH manufactured by INSTRON JAPAN CO. is used to measure
the stretch stress.
(2) A fixture is attached to the side edge portion 12 of
the sample except the second wing 14 so that the fixture may
extend along full length of the side edge portion 12. Of the
sample, the tape fastener 19 is held by an upper chuck and the
fixture is held by a lower chuck. A length dimension of the
sample measured between the upper and lower chucks is 70 mm.
(3) A length dimension of the non-stretched sample
extending between the upper and lower chucks without slacks is

set as 100%. The sample is stretched in the vertical direction
at a rate of 100 min/min so that the upper and lower chucks may
get away from each other. The sample is stretched to a length
dimension corresponding to 120% of its non-stretched length and
a stretch stress of the sample at this moment is measured and
then the sample is stretched to a length dimension corresponding
to 150% of its non-stretched length and a stretch stress of the
sample at this moment is measured.
EMBODIMENT 2
[0054]
Fig. 8 is a perspective view showing a pull-on diaper IB
as another embodiment of the invention, Fig. 9 is a sectional
view taken along the line IX-IX in Fig. 8, Fig. 10 is a developed
view showing the diaper IB of Fig. 8 with the front and rear
waist regions 8, 10 having been disconnected from each other
as partially broken away and Fig. 11 is an end view showing the
composite sheet forming the first and second wings 13, 14. In
Figs. 8 and 10, the transverse direction is indicated by an arrow
L and the longitudinal direction is indicated by an arrow M.
In Fig. 11, the transverse direction is indicated by an arrow
L and the thickness direction is indicated by an arrow N.
[0055]
The diaper 1B basically comprises a liquid-pervious

topsheet 2, a liqudd-impervious backsheet 3 and a
liquid-absorbent core 4 interposed between the top- and
backsheets 2, 3. The diaper 1B further comprises a plurality
of strand-like waist surrounding elastic members 5 and leg
surrounding elastic members 6 and a pair of leak-barrier sheets
7. As will be understood from Fig. 10, the diaper 1B has a
generally hourglass-like developed planar shape.
[0056]
The diaper 1B is composed of front and rear waist regions
8, 10 opposed to each other and a crotch region 9 extending
between these waist regions 8, 10 wherein the diaper 1B is
contoured by longitudinally opposite end portions 11 extending
in the transverse direction outside longitudinally opposite
ends 4a of the core 4 and transversely opposite side edge
portions 12 extending in the longitudinal direction outside
transversely opposite side edges 4b of the core 4. The front
waist region 8 is providec with a pair of first wings 13 extending
outward from respective side edge portions 12 of the front waist
region 8 in the transverse direction. The rear waist region
10 is provided with a pair of second wings 14 extending outward
from the respective side edge portions 12 of the rear waist
region 10 in the transverse direction. In the diaper 1B,
laterally outer end portions of the first and second wings 13,

14 are put flat and permanently bonded together at a plurality
of heat-sealing spots 38 arranged intermittently in the
longitudinal direction. Thereupon the diaper 1B is formed with
a waist-hole 36 and a pair of leg-holes 37.
[0057]
The topsheet 2 is formed from the same nonwoven fabric
15 as that of the diaper 1A and the backsheet 3 is formed from
the plastic film 16 and the nonwoven fabric 17 which are the
same as those of the diaper 1A. The core 4 is the same as that
of the diaper 1A and permanently bonded to the inner surface
of at least one of the top- and backsheets 2, 3.
[0058]
The longitudinally opposite end portions 11 are formed
from longitudinally opposite end portions 2a of the topsheet
2 and longitudinally opposite end portions 3a of the backsheet
3 extending outward beyond longitudinally opposite ends 4a of
the core 4 . The top- and backsheets 2, 3 are overlapped together
along the end portions 2a, 3a thereof and inner surfaces of these
sheets 2, 3 are permanently bonded together to form the
respective end portions 11. The waist surrounding elastic
members 5 are attached t o the inner surfaces of the top- and
backsheets 2, 3 so as to be interposed between the end portions
2a of the topsheet 2 and the end portions 3a of the backsheet

3 while these elastic members b are stretched at a given ratio
in the transverse direction.
[0059]
The transversely opposite side edge portions 12 are
formed from transversely opposite side edge portions 2b of the
topsheet 2 and transversely opposite side edge portions 3b of
the backsheet 3 extending outward in the transverse direction
beyond transversely opposite side edges 4b of the core 4. The
side edge portions 2b of the topsheet 2 extend outward in the
transverse direction slightly beyond the transversely opposite
side edges 4b of the core 4 and the side edge portions 3b of
the backsheet 3 as well as the side edge portions 7a of the
leak-barrier sheets 7 extend outward in the transverse
direction beyond the side edge portions 2b of the topsheet 2.
Along the side edge portions 12, the respective side edge
portions 2b, 3b, 7a are overlapped and permanently bonded
together. The leg surrounding elastic members 6 are interposed
between the side edge portions 3b of the backsheet 3 and the
side edge portions 7a of the respective leak-barrier sheets 7
and permanently bonded to the respective inner surfaces of these
sheets 3, 7 while these elastic members 6 are stretched at a
given ratio in the longatudinal direction.
[0060]

The leak-barrier sheets 7 are formed from the same
nonwoven fabric 20 as that of the diaper 1A and extend in the
longitudinal direction between the front and rear waist regions
8, 10. Each of the leak-barrier sheets 7 has the fixed side
portion 7a lying outside the associated side edge 4b of the core
4 and extending in the longitudinal direction, a movable portion
7b normally biased to rise above the topsheet 2 and
longitudinally opposite fixed end portions 7c lying on the
longitudinally opposite end portions 11, respectively, and
collapsed inward in the transverse direction of the diaper 1B.
An elastic member 21 expending in the longitudinal direction
is contractibly attached to the movable portion 7b in the
vicinity of its distal end. The movable portion 7b rises up
above the topsheet 2 so as to form barriers against bodily
discharges.
[0061]
The first and second wings 13, 14 have transversely inner
end portions 13a, 14a interposed between the side edge portions
3b of the backsheet 3 and the fixed side portions 7a of the
leak-barrier sheets 7 and permanently bonded to the respective
inner surfaces of these sheets 3, 7 by means of adhesive (not
shown) . The first and second wings 13, 14 are formed from an
elastically stretchable composite sheet 18, respectively,

which are elastically stretchable in the transverse direction.
[0062]
The composite sheet 18 comprises a breathable and
stretchable plastic film 25 and a pair of breathable and
heat-sealable fibrous ronwoven fabric layers 26A, 26B. The
plastic film 25 and the nonwoven fabric layers 26A, 26B have
respective surfaces overlapped and partially bonded together
by means of a plurality of heat-sealed spots 27 which are
distributed as evenly as possible. These nonwoven fabric
layers 26A, 26B are formed with a plurality of gathers 28 which
rise and fall in the thickness direction of the diaper 1B. The
nonwoven fabric layers 26A, 26B may be hydrophilic or
hydrophobic.
[0063]
The plastic film 25 is formed from a elastically
stretchable thermoplastic elastomer film 29 and thermoplastic
synthetic resin film layers 30 placed upon both surfaces of the
elastomer film 29. The elastomer film 29 and the synthetic
resin film layers 30 are overlapped and bonded together along
respective surfaces thereof opposed one to another. The
plastic film 25 is formed with a plurality of air passages 31
extending from its upper surface toward its skin
non-contactable side (i.e., toward the nonwoven fabric layer

26B) in the thickness direction of the diaper 1B. Each of these
air passages 31 is defined by a first opening 32 facing the
wearer's skin, a second opening 33 facing away from the wearer's
skin and having a diameter smaller than that of the first opening
32 and a tubular wall 34 extending between the first and second
openings 32, 33 so as tc be tapered from the first opening 32
toward the second opening 33.
[0064]
Inside the air passage 31, the nonwoven fabric layers 26A,
26B have respective surfaces facing each other bonded together
by means of heat-sealed spots 35. Similarly to the case of the
second wings 14 shown in Fig. 1, these nonwoven fabric layers
26A, 26B are bonded to each other in some of the air passages
31. At the heat-sealed spots 27, 35, these nonwoven fabric
layers 26A, 26B at the heat-sealed spots 27, 35 maintain a
fibrous state. In other words, a fiber density of the nonwoven
fabric layers 26A, 26B at these heat-sealed spots 27, 35 is
higher than a fiber density thereof in the remaining region.
[0065]
The elastomer film 29 and the synthetic resin film 30 are
formed from the same materials as those of the diaper 1A,
respectively. The process for making the stretchable composite
sheet 18 as well as the process for making the plastic film 25

are the same as those having been described in reference with
the diaper 1A. To shape the diaper 1B illustrated by Fig. 8
from its state illustrated by Fig. 10 in the developed plan view,
the diaper 1B may be folded along the crotch region 9 with the
topsheet inside so that the front and rear waist regions 8, 10
are opposed to each other and the outer end portions 13b, 14b
of the first and second wings 13, 14 may be permanently bonded
together by means of the heat-sealing lines 38.
[0066]
Of the composite sheet 18 forming each of the second wings
14, the fibrous nonwoven fabric layer 26A contacts the wearer's
skin during use of the diaper 1B, so it is not apprehended that
the wings 14 might uncomfortably stick to the wearer's skin in
spite of stretchable elasticity of the wings 14. Comfortable
feeling to wear the diaper 1B is further enhanced by forming
the nonwoven fabric layers 26A, 26B using polyolefin-based
synthetic resin fiber which is free from tackiness as well as
sliminess peculiar to rubber-based material. Tightness of the
diaper 1B around the wearer's waist can be appropriately
adjusted by utilizing the elasticity of the second wings 14 so
as to prevent the diaper 1B from slipping down from its proper
position.
[0067]

The stretchable plastic film 25 constituting the
composite sheet 18 is formed with a plurality of air passages
31 so that water vapor generated within the diaper 1B due to
sweat evaporation can be Let out from the diaper 1B through these
air passages 31 and thereby stuffiness possibly occurring
within the diaper 1B can be prevented. More specifically, each
of these air passages 31 extending through the plastic film 25
in its thickness direction is tapered from the first opening
32 toward the second opening 3 3 and a surface tension acting
on the air passage 31 is higher in the vicinity of the first
opening 32 than in the vicinity of the second opening 33.
Consequently, sweat having flowed into the first opening 32 can
be easily transferred toward the second opening 33, i.e., toward
the skin non-contacting side of the second wing 14 under the
surface tension. In this way, wetness on this side of the wing
14 can be rapidly eliminated.
[0068]
The nonwoven fabric layers 26A, 26B have fiber densities
higher in the heat-sealed spots 27, 35 than in the respective
remaining regions and therefore a capillary phenomenon occurs
more significantly in the heat-sealed spots 27, 35 than in the
remaining regions. Such significant capillary phenomenon
allows any amount of sweat having permeated the remaining region

of the nonwoven fabric layer 26A to be rapidly transferred and
thereby allows the remaining region to be rapidly dried. In
this way, uncomfortable tackiness and/or sliminess due to sweat
which would otherwise stay on the remaining region of the
nonwoven fabric layer 26A contacting with the wearer's skin can
be effectively eliminated. Inside some of the air passages 31,
the nonwoven fabric layers 26A, 26B are bonded together at the
heat-sealed spots 35, so water vapor generated as the amount
of sweat having moved tc the heat-sealed spots 35 is evaporated
can be let out from the diaper 1B through these air passages
31 and the amount of sweat having permeated the nonwoven fabric
layer 26A can be rapidly dried.
[0069]
The number of the air passages 31 formed through the
plastic film 25 is in a range of 10 - 80/cm2 in the plastic film
25 and a total area ratio of the first openings 32 of these air
passages 31 is in a range of 10 - 20% of the plastic film 25.
If the number of the air passages 31 is less than 10% and the
total area ratio of the first openings 32 of these air passages
31 is less than 10% of an area of the plastic film 25, the number
of the air passages 31 per square centimetre of the plastic film
25 as well as the opening area of the first openings 32 will
be insufficient to let the water vapor out from the diaper 1B

and to transfer the sweat toward the skin non-contacting side
of the second wings 14. As a result, it would be impossible
to prevent a stuffiness from being generated within the diaper
1B. If the number of the air passages 31 exceeds 80/cm2 and
the total area ratio of the first openings 32 of these air
passages 31 exceeds 20% of the area of the plastic film 25, on
the contrary, the film 25 will be formed with a number of the
first openings 32 excessively close one to another and the film
25 will be broken between each pair of the adjacent first
openings 32. Thereupon the second wings 14 will lose the
desired elasticity and no more contract again. In the diaper
1B, the nonwoven fabric layers 26A, 26B are bonded to each other
inside the air passages 31 formed through the film 25 by a range
of 1.5 - 10% with respect to all the air passages 31. If this
percentage is less than 1.5%, it will be impossible to let the
water vapor generated due to evaporation of the sweat having
been transferred to the heat-sealed spots 35 out from the diaper
1B and therefore to dry the sweat having permeated the nonwoven
fabric layer 26A.
[0070]
The first and second wings 13, 14 formed from a
stretchable composite sheet 18 present transverse stretch
stresses of 1.5 - 7.0 N as the wings 13, 14 are stretched in

the transverse direction to length dimensions in the transverse
direction correspondirg to 120% of non-stretched length
dimensions of the respective wings 13, 14 both set as 100% and
present transverse stretch stresses of 3.0 - 10.0 N as the wings
13, 14 are stretched to length dimensions in the transverse
direction corresponding to 150% of the non-stretched length
dimensions of the respective wings 13, 14. If the stretch
stresses of the first and second wings 13, 14 exceed the
above-mentioned higher limits, the wings 13, 14 will needlessly
clinch the wearer's waist as the diaper 1B is put on and the
wearer will experience a feeling of oppression partially around
his or her waist. If the stretch stresses of the first and
second wings 13, 14 are less than the above-mentioned lower
limits, on the contrary, contractile force of the wings 13, 14
will be substantially ineffective and it will be impossible for
these wings 13, 14 to clinch the wearer's waist appropriately.
The stretch stresses cf the first and second wings 13, 14 are
measured using the same method as has been described in
reference with the diaper 1A.
[0071]
Stock material for the topsheet 2 may be selected from
the group consisting of a hydrophobic fibrous nonwoven fabric
having a plurality of apertures and a plastic film having a

plurality of fine perforations. Stock material for the
backsheet 3 may be selected from the group consisting of a
breathable hydrophobic fibrous nonwoven fabric, a breathable
liquid-impervious plastic film and a composite nonwoven fabric
comprising two or more brsathable hydrophobic fibrous nonwoven
fabric layers laminated one upon another. Stock materials for
the leak-barrier sheets. 7 may be selected from the group
consisting of a composite nonwoven fabric comprising two or more
breathable hydrophobic fibrous nonwoven fabric layers
laminated one upon anotner and a composite sheet comprising
breathable hydrophobic fibrous nonwoven fabric and a breathable
liquid-impervious plastic film, laminated upon each other.
[0072]
As stock material for the backsheet 3 and the leak-barrier
sheets 7, it is also possible to use a composite nonwoven fabric
(SM nonwoven fabric or SMS nonwoven fabric) consisting of a melt
blown fibrous nonwoven fabric having a high water-resistance
and a spun bond fibrous nonwoven fabric having a high strength
as well as a high flexibility laminated on at least one side
of the melt blown fibrous nonwoven fabric.
[0073]
Fibrous nonwoven fabrics used to form the top- and
backsheets 2, 3, the leak-barreir sheets 7, the first and second

wings 13, 14, the tape fasteners 19 and the target tape 23 may
be selected from those obtained by spun lace-, needle punch-,
melt blown-, thermal bond-, spun bond- and chemical
bond-processes.
[0074]
The hydrophilic fibrous nonwoven fabric may be made of
any one of synthetic fiber, semi-synthetic fiber and
regenerated fiber each modified to become hydrophilic or
conjugate fiber thereof. The hydrophobic fibrous nonwoven
fabric may be formed from synthetic fiber and may contain
therein semi-synthetic fiber or regenerated fiber both treated
to become water repellent. While not specified, the synthetic
fiber may be selected from the group consisting of polyester-,
polyacrylonitrile-, polyvinyl chloride-, polyethylene-,
polypropylene- and polystyrene-based fibers. The suitably
useful synthetic fibers further include core-sheath type
conjugate fiber, side-by-side type conjugate fiber, macaroni
fiber, microporous fiber and bonded-type conjugate fiber.
[0075]
It is preferred to use hot melt adhesive as the adhesive.
In addition to hot melt adhesive, it is also possible to use
any one of acrylic adhesive and elastomeric adhesive. The
adhesive may be applied on the top- and backsheets 2, 3 and the

leak-barrier sheets 7 in a suitable pattern selected from the
group consisting of a spiral pattern, zigzag pattern, dotted
pattern and striped pattern. Application of the adhesive on
these sheets 2, 3, 7 in such pattern generates adhesive-coated
regions and adhesive-free regions, resulting in that these
sheets 2, 3, 7 are permanently bonded one to another in
intermittent fashion, the sheets 2, 3, 7 are bonded to one to
another in an intermittent, fashion and the core 4 is permanently
bonded to the sheets 2, 3.
[0076]
In the diaper 1A, not only the second wings 14 but also
the first wings 13 may be formed from the stretchable composite
sheet 18 and, in the diaper 1B, it is possible to use the
stretchable composite sheet 18 only for the second wings 14.

WE CLAIM
[1] A disposable diaper (1A, 1B) with elastically stretchable
and breathable wings, comprising:
a front waist regicn(8);
a rear waist regior(lO);
a crotch region(9) extending between these two waist
regions(8,10);
a pair of first wings(13) extending outward from
transversely opposite side edge portions of said front waist
region(8) in a transverse direction;
a pair of second wings(14) extending outward from
transversely opposite sice edge portions of said rear waist
region(10) in the transverse direction,
of said first and second wings (13,14) , at least said
second wings (14) are formed from an elastically stretchable
composite sheet(18) which comprises, in turn, a stretchy
plastic film (25);
a pair of breathable, heat-sealable fibrous nonwoven
fabric layers (26A,26B) partially bonded to both surfaces of
said plastic film(25) at of heat-sealed spots(27); said
diaper(1A,1B) being characterized in that:
said plastic film(25) is breathable and formed with a
plurality of air passages(31)extending through said plastic
film(25) each having a first opening (32) facing the wearer's
skin and a second opening (33) facing away from the wearer' s skin;
said nonwoven fabric layers(26A,26B)are formed with a
plurality of gathers rising and falling along surfaces of said
composite sheet(1);
inside said air passage(31), said fibrous nonwoven fabric
layers (26A, 26B) are bonded together at said heat-sealed
spots (27) and the number of said air passages (31) inside which
said fibrous nonwoven fabric layers (26A, 26B) are bonded to each
other is in a range of 1.5 - 10%; and
said fibrous nonwoven fabric layers(26A,26B) maintain a
fibrous state at said heat-sealed spots(27) and have a fibrous
density higher at said heat-sealed spots(27) than in the
remaining region except said heat-sealed spots (27).
[ 2] The diaper (1A,1B) as claimed in Claim 1, wherein said
plastic film (25) is formed from elastically stretchable
thermoplastic elastomer film (29) and a pair of polyolefin-

based thermoplastic synthetic resin film layers(30) bonded to
both surfaces of said elastomer film(29) and wherein said
fibrous nonwoven fabric layers(2 6A,26B) is formed from
polyolefin-based thermoplastic synthetic resin fiber.
[3] The diaper (1A,1B) as claimed in claim 1 or 2, wherein
said second openings (33) each has an area smaller than that
of each of said first openings (32) so that each of said air
passages (31) is tapered from each of said first openings (32)
toward each of said second openings (33).
[4] The diaper (1A,1B) as claimed in any one of claims 1
through 3, wherein said fibrous nonwoven fabric layers (26A,
26B) maintain a fibrous state at said heat-sealed spots (27)
and have a fibrous density higher at said heat-sealed spots (27)
than in the remaining regi on except said heat-sealed spots (27).
[5] The diaper (1A,1B) as claimed in any one of claims 1
through 4, wherein each of said second wings (14) formed from
said elastically stretch able composite sheet (18) presents a
transverse stretch stress of 1.5 - 7.0 N as each wing(14) is
stretched in the transverse direction to a length dimension in
the transverse direction corresponding to 120% of its
non-stretched transverse length dimension set as 100% and
presents a transverse stretch stress of 3.0 - 10.0 N as each
wing(14) is stretched to a length dimension in the transverse
direction corresponding to 150% of said non-stretched length
dimension.
[6] The diaper (1A,1B) as claimed in any one of claims 1
through 5, wherein said plastic film (25) has a thickness of
0.3-1 mm, and said fibrcus nonwoven fabric layers (26A, 26B)
each has a basic weight cf 20 - 60 g/m2, a thickness of 0.1 -
0.5 mm and a density of D.04 - 0.6 g/cm3.

Here is disclosed a disposable diaper improved so as to
give the wearer no uncomfortable feeling to wear this diaper
and to allow water vapor generated as a result of sweat
evaporation to be let out from the diaper through the wings.
A disposable diaper (1A) includes pair of second wings
(14) attached to transversely opposite side edge portions (12)
of a rear waist region (10) and extending outward in a transverse
direction are formed from an elastically stretchable composite
sheet (18). The composite sheet (18) comprises a breathable
stretchy plastic film formed with a plurality of air passages
each extending in a thickness direction from a first opening
facing the wearer's skin toward a second opening facing away
from the wearer's skin and breathable heat-sealable fibrous
nonwoven fabric layers partially bonded to both surfaces of the
plastic film and formed with a plurality of gathers rising and
falling along surfaces of the nonwoven fabric layers.

Documents:

31-KOLNP-2006-FORM-27.pdf

31-kolnp-2006-granted-abstract.pdf

31-kolnp-2006-granted-assignment.pdf

31-kolnp-2006-granted-claims.pdf

31-kolnp-2006-granted-correspondence.pdf

31-kolnp-2006-granted-description (complete).pdf

31-kolnp-2006-granted-drawings.pdf

31-kolnp-2006-granted-examination report.pdf

31-kolnp-2006-granted-form 1.pdf

31-kolnp-2006-granted-form 18.pdf

31-kolnp-2006-granted-form 3.pdf

31-kolnp-2006-granted-form 5.pdf

31-kolnp-2006-granted-gpa.pdf

31-kolnp-2006-granted-reply to examination report.pdf

31-kolnp-2006-granted-specification.pdf

31-kolnp-2006-granted-translated copy of priority document.pdf


Patent Number 230117
Indian Patent Application Number 31/KOLNP/2006
PG Journal Number 09/2009
Publication Date 27-Feb-2009
Grant Date 25-Feb-2009
Date of Filing 03-Jan-2006
Name of Patentee UNI-CHARM CO., LTD.
Applicant Address 182, SHIMOBUN, KINSEI-CHO, SHIKOKUCHUO-SHI, EHIME
Inventors:
# Inventor's Name Inventor's Address
1 MINATO HIRONAO C/O TECHNICAL CENTER, UNI-CHARM CO., LTD. 1531-7, WADAHAMA, TOYOHAMA-CHO, KANONJI-SHI, KAGAWA 769-1602
PCT International Classification Number A61F 13/56
PCT International Application Number PCT/JP2004/010956
PCT International Filing date 2004-07-30
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2003-204005 2003-07-30 Japan