Disposable absorbent article having breathable side flaps

Abstract

A simple disposable absorbent article including a chassis and an absorbent assembly. The chassis includes a water-impermeable sheet folded laterally inward at both of its side edges to form opposing side flaps. Each side flap is attached to the interior surface of the chassis adjacent to its end edges. Each side flap has a longitudinally extending elastic gathering member attached adjacent to its proximal edge. The absorbent assembly is smaller in width and in length than the chassis. The side edges and end edges of the absorbent assembly may be disposed proximally relative to the respective side edges and end edges of the chassis. The absorbent assembly includes an absorbent core that may contain superabsorbent particles, which may be contained inside pockets. The chassis may be extensible. The absorbent assembly may be in a cruciform pattern to the chassis to allow portions of the chassis to extend laterally.

1 . A disposable diaper comprising: 
 an absorbent assembly comprising an absorbent core; and 
 a chassis having a longitudinal axis, a lateral axis, a front waist region having a front waist edge, a back waist region having a back waist edge, a crotch region between the waist regions, laterally opposing side edges extending between the front waist edge and the back waist edge, an exterior surface, and an interior surface, the chassis forming a waist opening and two laterally opposing leg openings when the front waist region and the back waist region are attached together,  
 the chassis comprising a water-impermeable center sheet having laterally opposing side edges, an interior surface, and an exterior surface,  
 the chassis further comprising laterally opposing water-impermeable water vapor-permeable side sheets attached to the center sheet adjacent to its side edges, each of the side sheets being doubled and thereby having first and second layers over substantially its entire area,  
 at least portions of the side sheets being folded interiorly laterally inward to form laterally opposing breathable side flaps, each of the side flaps being attached adjacent to its longitudinally distal ends to the interior surface and having a longitudinally extending elastic gathering member attached adjacent to its proximal edge.  
   
     
     
         2 . The disposable diaper of  claim 1  wherein the first layer of the doubled side sheet has an edge, the second layer of the doubled side sheet has an edge, and the doubled side sheet is attached adjacent to the edge of the first layer to the interior surface of the center sheet and is attached adjacent to the edge of the second layer to the exterior surface of the center sheet.  
     
     
         3 . The disposable diaper of  claim 1  wherein the first layer of the doubled side sheet has an edge, the second layer of the doubled side sheet has an edge, and the doubled side sheet is attached adjacent to both the edge of the first layer and the edge of the second layer to the exterior surface of the center sheet.  
     
     
         4 . The disposable diaper of  claim 1  wherein the first layer of the doubled side sheet has an edge, the second layer of the doubled side sheet has an edge, and the doubled side sheet is attached adjacent to the edge of the first layer to the exterior surface of the center sheet and is also attached to itself adjacent to both the edge of the first layer and the edge of the second layer where the second layer is overlapped onto the first layer.  
     
     
         5 . The disposable diaper of  claim 1  wherein the elastic gathering member is sandwiched between the two layers of the doubled side sheet.  
     
     
         6 . The disposable diaper of  claim 1  wherein the two layers of the doubled side sheet are attached together in laterally spaced attachment zones extending longitudinally through at least the crotch region.  
     
     
         7 . The disposable diaper of  claim 1  wherein the two layers of the doubled side sheet are attached together in laterally extending attachment zones adjacent to each of the waist edges.  
     
     
         8 . The disposable diaper of  claim 7  wherein the two layers of the doubled side sheet are attached together laterally continuously in the laterally extending attachment zones.  
     
     
         9 . The disposable diaper of  claim 1  wherein at least a portion of the chassis is laterally extensible.  
     
     
         10 . The disposable diaper of  claim 9  wherein the center sheet is laterally extensible.  
     
     
         11 . The disposable diaper of  claim 9  wherein at least one of the side sheets is laterally extensible.  
     
     
         12 . The disposable diaper of  claim 9  wherein the extensible portion of the chassis is disposed in one of the waist regions and is laterally extensible to a maximum extensibility greater than a maximum extensibility of another portion of the chassis in the crotch region such that a lateral extension of each of the portions to its maximum extensibility imparts an hourglass shape to the chassis.  
     
     
         13 . A disposable diaper comprising: 
 an absorbent assembly comprising an absorbent core; and 
 a chassis having a longitudinal axis, a lateral axis, a front waist region, a back waist region, a crotch region between the waist regions, laterally opposing side edges extending between the front waist edge and the back waist edge, an exterior surface, and an interior surface, the chassis forming a waist opening and two laterally opposing leg openings when the front waist region and the back waist region are attached together,  
 the chassis comprising a water-impermeable water vapor-impermeable center sheet having laterally opposing side edges,  
 the chassis further comprising laterally opposing water-impermeable water vapor-permeable side sheets attached to the center sheet adjacent to its side edges,  
 at least portions of the side sheets being folded interiorly laterally inward to form laterally opposing breathable side flaps, each of the side flaps being attached adjacent to its longitudinally distal ends to the interior surface and having a longitudinally extending elastic gathering member attached adjacent to its proximal edge.  
   
     
     
         14 . The disposable diaper of  claim 13  wherein the elastic gathering member is enclosed inside a hem formed adjacent to the proximal edge of the side flap.  
     
     
         15 . The disposable diaper of  claim 13  wherein the side sheets are attached to the exterior surface of the center sheet.  
     
     
         16 . The disposable diaper of  claim 13  wherein the side sheets are attached to the interior surface of the center sheet.  
     
     
         17 . The disposable diaper of  claim 13  wherein at least a portion of the chassis in one of the waist regions is laterally extensible to a maximum extensibility greater than a maximum extensibility of another portion of the chassis in the crotch region such that a lateral extension of each of the portions to its maximum extensibility imparts an hourglass shape to the chassis.  
     
     
         18 . A disposable diaper comprising: 
 a chassis having a longitudinal axis, a lateral axis, a front waist region, a back waist region, a crotch region between the waist regions, laterally opposing side edges extending between the front waist edge and the back waist edge, an exterior surface, and an interior surface, the chassis forming a waist opening and two laterally opposing leg openings when the front waist region and the back waist region are attached together,    the chassis comprising a water-impermeable center sheet having laterally opposing side edges,    the chassis further comprising laterally opposing water-impermeable water vapor-permeable side sheets attached to the center sheet adjacent to its side edges,    at least portions of the side sheets being folded interiorly laterally inward to form laterally opposing breathable side flaps, each of the side flaps being attached adjacent to its longitudinally distal ends to the interior surface and having a longitudinally extending elastic gathering member attached adjacent to its proximal edge; and    an absorbent assembly comprising an absorbent core and being attached to the chassis in a cruciform pattern of attachment having a longitudinally extending portion intersecting with a laterally extending portion.    
     
     
         19 . The disposable diaper of  claim 18  wherein the longitudinally extending portion is disposed symmetrically with respect to the longitudinal axis and the laterally extending portion is disposed asymmetrically with respect to the lateral axis.  
     
     
         20 . The disposable diaper of  claim 19  wherein the laterally extending portion is offset toward the front waist region.