Disposable absorbent article having doubled side flaps and backsheet strips

Abstract

A disposable absorbent article includes two laterally opposing longitudinally extending backsheet strips attached to an exterior surface of an absorbent assembly in laterally opposing attachment zones. Each backsheet strip may include a water-impermeable layer and may be extensible. The absorbent assembly includes a lower covering sheet that is doubled by folding and thereby includes a first layer and a second layer. The absorbent assembly also includes laterally opposing side flaps which are formed by folding doubled portions of the lower covering sheet laterally inward. A longitudinally extending elastic gathering member is attached to each side flap adjacent to its proximal edge. When the article is worn, the elastic gathering members contract and raise the side flaps to form side barriers.

1 . A disposable diaper having a front waist region, a back waist region, a crotch region between the waist regions, a longitudinal axis, and a lateral axis, and comprising:
 an absorbent assembly having a front edge, a back edge, laterally opposing side edges extending between the front edge and the back edge, an exterior surface, and an interior surface; and   two laterally opposing longitudinally extending backsheet strips attached to the exterior surface of the absorbent assembly,   the absorbent assembly comprising an absorbent core and a water vapor-permeable lower covering sheet disposed exteriorly of the absorbent core,   laterally opposing longitudinally extending portions of the lower covering sheet being folded interiorly laterally inward to form the side edges of the absorbent assembly and laterally opposing breathable side flaps having proximal edges, the lower covering sheet being doubled by folding and thereby having first and second layers at least between each of the proximal edges and the respective side edge,   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 sandwiched between the first and second layers adjacent to its proximal edge.   
     
     
         2 . The disposable diaper of  claim 1  wherein the doubled lower covering sheet is water-impermeable. 
     
     
         3 . The disposable diaper of  claim 2  wherein the lower covering sheet is formed of a hydrophobic nonwoven material. 
     
     
         4 . The disposable diaper of  claim 1  wherein the absorbent assembly further comprises an additional bottom sheet disposed between the first layer and the second layer of the doubled lower covering sheet. 
     
     
         5 . The disposable diaper of  claim 4  wherein the additional bottom sheet is water-impermeable. 
     
     
         6 . The disposable diaper of  claim 5  wherein the additional bottom sheet is water vapor-permeable. 
     
     
         7 . The disposable diaper of  claim 1  wherein the elastic gathering member is sandwiched between the first layer and the second layer of the doubled lower covering sheet. 
     
     
         8 . The disposable diaper of  claim 1  wherein the proximal edges of both of the side flaps are formed by the folding of the lower covering sheet for doubling. 
     
     
         9 . The disposable diaper of  claim 1  wherein the doubled lower covering sheet has the first and second layers over substantially its entire area. 
     
     
         10 . The disposable diaper of  claim 9  wherein the lower covering sheet has two original longitudinally extending edges and the first layer and the second layer are overlapped and attached together adjacent to the original edges. 
     
     
         11 . The disposable diaper of  claim 1  wherein the first layer and the second layer are attached together in laterally spaced longitudinally extending attachment zones. 
     
     
         12 . The disposable diaper of  claim 11  wherein the laterally spaced longitudinally extending attachment zones are disposed between the proximal edges of the side flaps and the respective side edges of the absorbent assembly. 
     
     
         13 . The disposable diaper of  claim 11  wherein the laterally spaced longitudinally extending attachment zones are disposed below the absorbent core between the side edges of the absorbent assembly. 
     
     
         14 . The disposable diaper of  claim 1  wherein the first layer and the second layer are attached together in laterally extending attachment zones adjacent to the front edge and the back edge of the absorbent assembly. 
     
     
         15 . The disposable diaper of  claim 14  wherein the laterally extending attachment zones are laterally continuous. 
     
     
         16 . The disposable diaper of  claim 1  wherein when allowed the elastic gathering member is allowed to relax, the elastic gathering member contracts and lifts the proximal edge away from the interior surface of the absorbent assembly, thereby raising the side flap to form a side barrier. 
     
     
         17 . A disposable diaper having a front waist region, a back waist region, a crotch region between the waist regions, a longitudinal axis, and a lateral axis, and comprising:
 an absorbent assembly having a front edge, a back edge, laterally opposing side edges extending between the front edge and the back edge, an exterior surface, and an interior surface; and   two laterally opposing longitudinally extending backsheet strips attached to the exterior surface of the absorbent assembly,   the absorbent assembly comprising an absorbent core and a water vapor-permeable lower covering sheet disposed exteriorly of the absorbent core, the absorbent core being attached to the lower covering sheet in a cruciform pattern of attachment having a longitudinally extending portion intersecting with a laterally extending portion,   laterally opposing longitudinally extending portions of the lower covering sheet being folded interiorly laterally inward to form the side edges of the absorbent assembly and laterally opposing breathable side flaps having proximal edges, the lower covering sheet being doubled by folding and thereby having first and second layers at least between each of the proximal edges and the respective side edge.   
     
     
         18 . The disposable diaper of  claim 17  wherein at least a portion of the lower covering sheet lying outside the cruciform pattern is laterally extensible. 
     
     
         19 . A disposable diaper having a front waist region, a back waist region, a crotch region between the waist regions, a longitudinal axis, and a lateral axis, and comprising:
 an absorbent assembly having a front edge, a back edge, laterally opposing side edges extending between the front edge and the back edge, an exterior surface, and an interior surface; and   two laterally opposing longitudinally extending backsheet strips attached to the exterior surface of the absorbent assembly, each of the backsheet strips having at least one fastening element attached to it, the fastening element being adapted for fastening the front waist region and the back waist region together to encircle a waist and a leg of a wearer,   the absorbent assembly comprising an absorbent core and a water vapor-permeable lower covering sheet disposed exteriorly of the absorbent core,   laterally opposing longitudinally extending portions of the lower covering sheet being folded interiorly laterally inward to form the side edges of the absorbent assembly and laterally opposing breathable side flaps having proximal edges, the lower covering sheet being doubled by folding and thereby having first and second layers at least between each of the proximal edges and the respective side edge.   
     
     
         20 . The disposable diaper of  claim 19  wherein the fastening element includes a cohesive fastening patch.