Absorbent garments with monolithic films having zoned breathability

Abstract

Absorbent garments including monolithic backing members are provided having controlled regional breathability with high WVTR regions and low WVTR regions. The zoned monolithic films can be made by selectively applying adhesive to the monolithic film.

We claim:  
     
       1. A disposable, breathable absorbent garment defining an initial expanded shape having longitudinal and transverse axes, a front waist region, a back waist region, said front waist region and said back waist region being generally oppositely disposed on said longitudinal axis and a crotch region disposed between said front waist region and said back waist region and comprising: 
       a monolithic backing member comprising:  
       a first monolithic region having a WVTR of at least 800 g/m 2 /24 hours;  
       a second monolithic region having a WVTR less than said first monolithic region wherein the WVTR of said second monolithic region is at least 15% less than said WVTR of said first monolithic region;  
       a aqueous liquid pervious body-side liner joined to said monolithic backing member approximate a periphery of said joined body-side liner and said monolithic backing member;  
       a generally rectangular absorbent pad, having a front end edge, a back end edge and a pair of opposing side end edges, positioned between said body-side liner and said monolithic backing member in board of the periphery of said joined body-side liner and monolithic backing member; and,  
       leg elastics aligned along longitudinally extending margins of said periphery, rendering said garment elastically contractible and body-conforming adjacent the crotch of a wearer.  
     
     
       2. The garment of  claim 1 , wherein said monolithic backing member is a thermoplastic polymer. 
     
     
       3. The garment of  claim 1 , wherein said monolithic backing member comprises a water-proof moisture-vapor permeable unitary sheet material comprising a monolithic polymeric matrix having continuous passages extending through the thickness of said matrix and opening into both surfaces thereof. 
     
     
       4. The garment of  claim 1 , wherein said monolithic backing member comprises a multilayered coating from use in simultaneously imparting liquid resistance and breathability to a textile substrate wherein said coating comprising: 
       a first layer, adjacent to said textile substrate, consisting of a foamed adhesive wherein said adhesive is mechanically formed in solution from a fully reacted polymer latex chosen for the group consisting of polyvinyl chloride, acrylic, polyurethane, polyethylene, polystyrene copolymers of urethane and acrylic monomers, and mixtures thereof, to create an open celled surface;  
       a second layer, coated on said first layer distal to said textile substrate, comprising a monolithic membrane formed from a thermoplastic polymer selected from the group consisting of poly-vinyl diene fluoride, poly-vinyl diene chloride, and thermoplastic polyurethane, said second layer being capable of passing vapor across the width of said second layer in one direction from the surface adjacent to said first layer toward a third layer, and said second layer further being capable of inhibiting the flow of liquid across said second layer in the opposite direction; and,  
       said third layer, coated on said second layer, to inhibit said flow of liquid in the direction of said second layer, and to impart abrasion resistance to said multilayered coating and said textile substrate, said third layer comprising a continuous film formed from latexes selected from the group consisting of acrylics, poly-vinyl chloride, polyurethane, and mixtures thereof.  
     
     
       5. The garment of  claim 1 , wherein said second monolithic region of said monolithic backing member is adjacent said absorbent pad. 
     
     
       6. The garment of  claim 5 , wherein said first monolithic region of said monolithic backing member is adjacent said periphery of said joined body-side liner and monolithic backing member. 
     
     
       7. The garment of  claim 1  wherein said WVTR of said first monolithic region is at least about 3,000 and said WVTR of said second monolithic region is less than about 1,500. 
     
     
       8. The garment of  claim 2  wherein said WVTR of said first monolithic region is at least about 3,000 and said WVTR of said second monolithic region is less than about 1,500. 
     
     
       9. The garment of  claim 6 , wherein said monolithic backing member is a thermoplastic polymer. 
     
     
       10. The garment of  claim 6 , wherein said monolithic backing member comprises a water-proof moisture-vapor permeable unitary sheet material comprising a monolithic polymeric matrix having continuous passages extending through the thickness of said matrix and opening into both surfaces thereof. 
     
     
       11. The garment of  claim 6 , wherein said monolithic backing member comprises a multilayered coating from use in simultaneously imparting liquid resistance and breathability to a textile substrate wherein said coating comprising: 
       a first layer, adjacent to said textile substrate, consisting of a foamed adhesive wherein said adhesive is mechanically formed in solution from a fully reacted polymer latex chosen for the group consisting of polyvinyl chloride, acrylic, polyurethane, polyethylene, polystyrene copolymers of urethane and acrylic monomers, and mixtures thereof, to create an open celled surface;  
       a second layer, coated on said first layer distal to said textile substrate, comprising a microporous membrane formed from a thermoplastic polymer selected from the group consisting of poly-vinyl diene fluoride, poly-vinyl diene chloride, and thermoplastic polyurethane, said second layer being capable of passing vapor across the width of said second layer in one direction from the surface adjacent to said first layer toward a third layer, and said second layer further being capable of inhibiting the flow of liquid across said second layer in the opposite direction; and,  
       said third layer, coated on said second layer, to inhibit said flow of liquid in the direction of said second layer, and to impart abrasion resistance to said multilayered coating and said textile substrate, said third layer comprising a continuous film formed from latexes selected from the group consisting of acrylics, poly-vinyl chloride, polyurethane, and mixtures thereof.  
     
     
       12. The garment of  claim 1  wherein said first monolithic region surrounds said second monolithic region. 
     
     
       13. The garment of  claim 1  wherein said first monolithic region partially surrounds said second monolithic region. 
     
     
       14. The garment of  claim 1  wherein said second monolithic region is continuous in the machine direction. 
     
     
       15. The garment of  claim 1  wherein said second monolithic region is discontinuous in the machine direction. 
     
     
       16. The garment of  claim 1  wherein said second monolithic region is continuous in the cross-machine direction. 
     
     
       17. The garment of  claim 1  wherein said second monolithic region is discontinuous in the cross-machine direction. 
     
     
       18. The garment of  claim 1 , wherein said first region of said monolithic backing member is disposed in said front waist region of said garment. 
     
     
       19. The garment of  claim 18 , wherein said monolithic backing member is a thermoplastic polymer. 
     
     
       20. The garment of  claim 18 , wherein said monolithic backing member comprises a water-proof moisture-vapor permeable unitary sheet material comprising a monolithic polymeric matrix having continuous passages extending through the thickness of said matrix and opening into both surfaces thereof. 
     
     
       21. The garment of  claim 18 , wherein said monolithic backing member comprises a multilayered coating from use in simultaneously imparting liquid resistance and breathability to a textile substrate wherein said coating comprising: 
       a first layer, adjacent to said textile substrate, consisting of a foamed adhesive wherein said adhesive is mechanically formed in solution from a fully reacted polymer latex chosen for the group consisting of polyvinyl chloride, acrylic, polyurethane, polyethylene, polystyrene copolymers of urethane and acrylic monomers, and mixtures thereof, to create an open celled surface;  
       a second layer, coated on said first layer distal to said textile substrate, comprising a microporous membrane formed from a thermoplastic polymer selected from the group consisting of poly-vinyl diene fluoride, poly-vinyl diene chloride, and thermoplastic polyurethane, said second layer being capable of passing vapor across the width of said second layer in one direction from the surface adjacent to said first layer toward a third layer, and said second layer further being capable of inhibiting the flow of liquid across said second layer in the opposite direction; and,  
       said third layer, coated on said second layer, to inhibit said flow of liquid in the direction of said second layer, and to impart abrasion resistance to said multilayered coating and said textile substrate, said third layer comprising a continuous film formed from latexes selected from the group consisting of acrylics, poly-vinyl chloride, polyurethane, and mixtures thereof.  
     
     
       22. The garment of  claim 1 , wherein said first monolithic region of said monolithic backing member is disposed in said back waist region of said garment. 
     
     
       23. The garment of  claim 22 , wherein said monolithic backing member is a thermoplastic polymer. 
     
     
       24. The garment of  claim 22 , wherein said monolithic backing member comprises a water-proof moisture-vapor permeable unitary sheet material comprising a monolithic polymeric matrix having continuous passages extending through the thickness of said matrix and opening into both surfaces thereof. 
     
     
       25. The garment of  claim 22 , wherein said monolithic backing member comprises a multilayered coating from use in simultaneously imparting liquid resistance and breathability to a textile substrate wherein said coating comprising: 
       a first layer, adjacent to said textile substrate, consisting of a foamed adhesive wherein said adhesive is mechanically formed in solution from a fully reacted polymer latex chosen for the group consisting of polyvinyl chloride, acrylic, polyurethane, polyethylene, polystyrene copolymers of urethane and acrylic monomers, and mixtures thereof, to create an open celled surface;  
       a second layer, coated on said first layer distal to said textile substrate, comprising a microporous membrane formed from a thermoplastic polymer selected from the group consisting of poly-vinyl diene fluoride, poly-vinyl diene chloride, and thermoplastic polyurethane, said second layer being capable of passing vapor across the width of said second layer in one direction from the surface adjacent to said first layer toward a third layer, and said second layer further being capable of inhibiting the flow of liquid across said second layer in the opposite direction; and,  
       said third layer, coated on said second layer, to inhibit said flow of liquid in the direction of said second layer, and to impart abrasion resistance to said multilayered coating and said textile substrate, said third layer comprising a continuous film formed from latexes selected from the group consisting of acrylics, poly-vinyl chloride, polyurethane, and mixtures thereof.  
     
     
       26. The garment of  claim 1 , wherein said first monolithic region of said monolithic backing member is disposed in said front waist region and said back waist region of said garment. 
     
     
       27. The garment of  claim 6 , wherein said monolithic backing member is a thermoplastic polymer. 
     
     
       28. The garment of  claim 2 , wherein said second monolithic region of said monolithic backing member has a minimum dimension of 3 cm by 3 cm. 
     
     
       29. The garment of  claim 5 , wherein said second monolithic region of said monolithic backing member has a minimum dimension of 5 cm by 5 cm. 
     
     
       30. The garment of  claim 2 , wherein said thermoplastic polymer is a polyolefin polymer. 
     
     
       31. The garment of  claim 9 , wherein said thermoplastic polymer is a polyolefin polymer. 
     
     
       32. The garment of  claim 1 , wherein said first monolithic region has a WVTR in excess of 2500 g/m 2 /24 hours and said second monolithic region has a WVTR less than 1500 g/m 2 /24 hours and further wherein said second monolithic region comprises from about 5% to about 75% of the area of said monolithic backing member. 
     
     
       33. The garment of  claim 1 , wherein said second monolithic region has a WVTR at least about 25% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35 g/m 2 . 
     
     
       34. The garment of  claim 2 , wherein said second monolithic region has a WVTR at least about 25% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35g/m 2 . 
     
     
       35. The garment of  claim 3 , wherein said second monolithic region has a WVTR at least about 25% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35 g/m 2 . 
     
     
       36. The garment of  claim 4 , wherein said second monolithic region has a WVTR at least about 25% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35 g/m 2 . 
     
     
       37. The garment of  claim 1 , wherein said second monolithic region has a WVTR at least 50% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35 g/m 2 . 
     
     
       38. The garment of  claim 2 , wherein said second monolithic region has a WVTR at least 50% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35 g/m 2 . 
     
     
       39. The garment of  claim 1 , wherein said second monolithic region has a WVTR at least about 75% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35 g/m 2 . 
     
     
       40. The garment of  claim 2 , wherein said second monolithic region has a WVTR at least about 75% less than the WVTR of said first monolithic region and wherein each of said first and second monolithic regions have a basis weight less than about 35 g/m 2 . 
     
     
       41. The garment of  claim 1 , further comprising a third monolithic region, said third monolithic region having a WVTR intermediate to the WVTR of said first monolithic region and the WVTR of said second monolithic region and wherein said second monolithic region comprises from about 5% to about 75% of the area of said monolithic backing member. 
     
     
       42. The garment of  claim 2 , wherein said monolithic backing member comprises at least about 50% by weight of said thermoplastic polymer and other components. 
     
     
       43. The garment of  claim 1 , wherein said second monolithic region extends at least 5 cm in the cross-machine direction and extends substantially continuously in the machine direction of said monolithic backing member. 
     
     
       44. The garment of  claim 1 , wherein said second monolithic region is positioned symmetrically along the longitudinal axis of said garment. 
     
     
       45. The garment of  claim 44 , wherein said monolithic backing member has a WVTR gradient. 
     
     
       46. A disposable, breathable absorbent garment defining an initial expanded shape having longitudinal and transverse axes, a front waist region, a back waist region, said front waist region and said back waist region being generally oppositely disposed on said longitudinal axis and a crotch region disposed between said front waist region and said back waist region and comprising: 
       a monolithic backing member having regions of varied breathability comprising:  
       a first monolithic region comprising a polyolefin polymer;  
       a second monolithic region comprising a polyolefin polymer;  
       wherein said first and second monolithic regions comprise a continuous monolithic backing member and wherein the WVTR of said second monolithic region is less than the WVTR of said first monolithic region;  
       a aqueous liquid pervious body-side liner joined to said monolithic backing member approximate a periphery of said joined body-side liner and said monolithic backing member;  
       a generally rectangular absorbent pad, having a front end edge, a back end edge and a pair of opposing side end edges, positioned between said body-side liner and said monolithic backing member in board of the periphery of said joined body-side liner and said monolithic backing member; and,  
       leg elastics aligned along longitudinally extending margins of said periphery, rendering said garment elastically contractible and body-conforming adjacent the crotch of a wearer.  
     
     
       47. The garment of  claim 46 , wherein said first and second monolithic regions have a basis weight less than about 35 g/m 2  and said second monolithic region has a minimum dimension of 3 cm by 3 cm. 
     
     
       48. The garment of  claim 47 , wherein said second monolithic region comprises from about 5% to about 75% of the area of the monolithic backing member. 
     
     
       49. The garment of  claim 48 , wherein said first monolithic region has a WVTR between about 2000 g/m 2 /24 hours and about 5000 g/m 2 /24 hours and said second monolithic region has a WVTR less than about 1800 g/m 2 /24 hours. 
     
     
       50. The garment of  claim 48 , wherein said first monolithic region has a WVTR between about 2000 g/m 2 /24 hours and about 5000 g/m 2 /24 hours and said second monolithic region has a WVTR less than about 1500 g/m 2 /24 hours. 
     
     
       51. The garment of  claim 48 , wherein said first monolithic region has a WVTR between about 2000 g/m 2 /24 hours and about 5000 g/m 2 /24 hours and said second monolithic region has a WVTR less than about 1200 g/m 2 /24 hours. 
     
     
       52. The garment of  claim 48 , wherein said first monolithic region has a WVTR between about 2000 g/m 2 /24 hours and about 5000 g/m 2 /24 hours and said second monolithic region has a WVTR less than about 1000 g/m 2 /24 hours. 
     
     
       53. The garment of  claim 48 , wherein said first monolithic region has a WVTR between about 2000 g/m 2 /24 hours and about 5000 g/m 2 /24 hours and said second monolithic region has a WVTR less than about 800 g/m 2 /24 hours. 
     
     
       54. The garment of  claim 48 , wherein said second monolithic region has a WVTR less than about 1500 g/m 2 /24 hours and said first monolithic region has a WVTR in excess of about 2500 g/m 2 /24 hours. 
     
     
       55. The garment of  claim 49 , wherein said second monolithic region has a WVTR less than about 300 g/m 2 /24 hours and comprises from about 5% to about 60% of the area of said monolithic backing member. 
     
     
       56. The garment of  claim 47 , wherein said first and second monolithic regions each have substantially similar basis weights. 
     
     
       57. The garment of  claim 46 , wherein said second monolithic region has a WVTR at least about 50% less than the WVTR of said first monolithic region and comprises from about 5% to about 75% of the area of said monolithic backing member. 
     
     
       58. The garment of  claim 46 , wherein said second monolithic region has a WVTR at least about 25% less than the WVTR of said first monolithic region and comprises from about 5% to about 75% of the area of said monolithic backing member. 
     
     
       59. The garment of  claim 46 , wherein said second monolithic region has a WVTR at least about 75% less than the WVTR of said first monolithic region and comprises from about 5% to about 75% of the area of said monolithic backing member. 
     
     
       60. The garment of  claim 48 , wherein said polyolefin polymer of said first monolithic region and said polyolefin polymer of said second monolithic region comprise polypropylene. 
     
     
       61. The garment of  claim 47 , wherein said polyolefin polymer of said first monolithic region and said polyolefin polymer of said second monolithic region comprise polypropylene. 
     
     
       62. The garment of  claim 47 , wherein said monolithic backing member further comprises a third monolithic region having a WVTR less than the WVTR of said first monolithic region and greater than the WVTR of said second monolithic region. 
     
     
       63. The garment of  claim 62 , wherein said third monolithic region is contiguous with said second monolithic region and further wherein said second and third monolithic regions together comprise from about 5% to about 75% of the area of said monolithic backing member. 
     
     
       64. The garment of  claim 62 , wherein said second monolithic region has a dimension on the cross-machine direction less than the cross-machine dimension of said third monolithic region. 
     
     
       65. The garment of  claim 64 , wherein said second and third monolithic regions are contiguous and further wherein said second monolithic region comprises from about 5% to about 60% of the area of said monolithic backing member.