CA2210134C - Compound sanitary napkin - Google Patents

Abstract

The present invention pertains to a compound sanitary napkin. The compound sanitary napkin includes a primary absorbent member secured to a secondary absorbent member. The primary absorbent member includes an absorbent core wrapped in an outer cover, at least a portion of the outer cover being liquid impervious. The secondary absorbent member includes a liquid impervious backsheet and an absorbent material joined thereto. Optionally, the secondary absorbent member includes a backsheet, a topsheet joined to the backsheet and an absorbent core disposed between the backsheet and the topsheet.

Description

WO 96/25903 . PC'T/US96I016a7 COMPOUND SANITARY NAPKIN
s FIELD OF THE IIWENTION
The present invention relates to disposable sanitary napkins. As used herein, sanitary napkins are considered to be absorbent devices designed to be worn externally of the body by women, usually during their menswal periods, and to receive and contain menses and other vaginal dixharges. Disposable sanitary napkins are intended to be discarded after use and soiling rather than being cleaned and reused.
AA('xc;ROUND OF THE I1~TVENTION
In their simplest form, disposable sanitary napkins comprise an absorbent element (sometimes referred to as an absorbent core) interposed between a liquid ~s pervious body-contacting element (sometimes referred to as a topsheet or an overwrap) and a liquid impervious protective barrier (sometimes referred to as a backsheet). The absorbent element is intended to receive and contain menses and other vaginal dixharges. The body-contacting element is intended to provide more or less comfortable and dry-feeling contact with body surfaces while allowing free passage of zo fluids therethrough into the absorbent element. The protective barrier is intended to prevent menses or other vaginal dixharges which are expelled or which escape from the absorbent element from soiling the users garments.
In addition to the three functional elements mentioned above, disposable sanitary napkins are generally provided with means for supporting the device adjacent is the user's crotch area, even as the user moves, where it can most effectively perform its intended function. Typically, sanitary napkins are provided with an adhesive attachment means for securing the device to the inner crotch area of the user's undergarments.
While previously known sanitary napkins do perform their intended function, 3o each conventional design suffers from certain deficiencies in one or more of absorbency of body fluids, protection of the user's garments from soiling, and/or physical comfort to the user.
With respect to disposable sanitary napkins, at least two general classes presently exist. One such class is identified as being intended for the absorption of 3s medium to high menstrual flows. These sanitary napkins offer a relatively high absorptive capacity. Absorptive capacity is commonly. a~W~~ by providing the sanitary napkin with a relatively thick and bulky absorbent member. While having a relatively high absorptive capacity, the bulkiness of the absorbent member may cause a certain degree of wearing discomfort.
A second class of sanitary napkins are intended for light or low menstrual flows s and are commonly referred to as pantilinas or pantishields. Sanitary napkins of this class, as a group, are thinner, somewhat more flexible and generally more comfortable than thox of the first class. However, sanitary napkins of the second class typically lack the absorptive capacity of sanitary napkins of the first class.
One attempt to provide the benefits of the previously described two classes of io sanitary napkins into a single compound sanitary napkin is disclosed in commonly assigned U.S. Patent No. 4,425,130 issued to DesMarais on January 10, 1984.
The compound sanitary napkin of DesMarais comprises a primary ma>Stnral pad and a panty protector joined to one another at their corresponding ends in such a manner that the two constituents are free to move relative to one another along essentially their ~s entire common length. The primary mend pad is intended to absorb the bulk of the bodily fluids discharged by the user, while the panty protector is intended to protect the user's garments from soiling. In use, the relative freedom of movement between the primary menstrual pad and the panty protector serves to maintain the primary menstrual pad adjacent the user's crotch region while the patsy protector remains associated with zo the user's undergarment. While the relative freedom of movement between the primary menstnral pad and the panty protector saves to maintain the primary mensuual pad near the user's crotch region, this freedom of movement may lead to a lack of stability if the primary me~tnul pad moves laterally beyond the side edges of the panty protector, providing an opportunity for soiling the uses undergarment.
Zs Furthermore, the relative freedom of movement betwan the primary menstrual pad and the panty protector alone may be insuff dent to capture bodily fluid as it exits the weues vaginal opening. The prinury nxnstrual Paid is preferably narrow enough to at least reside partially within the exta~nal genitalia. Optionally, the primary mennnul pad may be wider than the distance between the labia majors, but exhibits a so lateral compression or conformability at rclativdy low forces, such as the forces exerted by the soft tissue of the female external gtnitalia, such that a portion of the primary menstrual pad is able to at least reside partially within the e~~
female genitalia. By being conformable at relatively low forces, the primary absorbent member remains comfortable during ux. In addition, the primuy menstrual Pad preferably ss exhibiu a resilient recovery to enable the pad to conform to the body as the pad and body interface is subjected to shape changes.

As the primary menstrual pad is made narrower to fit the body, the panty protector preferably remains sufficiently wide enough to provide a stable attachment to the wearer's undergarment and to sufficiently cover the undergarment to protect it from soiling.
SUMMARY OF THE INVENTION
The present invention pertains to a compound sanitary napkin. The compound sanitary napkin comprises a primary absorbent member including an absorbent core wrapped in an outer covering, at least a portion of the outer covering being liquid 1o impervious. The compound sanitary napkin further comprises a secondary absorbent member that is secured to the primary absorbent member. The secondary absorbent member comprises a liquid impervious backsheet and an absorbent material joined thereto. Optionally, the secondary absorbent member comprises a backsheet, a topsheet joined to the backsheet and an absorbent core disposed between the t5 backsheet and the topsheet.
In accordance with one embodiment, a compound sanitary napkin comprises a primary absorbent member including an absorbent core and an outer cover, and a secondary absorbent member joined with the primary absorbent member, the secondary absorbent member including a liquid impervious backsheet and an 2o absorbent element joined to the backsheet;
wherein the outer cover substantially encircles or completely wraps the absorbent core, at least a portion of the outer cover being liquid impervious.
In accordance with a further embodiment, a compound sanitary napkin comprises a primary absorbent member having a centerline dividing the primary z5 absorbent member into an upper portion and a lower portion, the primary absorbent member including an absorbent core and an outer cover which substantially encircles the absorbent core; and a secondary absorbent member joined with the primary absorbent member, the secondary absorbent member including a backsheet and an absorbent element joined 3o to the backsheet;

3a wherein the outer cover comprises:
a first segment juxtaposed the absorbent core in at least the upper portion, the first segment being fluid pervious; and at least one second segment juxtaposed the absorbent core and s disposed in the lower portion, at least a portion of the segment being fluid impervious.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and 1o distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the following drawings, in which like reference numbers identify identical elements and wherein:
FIG. 1 is a top plan view of one embodiment of the compound sanitary napkin of the present invention;
1 s FIG. 2 is a side elevation view of the compound sanitary napkin shown in FIG. 1;
FIG. 3 is a cross-sectional view of the compound sanitary napkin shown in FIGS. 1 and 2 as taken along section line 3-3 of FIG. 2; and FIGS. 4, 5, and 6 are cross-sectional views of other embodiments of the 2o compound sanitary napkin of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
This invention is of a body fitting compound sanitary napkin which exhibits absorbency for bodily fluids, the protection of the user's garments from 2s soiling, and physical comfort to the user. The term "sanitary napkin", as used herein, refers to an article which is worn by females adjacent to the pudendal region and which is intended to absorb and contain the various exudates which are discharged from the body (e.g., blood, menxs, and urine) and which is intended to be discarded aRer a single ux (i.e., it is not intended to be laundered or otherwise restored or reused). The term "compound sanitary napkin", as used herein, refers to a sanitary napkin comprised of xparate constituents joined to one another to form a unitary structure.
Interlabial s devices which reside partially within and partially external of the wearers vestibule are also within the scope of this invention. As used herein, the term "pudendal"
refers to the externally visible female genitalia and is limited to the labia majors, the labia minors, the clitoris, and the vestibule.
Referring now to FIGS. I-3, then is shown one preferred embodiment of a ~o compound sanitary napkin 20 of the present invention. As can be seen in FIGS. 1-3, the compound sanitary napkin 20 comprises a primary absorbent member 30 and a secondary absorbent member 50 joined together by union means 70. The compound sanitary napkin has two surfaces, a body contacting or facing stuface, and a garment facing or contacting surface. The primary and secondary absorbent members each have ~s corresponding body facing and garment facing sirrfaca. The compound sanitary napkin 20 has two centerlines, a longitudinal centerline L and a transverx centerline T.
The term "longitudinal", as ux herein, refer to a line, axis or direction in the plane of the compound sanitary napkin that is generally aligned with (e.g., approximately paralld to) a vertical piano which bisects a standing wearer into leR and right body zo halves when the compound sanitary napkin is worn. The terms "transverse" or "lateral", as used herein, are interchangeable, and refer, to s line, axis, or direction which Los within the plane of the compound sanitary napkin that is generally perpendicular to the longitudinal direction.
The primary absorbent member 30 hss side edges 24 and end edges 25 which is together form the periphery 26 of the primuy sbsorbalt member 30. The xcondary abrtorbent n>errrber 50 hss side edges 21 and end edges 22 which together form the p~iphay 23 of the secondary absorbent munba and the compound sanitary napkin 20.
The compound sanitary napkin 20 has a fast end region 27, a central region 28, and a second end region 29.
3o The primary absorbent member 30 is that constmrent of the compound sanitary napkin 20 intended to absorb the bulk of bodily 9uids dixharged by the uxr.
The primary absorbent member 30 has a centerline 200, as shown in FIG. 3 that divides the primary absorbent member 30 into an upper portion 202 and a lower portion 204.
The primary absorbent member 30 comprises an absorbent means 33, such as absorbent 3s core 34, and an outer cover 32 superimposed on the absorbent core 34. (As used herein, the term "superimposed" means adjacent or juxtaposed, but not necessarily in WO 96/25903 PCT'/US961016.i7 contact with or joined to.) The outer cover 32 preferably comprises a first segment 206 disposed in the upper portion 202 and at least one second segment 208 disposed in the lower portion 204. The first segment 206 is liquid pervious whereas at least a portion of the second segment 208 is preferably liquid impervious. Preferably, the s entire second segment 208 disposed in the lower portion 204 is liquid impervious.
Other embodiments are contemplated wherein the second segment 208 is hydrophobic and not necessarily liquid impervious.
Preferably, at least the first xgenatt 206 of the outer cover 32 is compliant, soft feeling, and non-irritating to the weara's skin. Further, as stated above, at least the first segment of the outer cover 32 is liquid pervious, permitting liquid to readily penetrate through its thickness. A suitable outs cover 32 may be manufactured from a wide range of materials such as woven and nonwoven materials; polymeric materials such as apertured formed thermoplastic films, apertured plastic films, and hydroformed thermoplastic films; porous foams; reticulated foams; reticulated thermoplastic films;
~s and thermoplastic scrims. Suitable woven and nomwoven materials can be comprised of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polymeric fibers such as polyester, polypropylene, or polyethylene fibers); or firm a combination of natural and synthetic fibers.
The outer cover 32 may be a unitary or may be comprised of two or so more elements joined together to form the outer cover 32. Further, the arty portion of the materials comprising the outs coves may be coated, laminated, treated or otherwise manipulated to impart or athance any desired characteristics such as strength, flexibility, liquid perviousness or imperviousness.
A preferred outer coves 32 comprises formed film having aperttues in at least is the first segment 206. Formed films are preferred for the outer cover 32 because they are resistant to wicking and are easily manufactured hsving portions with apertures and portions witlwut apertures. The spatured segments of a formed film are generally pervious to body arudates and yet non-absorbent, thus reducing the likelihood of liquids passing back through the film and rewetting the wearer's skin.
Accordingly, the 3o surface of the formed film which is in contact with the body remains dry, thereby reducing body soiling and creating s more comfortable fed for the wearer. The non-apertured segments of the formed films are liquid impervious, thus preventing any fluids from passing therethrough. Suitable formed films are described in U.S.
Pat. No.
3,929,135, issued to Thompson on Decanba 30, 1975; U.S. Pat. No. 4,324,246, 3s issued to Mullane, et al. on April 13, 1982; U.S. Pat. No. 4,342,314, issued to ltadel, et al. on August 3, 1982; U.S. Pst. No. 4,463,045, issued to Ahr, et al. on July 31, 1984;

WO 96!25903 PCTIL,'S96~016.J?

and U.S. Pat. No. 5.006.394, issued to Baird on April 9, 1991.
One especially prefetted outer cover 32 for the primary absorbent member 30 of the present invention comprises a formed film described in one or more of the above patents and marketed on s~itary rupkins by The s Procter ~ Gamble Company of Cincinnui, Ohio as 'DRI-WEAVE".
In a preferred embodiment of the present invention, the exposed surface of at least the first stgment 206 of the outs coves 32 comprising the formed film is hydrophilic so as to help liquid trar>sfer through the outs cover 32 faster than if the body surface was not hydrophilic. This diminishes the likelihood that menstrual fluid 1o will flow off the first xgment 206 of the outs cover 32 rather thus flowing into and being absorbed by the absorbent core 34. In a prefaTed embodiment, surfactant is incorporued into the polymeric materials of the formed film.
1s Altaas:;vdy, s ssufaetartt may be incorporated within the polymer resin forming the outer coves 32 or the body surface of the first xgment 206 of the outs coves 32 can be made hydrophilic by tresting it with a surfactant such a described in U.S. Pat. No. 4,950,264 issued to Osborn on August 21, 1990.
so As stated above, the outs cover 32 is preferably superimposed on the absorbent core 34. To insure props fluid transfer between the outs coves 32 and the absorbatt core 34 it is preferred that the outer coves be substantially continuously joined to the underlying absorbent core 34 throughout the'sr common association or i~e~Ce. (As used beren, the term "jeined~ encampasxs configurations whereby an xs d~att is direaty warred to aratha demau by aflnong the dement to the other due, as well as con5gurstions whereby an danatt is indirectly secured to another danmt by axing the dement to an inte:mediate member or members which in turn are a~Ced to the other dement.) By substantially continuously joining the outer cover 32 to the underlying absorbent core 34 the outer coves 32 will have s reduced tendency »o to separate fiem the absorbent core 34 during ux. Separstion of the absorbent core from the outs coves 32 may inhibit fluid transfer from the outer coves 32 into the uitderlyirtg absorbent core 34. The outer cover 32 may be joined to the absorbent core 34 by any suitsble means, including, but not limited to joining the outer cover 32 with the absorbent core 34 with adl>wves such as by spray-gluing or applying lines or spots is of adheswa between the outs coves 32 and the absorbent core 34.
Alternatively, or additionally, the outer cover 32 may be joined with the absorbent core 34 simply by PCTIti 596016.1' wrapping the outer covet 32 about the absorbent core 34, by entangling the fibers of the absorbent core 34 with the outer cover 32, by fusing the outer cover 32 to the absorbent core 34 with a plurality of discrete individual fusion bonds, or by any ocher means known in the art.
s The absorbent core 34 may be any absorbent means which is generally compressible, conformable, resilient, non-irritating to the wearers skin and capable of absorbing and containing body exudues. The total absorbent capacity of the absorbent core 34 should be compatible with the intended exudate loading for the primary absorbent member 30 of the compound sanitary napkin 20. Further, the absorbent to capacity of the absorbent con 34 may be varied to accommodate wesren ranging in the arpceted amount of exudue fluid volume. For instarue, a different absorbent capacity msy be utilized for compound unitary nspkina intended for day time ux as compued with thox intended for night time use, or for compound sanitary napkins intended for ux by teenage females as compared with those intended by more mature is women.
The absorbent core 34 may be manufactured from s wide variety of liquid absorbent muerials commonly used in disposable sanitary napkins, and other disposable absorbent articles. Examples of suitable absorbent muerials include comminuted wood pulp, which is generally referred to as airfdt; creped cellulose wadding, modified so cross-linked ceUulox fibers such as thox described in U.S. Puent No.
5,217,445 issued to Young, et al. on June 8, 1993; capillary channd fibers (fiber:
having intra-fiba capillary char»nds such as thox described in U.S. Patent No. 5,200,248 issued to Thompsott, et al. on April 6, 1993); absorbent foams such as thox described in U.S.
Pstmt No. 5,260,345, issued to DesMarais,, et al. on November 9, 1993 and U.S.
xs Pateat No. 5,268,244 issued to DesMarais, et al. on December 7, 1993 );
thermally bO~d si>t'lay muetfal! such as thOx materials described in U. S . Patent 5, 607, 414 entitled 'Catamaual Absorbent Structures Having Thermally Honded Laycs For Improved Handling of Ma>strusl Fluids and Their Ux In Catamenial Pads Having Improved Fit and Comfort' filed in the name of Richards, et ao al. on October 21, 1993 (PEG Case 5051); absorbent sponger; synthetic staple fibers;
poiyntaic fibers; hydrogd-forming polymer gelling agents; peu moss; or any equivalent materials or combinstions of materials.
Suitable absoctiatt cores comprising foams arc described in U.S. Pat. No.
as 5,260,345 is~red November 9, 1993, U.S. Pat. No. 5,147,345 issued September 15, 1992, and U.S. Pat. No. 5,149,720 issued September 22, 1992. The first and third WO 96125903 PCTIU596~016.J"

patenu listed in the names of DesMarais, et al., and the second patent issued in the name of Young, tt al. Additional coca comprising foams are described in European Application 0 293 208 Bl. Absorbent cores comprising sponges are described in U.S.
Pat. Nos. 3,512,530; and 3,954,493; and French Patent 2,203,827. Examples of alternative suitable absorbent coca are described in detail in Canadian Patent No. 2,167,272.
Matenals xlected for ux as t~ absorbent core 34 arc preferably compliant, soft, comfortable, compressible and resiliatt to a>ttattce body fit and comfort of the ~c prinury absorbent member 30. Prefersbly, the absorbent core 34 is compressible such that the primary absorbent manba 30 will deform undo relatively small forces that are experienced during normal use. In sddition to being compressible, the materials comprising the absorbent core are preferably conformable such that the pritaa~y absorbent member 30 is able to provide improved fit into and around the labia and a perineum. While being generally compressible and conformable under relatively small forces, thox forces exerted by the external female genitalia during use, it is also important that the primary absorbent member 30 be suf5ciently resilient such that when subjected to normal wearing forces 'rt does not pe:manently collspx.
Preferably, the primuy absorbent member 30 will be su~cientty resilient that it will conform to the so contours of the body to provide irttirnate contact with the exposed genitalia of the female user. Intin>ste contact with the exposed female geniulia helps provide better fluid ttansfa firm the uses into the primary absottiatt mamba 30 without allowing fluid to bypass andlor run-off the primary ab:orbettt mernba 30. While the resilient cheractecistia of the absorbent core 34 allow for impmved fit, they must be balanced a sga~ the need for the product to be both soft and comfortable for the wearer.
Ahhough the oorc 34 shown in FIG. 3 has a generally drculu cross-section, the al~orbe~ core may be manufscaued in s wide variety of shapes such as rectangular, uiangular, oval, ware, pentagonal, U-shaped, Z-folded, etc.
The primary absorbatt member 30 may Rrrtha comprix a resilient member 45 so as is i>fustrated in FIG. 4. The raiIient member 45 may comprise a single member or a plurality of individual members. Suitable materials which may be used as the resilient mamba 45 include, but are not limited to, nylon, polypropylene, polyurethane, polyeshyient, polyester, synthetic rubber, and other synthetic materials such as formed films, or natures! materials such as rubber, sponges, and the like or any suitable material a~ which is capable of resisting coUspx undo normal wearing conditions of sanitary napkins during ux. The resiliatt member 45 may be manufactured in a wide variety of w O 96!.5903 PC1'ILv596i0161~

Shapes such as rectangulu, triangular, oval, squue, pentagonal, U-shaped, Z-folded or any ocher shape as is known in the art.
The resilient member 45 may extend throughout the entire Vength of the primary absorbent member 30. The resilient member 45 msy only extend through a portion of s the length of the primary absorbent member 30. The resilient member 45 may be positioned within the first end region 27, the central region 28, the second end region 29 or any combination of the above. For example, the resilient member 45 may be positioned in either the first end region 27 or the second end region 29 of the primary absorbent member 30, in both the first end region 27.and the second end region 29 of ~o the primary absorbent member 30, in the central region 28 of the primary absorbent member 30, or in the central region 28 and the end regions 27 and 29 of the primary absorbent member 30. The resiliency of the resilient member 45 is preferably not affected by the presence of body exudates absorbed by and contained within the absorbent core. The sustained resiliency of the resilient member 45 permits the primary ~s absorbent member 30 to maintain intimate conttct with the body of the weuer during ux. The primary absorbatt member 30 may include s resilient member 45 similar to the internal shaping component disclosed in U.S. Patent Nos. 5,558,b56J
entitled "Sanitary Nspkin Fisvu~g an internal Shaping_ Component", filed April 8, 1994, in the name of Carl L. Ber~narr and 5, 591,148 =o entitled "Sanitary Napkin Having ctrl Indepa~dently Displaceable Central Core Segment", filed Aaril 8, 1994. in the names of Ronald R McFaD a sl.
is The prisnaty absotbau manber 30 may comprix an acquisition layer 46, as s6oare in FIG 4, positioned betwe~at the outer cover 32 and the absorbent core 34.
The acquisacion layer 46 may serve several functioro including improving wicking of eatdates ova and into the absorbent core 34. Hy improving the wicking of exudates, the acquisition layer 46 provides s more even distribution of the exudates throughout so the absorbaa core 34. The acquisition lays 46 may be comprixd of several different materials including nonwovar or woven webs of synth~c fibers including polyester, polypropylene, or polyethylene; neural fibers inchrding cotton or ceilulox;
blends of such fibers; or any equivalent muerials or combinatioro of materials. Examples of sar>itaty napkins having an acquisition lays are more fully described in U.S.
Pat. No.
4,950,264 issued t0 OsbOrn itfd Canadian Patent No. 2, 124, 798 "Absorbent Article Having Fused Layers", filed on November 6, 1992.

W O 961'..5903 PCTII; S96~0 i W' In a preferred embodiment, the acquisition lays 46 may be joined with the outer cover 32 by uiy of the canventiorsal means for joining webs together, most preferably by fusion bonds as is more fully described in the above-referenced Cree application.
s While the primary absorbent member 30 can be generally of any cross-sectional shape in its unstressed condition it is preferably generally circular or oval in cross-sxaon. The length 40 and the width 41 of the ptimuy absorbent member 30 can be of any comreruau dimension. The primary sbsortiertt member 30, is preferably from about 2 to 35 cm long, more prcfersbty from about 10 to 35 cm long, and most preferably ~o from about 20 to 35 cm long. A particularly preferred primary absorbent member 30 has a length of about 24 era. The primary absorbent member 30, is preferably from about 0.5 to 5 cm wide, more preferably from about 0.5 to about 4 cm wide, and most preferably from about 0.5 to about 3 an wide.
It may be desirable to provide a compound sanitary nsplon having a primary a absorbent member with varying degrees of width or caliper throughout its length. For example, the primary absorbertt member may be rrlativdy thicker in the central region as opposed to the end regions. Alterttstivdy, the primuy absorbent member may be relatively thinner in the cxntral region as opposed to the aid regions.
The second constituent of the compound sanitary naplon of the present so invention is the secondary absorbent manta 50. The secondary absorbent member can be of generally rasangular shape. However, other suitable shapes include but are not limited to oval, hotmgtau, dog-bone, asymmetric and other shapes that are icrtown in the art. Faiths, the secondary absortiau martber 50 of the present invention is preferably tdativdy thin and 9esable. The saxrtdary absortiau member 50 preferably =s was s caliper of less than about 3.0 miljitnttas, more preferably less than about 2.6 acs, eves more pr~fa~bty less than about 2.2 millimeters, and most preferably Ins than about 2.0 millimaas.
The secondary absorbent mamba 50 preferably comprises an absorbent element SG and a Gqttid impervious backsheet 54 joined with the absorbent dement 56.
As ao shown in FIG. 3, the sbtorbait dement 56 may form the body contacting surface 87 of the secondary absori»t martber 50. In other preferred embodiments, as shown in~
FIGS. 4 sad 5, the secondary absorbent member 50 comprises a liquid impervious badcsheet 54, s liquid pervious topsheet 52 joirxd with the backsheet 54 and an absorbau dement 56 positioned between the topsheet 52 and the bscksheet 54. In yet as other ernbodiments, as shown in FIG. 6, the secondary absorbent member 50 may comprise as acquisition layer 88 in addition to or i~t place of the topsheet 52. .

WO 96125903 PCT~i:S96~0161' The topsheet 52 can be any fluid pervious material commonly used in sanitary napkins, disposable diapers, and the like. The topsheet 52 can be any of the materials described above as being useful in the outs cover 32 of the primary absorbent member 30, including, but not limited to apertured formed films.
s The acquisition layer 88 of the secondary absorbent member 50 may comprise any of the materials described above with regard to the primary absorbent member's 30 acquisition layer 46. In preferred embodiments, the secondary absorbent member comprises an acquisition layer 88 disposed between the topsheet 52 and the absorbent element 56 as shown in FIG. 6. However, embodimenu are contemplated wherein the 1o acquisition lays 88 repisca the topshat 52, the absorbent element 56 or both. In such configurations, the acquisition layer 88 provider any absorption characteristics desired in the secondary absorbent member 50.
The absorbent dement 56 of the secondary absorbent member 50 primarily funetiona to protect the uses garmenu from soiling by absorbed fluids which may be 1s expelled from the primary absorbent member 30 or which may inadvertently bypass the primary absorbent member 30. Thus, the absorbent dement 56 of the secondary absorbent member 50 generally performs a different function from thu of the absorbent core 34 and is preferably somewhat thinner and less bulky than the absorbent core 34.
The absorbent element 56 may comprix any of the materials described above as being io useful in the absorbent core 34 or the acquisition layers 46 and 88.
However, paper tissue (either single or multiple pees) is also suitable for ux in the absorbent element 56. In one preferred embodiment, the absorbent dement 56 is formed of from about 1 to about 5 plies of papa tissue.
Paper tissue comprising one or more pees having s basis weight of from about a 24 to about 48 grams pa square mesa and an apparent density of from about 0.10 to about 0.12 g~ pa orbit centimeter as made by tha process described in U.S.
Pat.
No. 3,301,746 issued to Sanford and Sisson on Jan. 31, 1967 his been found to be quite ssustactory for use as the absorbau demerit 56. Papa tissue made by the process described in U.S.
Pat.
>o No. 3,994.771 issued to Morgan et al. on Nov. 30, 1976 can also be uxd to good advantage as the absorbent . d56. Wet strength trains and lstac binders can be, and preferably are, used to provide additional strength to the papa tissue used in the absorbent element 56.
The backsheet 54 of the secondary absorbertt member 50 is impervious to is liquids (e.g., menses andlor urine) and is preferably manufactured from a thin plastic film, although other flexible liquid impervious materials may also be used. As used WO 96!25903 PCTlL,'S9610164' herein, the term "flexible" refers to materials which are compliant and will readily conform to the general shape and contoun of the human body. In ux, the bscksheet 54 is interposed betyvetn the absorbent element 56 and the uses undergarmems.
The function of the backsheet S4 is to prevent exudates which may be expelled from or s which inadvertently bypass the primary absorbent dement and exudates absorbed and contained in the absorbent element 56 from contscting and soiling the uxt's undergarments. The backshed 54 may thus camprix a woven or nonwoven material, polymeric films such as thermoplastic films of polyethylene or polypropylene, or composite materials such as a film-coated nonwoven material. Preferably, the backsheet is a polyethylene film having s thidatess of from about 0.012 mm (0.5 mil) to about 0.015 mm (2.0 mil). Exemplary poiyethyiau films are maaufsnvred by Clopay Corporuion of Cincinnui, Ohio under the designuion P 18-0401 and by Ethyl Corporuiot~ Ysqueen Division, of Terra Haute, Indiana, undo the designation J~-39385. A particularly preferred extensible bscksheet is an extended adhesive film a known as Foritrula X198-388 manufactured by the Ftrtdley Adhesives Company of Wauwatosa, Wisconsin. The bsckshert is preferably embossed and/or matte finished to provide a more clothliice appearsnce. Further, the backsheet may permit vapon to escape from the absorbent element 56 (i.e., breathable) while still preventing exudates from passing through the backsheet.
so In preferred embodiments, the secondary absorbestt member 50 is provided with a support meals or sttathment means., such as adhesive stuchment meals 58. The adhesive a:tachment means SS provides a means for securing the compound sanitary napkin 20 art the notch portion of the user's undergarment or panty. Thus, a portion or all of the outer or garmau surfact 5 5 of the backsheet 54 is coated with adhesive. In a =s prdared erttbodiment, at least a portion of the adhesive 58 is positioned on the stu6ce 55 of the backsheet 54 adjacent the lonptudieul side edges 2I of the seoondaty absorbent 50. My adhesive or glue used in the alt for such purposes an be used for the adhesive hereir>, with prasure~ser>sitive adhesives being preferred. Suitable sdhesiva are Century A-305-I~manufsred by the Century >o Adhesives Corporation of Columbus, Ohio; Insunt Lock 34-2823 manufscwred by the Nstional Starch and Chemical Company of Bridgrwata, NJ; Fuller HI.2TM8 manufactured by the H.B. FuUer Company of St. Paul, MN; and Savate LA203 manufactured by Savare LC. of Milano Italy. Other suitable adhesive fasteners are also described in U.S. Pat. No. 4,917,697.
~s The pressure-sensitive adhesive is typically covered with a removable release Liner 59 in order to keep the adhesive from drying out or adhering to s surface other W O 9615903 PCl'lI: S96i016.1' than the crotch portion of the panty prior to ux. (Embodiments are contemplated wherein the release liner is integral with the package comprising the sanitary napkin and thus, is not a sepuate liner that must be removed before ux.) Suitable release liners are also described in the above referenced U.S. Pat. No. 4,917,697. Any commercially s available release liners commonly used for such purposes can be utilized herein. Non-limiting examples of suitable release liners are BL30MG-A Silox E1I0 and Silox 4P/0 both of which are manufactured by the Akrosil Corporuion of Menasha, WI. The compound sanitary napkin 20 of the ptesatt invention is used by removing the releax liner 50 and thereafter placing the sanitary napkin in a panty so that the adhesive io 58 contacts the panty. The adhesive 58 maintains the sanitary napkin in its position within the parny during ux.
The secondary absorbent member 50 may also have flaps which extend luerally from the side edge of the sbsorbent core 34. A number of sanitary napkins having. flaps suitable or adaptable for ux with the secondary absorbent member 50 of the compound a sanitary napkin 20 of the present invention are disclosed in U.S. Pu. No.
4,687,478 issued to Van Tilburg on Aug. 18, 1987; U.S. Pu. No. 4,589,876 issued to Van Tilburg on May 20, 1986; and U.S. Pat No. 4,608,047 issued to Mattingly on Aug. 26, 1986.
Optionally, the secondary sbsorbatt member may compcix components that :o naturally wrap the sides of a weeds panties. A sanitary napkin having components that nanrrally wrap the sides of a weards panties suitable for use with the secondary absorbatt member of the compound sanitary napida 20 of the eresent invention are disClpxd in Canadian Patent No. 2,140, 767 ~utled "Abaorba~t Article having Panty Covering Components that NttiuaUy Wrap the Sides ~s of Pansies', filed July Z2, 1993, in the names of Lavash, et al and Canadian Patent No . 2,167, 272 entitled 'Absortiertt Articles Hsviag Undergarment Covering Componerus with Zones of Exta~sibility', filed July 22 1994.
so Ring now to FIG. 1, the secondary absorbau mrmbet 50 preferably has a length 60 and a width 61. The secondary absorbent member 50 is preferably from about 20 to 40 cm tong, more preferably from about 25 to 35 cm long, and most preferably is about 30 an long. The secondary absorbent member 50 is preferably from about 5 to 15 cm in width, more preferably from about 5 to 10 crn in width, and most ~s preferably from about 5 to 8 cm in width. The thicfesess of the secondary absorbent member 50, as shown in cross-section in FIGS. 2 and 3, is generally somewhat less WO 96!25903 PCT/L'596~016~' than its width.
The individual componenu of the primary absorbent member 30 and the secondary absorbent member 50 may be comprised of components that are extensible (preferably, capable of straching) particularly in the longitudinal direction when the compound sanitary napkin is worn. Preferably, the compound sanitary napkin is capable of elongating in the longitudinal direction betwxn about 15~/. and about 40°~, of its unstretched length. This actensibility provide better in-ux fit, comfort, and darased staining when the compound sanitary napldrt is affvced to the wearer's undergarments. Sanituy napkins having extensible components are described in U.S.
'° Patent No. 5,824,004 and Canadian Patent No. 2,092,198 both filed July 23, 1992, in the name of Osboln, et al. (PCT Publication Nos. WO 93/01785 and 93/01786, both published February 4, 1993).
In one preferred embodimatt the primuy absorbent member 30 and the secondary absorbent member 50 sharer a common length 65. The common length, refers to the length that the primary abaotbent member 30 and the secondary absorbent member 50 have in common. I~ioweva, it is quite possible for the secondary absorbent member to be somewhat longs than the primary absorbatt member and still function effectively.
so Preferably, the width of the secondary absorbent member 50 is st least 1.5 times the width of the primary absorbaa manbe: 30. Morc preferably, the width of the secondary absorbent membc 50 i: at least 2 times the width of said primary absorbent memb~a 30. Most preferably, the width of the secondary absorbau manta 50 is in the range lsom about 3 to about 3 lima the width of the primary absotbatt member 30.
a To form the compound sanitary napiort of the prexru invention, the primary manta 30 and the secondary absorban member are joined by union means genaralfy indented as '70 in FIGS. 2 and 3. The precix ~ of the union means is immaterial so long as the union means sdected server to join the primary absorbent member 30 std the secondary absorbatt me3nba 50 into the compound sanitary napkin so 20 of the praent invention with student tenacity that the primary absorbent member 30 and the secondary absorbent manta 50 are not disconnected during use. Union means such as adhesive attachment with well iatown hot meh and prrsszrre sensitive adhesives are quite satisfactory. If the nature of the componenu xlected to constnra the constituenu of the compound sanitary napiau 20 so permit, crimping, heat welding, » ultrasonic welding, dynamic mechanical bonds or a combination of any of.the above-mentioned means can be used. Further, the individual members of the sanitary napkin ,.

WO 96/25903 ~ PCT/US96/01647 20 may be joined continuously or intermittently depending on the desired characteristics of the product. (As used herein, the term "continuously" means substantially unbroken or uninterrupted. The term "intermittent" refers to union means that are not continuous.) s Referring now to FIG. 3, it can be seen that outer cover 32 completely wraps the absorbent core 34 of the primary absorbent member 30. (As uxd herein, the term "wraps" or "wrapped" means completely encircles the absorbent core.) The outer cover 32 is shown in FIG. 3 to have a sam 85 adjacent the secondary absorbent member 50. Although such a configuration is advantageous to keep the seam 85 away ~o from any body contact, the figure is not meant to limit the scope of the invention.
Other suitable embodiments are contemplated wherein the seam 85 is disposed in any location about the absorbent core. Further, any number of seams, folds, pleats or bonds in the outer cover 32 are acceptable so long as the primary absorbent member 30 is able to function to absorb and contain bodily fluids while being comfortable to wear.
~s The outer cover 32 of the primary absorbent member 30 is shown in FIG. 3 to be a separate and distinct element from the topsheet 52 of the secondary absorbent member 50. In such embodiments, the outer cover 32 is preferably joined to the topsheet 52 of the xcondary absorbent member 50 by union means 70.
As noted above, the primary absorbent member 30 has a centerline 200 dividing zo the member into an upper portion 202 and s lower portion 204. The outer cover 32 comprises a liquid pervious first xg:r>ent 206 disposed in st least the upper portion 202. The outs cover hrrtha comprises at least one second segment 208 disposed in the lower portion 204. At least s portion of the second segmerlt(s) 208 is liquid impervious. 'This is intended to prevent arty liquid absorbed but not retained by the a core 34 from soiling the wearer's undergarments. Any liquid that is not absorbed by the core 34 beause it runs off the surface of the primary absorbent rt>ember 30 will be absorbed by the secondary absorbent mamba 50.
In another tmbodi~t, as shown in FIG. 4, tt~ outer cover 32 does not completely encircle the absorbent core 34 of the primary absorbent member 30.
3o Rather, tt~ second segments 208 of the outs cova 32 terminate apart from each other. In such embodiments, the outer cover 32 preferably substarnially encircles the absorbent core 34. (As used herein, the tam "substar>tially encircle" means that the outer cover overlays more than half of the absorbent core, and more preferably most of the absorbent core.) As described above, at least a portion of the second xgment(s) 3s 208 should be liquid impervious. In preferred embodiments, the liquid impervious portions of the second xgments 208 are juxtaposed the topsheet 52 or absorbent WO 96/25903 PCTIUS96/016-t7 element 56 of the secondary absorbent member 50. Because the outer cover 32 does not completely encircle the absorbent core 34, a channel 80 is formed. The channel 80 provides a means for any liquid not retained by the primary absorbent member 30 to be deposited onto the topsheet 52, the absorbent element 56 or any other element of the s secondary absorbent member 50 such that it may be absorbed and contained therein.
(An alternative embodiment of the present invention comprising a channel 80 is shown in FIG. 5. ) Optionally, as shown in FIG. 5, the outer cover 32 of the primary absorbent member 30 and the topsheet 52 of the secondary absorbent member 50 may comprise a single web of material, such as web 100. In such embodiments web 100 substantially encircles the absorbent core 34 of the primary absorbent member 30 and extends outwardly therefrom to cover at least a portion of the secondary absorbent member 50.
In such embodiments, the web' 100 must comprix areas that are liquid pervious as well as areas that are liquid impervious. The web 100 must be liquid impervious in at least a ~s part of the lower portion 204 while it must be liquid pervious in at least a part of the upper portion 202. In preferred embodiments, the web 100 is also liquid pervious where it acts as the topsheet 52 of the secondary absorbent member 50.
Suitable materials for ux as the web 100 are described above with regard to the outer cover 32 of the primary absorbent member and the topsheet 52 of the secondary absorbent so member 50.
Although the web 100, as shown in FIGS. 5 and 6, may cover the entire body facing s<rrfact of the second absorbent member 50, it need not do so. Further, as shown in FIGS. 5 and 6, the exact configuration of the web 100 may vary so tong as it subatarrtiauy enc'vcles the absorbent core 34 of the prinury absorbent member 30.
zs Thus, the web 100 may compldely wrap the core 34, as shown in FIG. 6, or may form the charred 80, as shown in FIG. 5.
In the anbodimart of FIGS. 5 and 6 the web 100 serves as a union means connecting the primary absorbent member 30 and the secondary absorbent member together. The compound sanitary napkin nuy also include additional union means to 3o connect the prinury abaorban member 30 to the secondary absorbent member.
Suitable additional union mans include but aro not limited to adhesives and fusion bonds.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to thox skilled in the art that various other changes and 3s modi5cations can be made without departing from the spirit and scope of the invention.
It is therefore intended to cover in the appended claims all such changes and WO 96/25903 ' ~ PCTIUS96/01647 modifications that are within the scope of this invention.
WHAT IS CLAIMED IS:

Claims (10)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A compound sanitary napkin comprising:
a primary absorbent member including an absorbent core and an outer cover; and a secondary absorbent member joined with said primary absorbent member, said secondary absorbent member including a liquid impervious backsheet and an absorbent element joined to said backsheet; wherein said outer cover substantially encircles or completely wraps said absorbent core, at least a portion of said cover being liquid impervious.

2. A compound sanitary napkin comprising:
a primary absorbent member having a centerline dividing said primary absorbent member into an upper portion and a lower portion, said primary absorbent member including an absorbent core and an outer cover which substantially encircles said absorbent core; and a secondary absorbent member joined with said primary absorbent member, said secondary absorbent member including a backsheet and an absorbent element joined to said backsheet; wherein said outer cover comprises:
a first segment juxtaposed said absorbent core in at least said upper portion, said first segment being fluid pervious; and at least one second segment juxtaposed said absorbent core and disposed in said lower portion, at least a portion of said second segment being fluid impervious.

3. The compound sanitary napkin of claim 2 wherein said outer cover comprises a pair of second segments laterally opposed to one another and forming a channel through which fluids may pass to said second absorbent member.

4. The compound sanitary napkin of any one of claims 1 to 3 wherein said outer cover is a unitary member or wherein said outer cover comprises a liquid pervious member joined with a liquid impervious member.

5. The compound sanitary napkin of any one of claims 1 to 4 wherein said outer cover comprises a nonwoven or a formed film.

6. The compound sanitary napkin of any one of claims 1 to 5 wherein said absorbent element comprises a tissue.

7. The compound sanitary napkin of any one of claims 1 to 6 wherein said primary absorbent member comprises an acquisition layer between said outer cover and said absorbent core.

8. The compound sanitary napkin of any one of claims 1 to 7 wherein said secondary absorbent member comprises a topsheet joined to said backsheet and more preferably comprises an acquisition layer disposed between said topsheet and said backsheet.

9. The compound sanitary napkin of any one of claims 1 to 8 wherein said outer cover extends laterally outwardly from said absorbent core to thereby overlap at least a portion of said absorbent element of said second absorbent member.

10. The compound sanitary napkin of any one of claims 1 to 9 wherein said primary absorbent member comprises a resilient member.