Breathable disposable sanitary product construction and barrier sheet

A breathable disposable sanitary product construction having a cloth-like outer surface and including a plurality of materials comprising, from the skin-facing side outwardly:

• (A) a topsheet of liquid- and vapor-permeable hydrophilic material;
• (B) a core of highly absorbent material disposed outwardly of said topsheet for absorbing liquid received through said topsheet, said core having an inner surface in fluid communication with said topsheet and an outer surface;
• (C) a backsheet formed of a multilayer non-woven material which is hydrophobic and vapor-permeable for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said backsheet being disposed at least partially as an outer surface of said diaper, said backsheet material having at least two meltblown layers and being one of:
• (i) a three-layer spunbond-meltblown-meltblown non-woven fabric consisting essentially of a spunbond layer and a plurality of meltblown layers disposed on an inner side of said spunbond layer, and
• (ii) a four-layer spunbond-meltblown-spunbond-meltblown non-woven fabric consisting essentially of two spunbond layers and two meltblown layers, one of said meltblown layers being disposed intermediate said two spunbond layers and bonding them together.

A breathable disposable sanitary product construction having a cloth-like outer surface and including a plurality of materials comprising, from the skin-facing side outwardly:

• (A) a topsheet of liquid- and vapor-permeable hydrophilic material;
• (B) a core of highly absorbent material disposed outwardly of said topsheet for absorbing liquid received through said topsheet, said core having an inner surface in liquid communication with said topsheet and an outer surface;
• (C) a barrier formed of a multilayer non-woven material which is hydrophobic and vapor-permeable for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said barrier having a base disposed adjacent said core outer surface;
• and
• (D) a backsheet formed of a multilayer non-woven material which is hydrophobic and vapor permeable for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said backsheet being disposed at least partially as an outer surface of said diaper;
• at least one of said barrier material and said backsheet material having at least two meltblown layers.

A breathable disposable sanitary product construction having a cloth-like outer surface and including a plurality of materials comprising, from the skin-facing side outwardly:

• (A) a topsheet of liquid- and vapor-permeable hydrophilic material;
• (B) a core of highly absorbent material disposed outwardly of said topsheet for absorbing liquid received through said topsheet, said core having an inner surface in fluid communication with said topsheet and an outer surface;
• (C) a barrier formed of a multilayer non-woven material which is hydrophobic and vapor-permeable for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said barrier having a base disposed adjacent said core outer surface;
• and
• (D) a backsheet formed of a multilayer non-woven material which is hydrophobic and vapor permeable for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said backsheet being disposed at least partially as an outer surface of said diaper;
• at least one of said barrier material and said backsheet material having at least two meltblown layers and being one of:
• (i) a three-layer spunbond-meltblown-meltblown non-woven fabric formed of a spunbond layer and a plurality of meltblown layers disposed on an inner side of said spunbond layer, and
• (ii) a four-layer spunbond-meltblown-spunbond-meltblown non-woven fabric formed of two spunbond layers and two meltblown layers, one of said meltblown layers being disposed intermediate said two spunbond layers and bonding them together.

A barrier sheet comprising a multilayer non-woven material having a cloth-like outer surface and which is hydrophobic and vapor-permeable for limiting the outward escape of fluid therethrough while enabling the outward escape of heat and water vapor therethrough;

• said barrier sheet material having at least two meltblown layers and being one of:
• (i) a three-layer spunbond-meltblown-meltblown non-woven fabric formed of a spunbond layer and a plurality of meltblown layers disposed on one side of said spunbond layer, and
• (ii) a four-layer spunbond-meltblown-spunbond-meltblown non-woven fabric formed of two spunbond layers and two meltblown layers, one of said meltblown layers being disposed intermediate said two spunbond layers and bonding them together;
• said barrier sheet material including a relatively coarse meltblown layer formed of fibers having a diameter of 3-5 microns and a relatively fine meltblown layer formed of fibers having a diameter of 0.5-1.5 microns, said relatively fine meltblown layer being disposed on one side of said relatively coarse meltblown layer.

A breathable disposable sanitary product construction including a plurality of materials comprising, from the skin-facing side outwardly:

• (A) a topsheet of liquid- and vapor-permeable hydrophilic material;
• (B) a core of highly absorbent material disposed outwardly of said topsheet for absorbing liquid received through said topsheet, said core having an inner surface in fluid communication with said topsheet and an outer surface;
• (C) a barrier formed of a multilayer non-woven material which is hydrophobic and vapor-permeable for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said barrier having a base disposed adjacent said core outer surface;
• and
• (D) a backsheet formed of a multilayer non-woven material which is hydrophobic and vapor permeable for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said backsheet being disposed at least partially outwardly of said barrier base.

A breathable disposable sanitary product construction including a plurality of materials comprising, from the skin-facing said outwardly:

• (A) a vapor-permeable topsheet of hydrophilic, liquid-distributing, non-woven material, said topsheet including an inner layer of hydrophilic non-woven material and an outer layer of liquid-distributing material;
• (B) a core of highly absorbent material disposed outwardly of said topsheet for absorbing liquid received through said topsheet, said core having an inner surface in fluid communication with said topsheet, an outer surface and two lateral side surfaces;
• (C) a hydrophobic and vapor-permeable barrier formed of a three-layer spunbond-meltblown-spunbond non-woven fabric formed of two spunbond layers and a meltblown layer disposed intermediate said spunbond layers and bonding them together, for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, in use said barrier being in a U-shaped configuration having a base disposed adjacent said core outer surface and a pair of flanges upstanding from said base and each extending inwardly adjacent to a respective one of said core lateral side surfaces;
• (D) a vapor-permeable hydrophobic enhancer formed of a three-layer spunbond-meltblown-spunbond non-woven fabric formed of two spunbond layers and a meltblown layer disposed intermediate said spunbond layers and bonding them together, for limiting the outward escape of heat and water vapor therethrough, said enhancer being disposed at least partially outwardly of said barrier;
• and
• (E) a hydrophobic and vapor-permeable backsheet formed of a three-layer spunbond-meltblown-spunbond non-woven fabric formed of two spunbond layers and a meltblown layer disposed intermediate said spunbond layers and bonding them together, for limiting the outward escape of liquid therethrough while enabling the outward escape of heat and water vapor therethrough, said backsheet being disposed at least partially outwardly of said enhancer.