MXPA00005239A - Method of making a shaped absorbent interlabial device - Google Patents

Abstract

A method of making an absorbent device that is worn interlabially by female wearers for catamenial purposes, incontinence protection, or both, is disclosed. The method involves at least partially enclosing a continuous length of absorbent material in a cover material. The cover material is positioned so that it lies on opposite sides of the length of absorbent material. The absorbent material is then optionally shaped so that along its length there are regions of greater and lesser thickness on alternating sides of the longitudinal axis of the absorbent material. In one embodiment, the shaping is accomplished by bonding a first portion of the cover material to a second portion of the cover material on the opposite side of the absorbent material so that the bonding penetrates through the absorbent material. A generally transverse direction cut is made across the length of absorbent material which alternates longitudinally across the length of absorbent material to provide the device with shaped ends. The method produces a plurality of interlabial devices having an asymmetrical shape about a longitudinal axis and shaped end with a minimum of waste therebetween.

Description

METHOD FOR PREPARING A FORMULATED INTERLABIAL ABSORBENT DEVICE FIELD OF THE INVENTION This invention relates to a method for making an absorbent device that is worn interlabially by female users for catamenial purposes, protection of incontinence, or both. Particularly, the present invention relates to a method for making an interlabial absorbent device having an asymmetric shape about a longitudinal axis with a minimum of waste.

BACKGROUND OF THE INVENTION Of course, all the ways and varieties of absorbent articles configured for the absorption of body fluids such as menstruation, urine and faeces are well known. With regard to feminine protection devices, the technique has offered two basic types: sanitary napkins that they have been developed for external use around the pudendal region while the tampons have been developed for internal use within the vaginal cavity for the interruption of menstrual flow therefrom. These tampon devices are disclosed in U.S. Patent No. 4,412,833, entitled "Buffer Applicator", issued to Weigner, and others on the 1st. November 1983, and in U.S. Patent No. 4,413,986, entitled "Buffer assembly with means for sterile insertion", issued to Jacobs on November 8, 1983.

Hybrid devices have also been proposed which attempt to fuse the structural characteristics of sanitary napkins and tampons into a simple device. These hybrid devices are disclosed in U.S. Patent No. 2,092,346, entitled "Catamenial Pad", issued to Arone on September 7, 1937, and in U.S. Patent No. 3,905,372, entitled "Protection Shield for feminine hygiene ", issued to Den inger on September 16, 1975. Other less intrusive hybrid devices are known as lip or interlabial sanitary napkins and are characterized by having a part that resides at least partially within the wearer's vestibule and a part that resides at least partially outside the user's lobby. These devices are disclosed in U.S. Patent No. 2,662,527, entitled "Sanitary pad", issued to Jacks on December 15, 1953; and in U.S. Patent No. 4,631,062, entitled "Lip Sanitary Pad", issued to Lassen, et al. on December 23, 1986. Interlabial pads have the potential to provide even greater freedom of inconvenience because of their size small and reduced risk of leaks. In the past, numerous attempts have been made to produce an interlabial pad which would combine the best characteristics of tampons and sanitary napkins while avoiding some of the disadvantages associated with each of these types of devices. Examples of these devices are described in United States Patent No. 2, 917,049 issued to Delaney on December 15, 1959, United States Patent No. 3,420,235 issued to Harmon on January 7, 1969, patent of the United States No. 4,595,392 issued to Johnson, and others on June 17, 1986, and United States Patent Nos. 5,074,855 and 5,336,208 issued to Rosenbluth, and others on December 24, 1991 and August 9, 1994, respectively, and in U.S. Patent No. 5,484,429 issued to Vukos, and others on January 16, 1996.

A commercially available interlabial device is the interlabial pad "FRESH 'N FIT PADETTE" (also known as "IN-SYNC") which is marketed by Athena Medical Corp. (now known as A-Fem) of Portland, OR and described in U.S. Patent Nos. 3,983,873 and 4,175,561 issued to Hirschman on October 5, 1976 and November 27, 1979, respectively. However, many of these devices did not find great commercial success. There are disadvantages associated with all of the above products. For example, the device described in the Delaney patent does not appear to be capable of easy and convenient insertion, due to the possibility that the layers of the absorbent material open upwards during insertion. The commercially available interlabial devices "PADETTE" suffer from the disadvantage that the blunt edges of the device cause discomfort to the user. These dull edges also increase the tendency of the fluids deposited near the edges of the product that run off its edge without being absorbed towards the center of the product. U.S. Patent No. 3,983,873, issued to Hirschman, discloses an interlabial device having tapered ends, but these tapered ends are purely linear. This configuration increases the surface area presented for absorption as compared to a non-tapered product, but the product of the present invention increases that area even further than that achieved with the Hirschman device. Additionally, the speed at which the interlabial device "PADETTE" can be manufactured is limited due to its incorporation of stitches with thread. Interlabial devices without flexible extensions can not reliably cover the urethra and / or the introitus during all movements of the body (for example, when the user is crouching). Also these products can not be reliably expelled when the user urinates.

It has been found during the development of the present invention that the comfort of the product can be increased by providing an interlabial device with increased stiffness relative to the compression forces at the center of the product, but decreased stiffness relative to these forces near the ends of the product. The more rigid center of the product contributes to a greater ease of insertion and to a better placement of the device within the lips as compared to the products of the prior art. Correspondingly, the increased compression capacity (or decreased stiffness) near the ends of the device contributes to greater comfort associated with the use of the device. Therefore, a need exists for an interlabial device with formed edges which increase the total absorbent area of the product that faces the bottom of the vestibule. A need also exists for an interlabial device with a relatively less compressible center and relatively more compressible ends. Also a need exists for an interlabial device, which can be manufactured at high speeds with a minimum of waste. A need also exists for an interlabial device that is small in size and that can be easily inserted and that provides protection against incontinence, menstrual discharges and discharges of body exudates throughout a wide range of user movements. A need also exists for an interlabial device that will be reliably ejected when the user urinates. There is also a need for an interlabial device that facilitates sanitary insertion and removal. That is, there is a need for a device that can be inserted into the interlabial space of a wearer while covering the tips of the fingers, thereby preventing the tips of the fingers from touching the inner surfaces of the lips. It is therefore an object of the present invention to provide an interlabial absorbent device having tapered ends with at least one curvilinear segment. It is another object of the present invention to provide an interlabial absorbent device with a relatively less compressible center and relatively more compressible end. It is another object of the present invention to provide an interlabial absorbent device with increased flexibility along its center line and at its ends, thus allowing it to bend more easily. It is another object of the present invention to provide an interiabial absorbent device that consistently blocks the urethra in a manner that provides protection against incontinence, menstrual discharges, and discharges of body exudates over a wide range of movements of the usury. It is another object of the present invention to provide an interlabial absorbent device that can be inserted interlabially without the user's hand touching the inner surfaces of the lips. It is another object of the present invention to provide an interlabial absorbent device that is reliably ejected when the user urinates in such a way that the user does not have to touch the stained product. It is another object of the present invention to provide an interlabial absorbent device that can be optionally removed with the fingers without the user's hand touching the inner surfaces of the lips. It is another object of the present invention to provide an interlabial absorbent device having signals that help a user to properly insert the interlabial device. It is another object of the present invention to provide a method for making an interlabial absorbent device having formed ends.

It is another object of the present invention to provide a method for making an interlabial absorbent device that is symmetrical about a transverse and asymmetric axis around of a longitudinal axis. It is another object of the present invention to provide a method for making an interlabial absorbent device that involves minimal waste. It is another object of the present invention to provide an improved method for joining an interlabial absorbent device to impart the shape to the interlabial device. It is another object of the present invention to provide a method of attachment through the interlabial device that provides greater flexibility in the joining patterns than the stitches. These and other objects of the present invention will become more readily apparent when considered with reference to the following description and when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE INVENTION The present invention relates to absorbent devices, and more particularly to an absorbent device that is capable of being inserted into the interlabial space of a female user for catamenial purposes, protection of incontinence, or both. The interlabial absorbent device of the present invention comprises a main absorbent portion comprising an upper portion, a lower portion opposite the upper portion, and two ends. The upper portion faces the bottom of the wearer's vestibule during the insertion of the absorbent device into the interlabial space of the wearer and during use. That is, the upper portion is positioned farther inwardly in the space between the wearer's lips thereby directing the lower portion of the absorbent device during insertion. Upon insertion occurring, the lower portion is less fully inserted into the interlabial space of the wearer than the upper portion and the lower portion away from the bottom of the wearer's vestibule. In a particularly preferred embodiment, the upper portion has a width in the greater transverse direction (ie, gauge) than the lower portion along the transverse central line of the interlabial absorbent device. In said particularly preferred embodiment, the projected width seen on the upper floor of the absorbent device (the projected view of the insertion edge) is preferably less than the maximum width of the end edges of the device. The ends of the interlabial absorbent device are preferably tapered such that the lower portion of the interlabial device is larger than the upper portion. The ends are also provided with at least one curvilinear segment. In a particularly preferred embodiment of the present invention, the ends of the interlabial device have a sinusoidal or "S" shaped shape. This tapered arrangement with a curvilinear segment exposes the ends of the fibers near the ends of the device allowing the exposed fibers to capillary absorb the liquids deposited near the ends of the device inward toward the center of the device. The interlabial absorbent device also preferably has a bonding pattern that provides the interlabial device with improved flexibility and a central region that is more resistant to compression than its end regions. The joint pattern provides bending points for the interlabial device to adjust the curvature of the bottom of the user's vestibule against which the device will be placed. The binding pattern can also be used to provide the interlabial device with signals to assist the user in appropriately inserting the interlabial device. Preferably, the joint also provides an indented portion that serves as a grip region for the finger to hold the device during insertion. The interlabial absorbent device also preferably includes flexible extensions which extend downwardly and outwardly from the absorbent main portion and are attached thereto. Preferably, the flexible extensions are able to maintain contact with the internal surfaces of the wearer's lips and cover a substantial part thereof. The flexible extensions are also preferably able to cover the tips of the user's fingers as the absorbent device is inserted into the interlabial space of the wearer. Preferably, the flexible extensions are able to maintain contact with and cover the internal surfaces of the wearer's lips when the user's body goes through a range of movements including crouching. The flexible extensions of the preferred design also block a direct "line of sight" from the outer perimeter of the labia majora to the introitus of the vagina so that exudates from the body can not "miss" the product and the flow of these exudates. be intercepted by the nterlabial absorbent device. In another preferred modality, the main absorbent portion comprises a web of continuous material folded in a folded structure. This structure improves the surface area available for fluid absorption by allowing the fluid to easily penetrate between the folds of the main absorbent portion. The present invention relates to a method for making a plurality of interlabial absorbent devices which are symmetrical about a transverse axis and asymmetric around a longitudinal axis with minimum waste, the method comprising the steps of: a) providing a continuous length of material absorbent; b) displacing the continuous length of the absorbent material in a longitudinal direction; c) providing a core material for at least partially wrapping the continuous length of the absorbent material; d) enclosing at least partially the continuous length of the absorbent material in the cover material in such a way that the cover material is placed on opposite sides of the length of the absorbent material; e) joining a first part of the cover material to a second portion of the cover material which is located on the opposite side of the length of the absorbent material, the joint penetrating through the absorbent material and being provided in an alternating pattern where in each other application of the joint pattern, the joints are formed on opposite sides of the longitudinal axis of the length of the absorbent material; and f) making a continuous cut in the generally transverse direction in the continuous length of the absorbent material, wherein the cut in the generally transverse direction alternates longitudinally through the length of the absorbent material to provide a minimum of waste between the interlabial devices.

BRIEF DESCRIPTION OF THE DRAWINGS Although the description concludes with the claims pointing out in a particular way and claiming differently the material that is considered as constituting the present invention, it is believed that the invention will be better understood from the following description taken in combination with the accompanying drawings , in which similar numbers represent similar elements in all, and in which: Figure 1 is a side view of an interlabial absorbent device having a main absorbent portion with the formed ends and with discrete bonding sites. Figure 1A is a bottom view of an interlabial absorbent device shown in Figure 1. Figure 1 B is a cross-sectional view taken through the transverse centerline of the interlabial absorbent device shown in line 1 throughout of line 1 B-1 B. Figure 2A is a perspective view of the interlabial absorbent device shown in Figure 1. Figure 2B is a side view of an interlabial absorbent device having a main absorbent portion with formed ends and showing an alternative configuration of the discrete union sites. Figure 3 is a simplified schematic side view of the interlabial absorbent device of the present invention that is formed in a convex configuration when placed against a user's body. Figure 4 is a bottom view of an interlabial absorbent device showing how the ends crush when the interlabial device is bent in the configuration shown in Figure 3. Figure 5 is a simplified schematic top view of the interlabial absorbent device showing how the ends of the device widen to adjust the configuration of the interlabial space. Figure 6 is a perspective view of an interlabial device according to the present invention which has a pair of optional flexible extensions attached to the main absorbent portion.

Figure 7 is a side view of an interlabial device having a pair of optional flexible extensions having the end edges with the same configuration as the ends of the main absorbent portion. Figure 8 is a bottom view of a preferred embodiment of the present invention having a folded absorbent main portion. Figure 9 is a sagittal cross-sectional view of a human female user showing the placement of the nterlabial absorbent device in the wearer's interlabial space. Figure 10 is a perspective view of the method of the present invention. Figure 10A is a perspective view of an alternative embodiment of the method of the present invention, which shows the union of a pair of flexible extensions to the nterlabial device. Figure 11 is a perspective view showing the flexible extensions of the present invention covering the tips of the user's fingers as the absorbent device of the present invention is retained for insertion into the user's liplabial space. Figure 12 is a schematic perspective view of the three point bending test apparatus. Figure 13 is a plan view of an apparatus suitable for determining the discharge capacity according to the method described in the TEST METHODS section, below. Figure 14 is a cross section of an apparatus for the discharge capacity of Figure 13 taken along line 14-14 thereof. Figure 15 is a front view of an individual package for the interlabial device in an unopened condition.

Figure 16 is a front view of the individual pack in an open condition with the interlabial device inside.

DETAILED DESCRIPTION OF THE INVENTION I. The interlabial absorbent device. The present invention is directed to an interlabial absorbent device. Figure 1 shows an embodiment of an interlabial absorbent device, interlabial device 20. However, the present invention is limited to this structure having the particular configuration shown in the drawings. As used herein the term "interlabial absorbent device" refers to a structure having at least some absorbent components, and which is specifically configured to reside at least partially within the interlabial space of a female user during use. Preferably, more than half of the total interlabial absorbent device 20 of the present invention resides within this interlabial space, more preferably substantially the total interlabial absorbent device 20 resides within the interlabial space, and most preferably the total interlabial absorbent device 20 resides within this interlabial space of a female user during use. As used herein, the term "interlabial space" refers to the space in the pudendal region of the female anatomy that lies between the interior surfaces of the labia majora extending into the vestibule. Located within this interlabial space are the labia minora, the vestibule, and the main urinary genital limbs, including the clitoris, the hole in the urethra, and the orifice of the vagina. The standard medical authorities teach that the vestibule refers to the space joined laterally by the internal surfaces of the labia minora and that extends internally towards the bottom between the clitoris and the orifice of the vagina. Therefore, it will be recognized that the interlabial space as defined above can refer to the space between the inner surfaces of the labia majora, including the space between the inner surface of the labia minora also known as the vestibule. The interlabial space for the purposes of the present disclosure does not extend substantially beyond the vaginal orifice of the vagina. The term "lips" as used herein generally refers to both of the labia majora and labia minora. The lips end anteriorly and posteriorly at the anterior commissure and at the posterior commissure, respectively. It will be recognized by those skilled in the art that there is a wide range of variations among women with respect to the relative size and shape of the labia majora and the labia minora. For the purposes of the present description, however, these differences do not need to be specifically addressed. It will be recognized that the provision of the interlabial absorbent device within the interlabial space of a user as defined above will require placement between the inner surfaces of the labia majora without considering the precise location of the boundaries between the labia majora and the labia minora for a user. particular. For a more detailed description of this part of the female anatomy, attention is directed to Gray's Anatomy, Running Press 1901 Ed. (1974), at 1025-1027. The proximal absorbent device 20 shown in Figures 1 to 2A has a longitudinal centerline L which runs along an "x" axis shown in Figure 2A. The term "longitudinal" as used herein, refers to a line, axis or direction in the plane of the endpoint device 20 that is generally aligned with (e.g., approximately parallel to) a vertical plane that divides a standing user in left and right body halves when wearing the interlabial device 20. The terms "transverse", "lateral" or "direction and" as used herein, are interchangeable and refer to a line axis or direction that is generally perpendicular to the longitudinal direction. The lateral direction is shown in Figure 1A as the "y" direction, the lip-absorbent absorbent device 20 shown in Figure 2A also has a transverse center line T shown in Figure 2A. The "z" direction shown in Figure 2A is a direction parallel to the vertical plane described above. The term "upper" refers to an orientation in the z-direction towards the user's head. "Bottom" or down is towards the user's feet. As shown in Figure 1, the interlabial device 20 comprises at least one main absorbent portion 22 (or "central absorbent"). The main absorbent portion 22 includes an upper portion 26 and a lower portion 28 that is opposite the upper portion. In use, the upper portion 26 is positioned farther inwardly over the interlabial space of the wearer. The main absorbent portion 22 also comprises a pair of ends 34 that are tapered (ie, the ends are further apart in the lower portion 28 of the device 20 than in the upper portion 26. In addition to being tapered, the ends 34 are provided with at least one curvilinear segment The main absorbent portion 22 must be at least partially absorbent The main absorbent portion 22 may comprise nonabsorbent parts, such as a liquid impermeable barrier to prevent the absorbed exudates from leaking out from the main absorbent portion 22. The interlabial device 20 should be a suitable size and shape that allows at least a portion of it to fit comfortably within the interlabial space of the wearer and cover the vaginal orifice of the wearer, and preferably also the urethra of the wearer. the user The interlabial device 20 blocks at least partially, and more preferably blocks out of to complete and intercept the flow of menstruation, urine and other body exudates from the vaginal orifice and urethra of the user.

The size of the interlabial device 20 is also important for the comfort associated with the use of the device. In the embodiment shown in Figure 1, the main absorbent portion 22 of the interlabial device 20 preferably has a length as measured along the upper surface of the upper portion 26 of between about 15 mm and about 65 mm. The length of the main absorbent portion 22 of the interlabial device 20, measured along the bottom surface of the lower part 28 is preferably between about 35 mm and about 120 mm. More preferably, the length of the main absorbent portion of the interlabial device 20, measured along the upper portion 26 is from about 35 mm to about 45 mm, most preferably about 38 mm, and the length measured along the length of the lower portion 28 is from about 55 mm to about 65 mm, most preferably about 62 mm. The length of the interlabial device 20 can also be measured along the longitudinal center line (at a distance halfway between the upper and lower surface of the device). Suitable lengths measured in this manner may include, but are not limited to lengths of 40 mm, 50 mm and 60 mm. In addition, if desired, a user may use a system of interlabial devices of these varying lengths. The gauge (or width) of the main absorbent portion 22 of the interlabial device as measured in the transverse direction (or "y" direction) is preferably less than or equal to about 8 mm, more preferably the caliber of between about 3 mm and about 6 mm, most preferably, the gauge is about 4.5 mm. The caliper measurements given here were measured using a reference "" AMES "with a load of 1.7 kPa (reference) and a base diameter of 2.44 cm. Those skilled in the art will recognize that if a base diameter of 2.44 cm is not appropriate for a particular sample size, the size of the base can be varied while the load on the reference is therefore varied to maintain a confining pressure of 1.7 kPa (reference) .The height (or dimension in the direction "z ") of the main absorbent portion 22 is preferably between about 8 mm and about 35 mm, and more preferably about 20 mm The interlabial device 20 is preferably provided with sufficient absorbency to absorb and retain discharged exudates from the body of the However, the capacity of the product is dependent at least partially on the physical volume of the interlabial absorbent device 20, p jointly the main absorbent portion thereof. The main absorbent portion 22 preferably has a capacity of at least about 1 gr. of saline solution at 0.9% by weight, and can have a capacity of up to 30 gr. using absorbent gels or foams that expand when wet. The capacities can typically vary from approximately 2 to approximately 10 gr., For saline solution. Those skilled in the art will recognize that the ability for absorption of body exudates such as menstruation will typically be less than the capacities given above for the absorption of saline. A method for measuring absorbent capacity is described in the Test Methods section, below. Since the interlabial space can expand, larger volumes can be stored in the labial space, if the fluid is stored as a gel, which adjusts to body pressures. Additionally, if the interlabial device 20 does not completely reside within the interlabial space of the wearer, some of the absorbed exudates may be stored externally to the interlabial space of the wearer. Serving The main absorbent 22 of the embodiment shown in Figures 1 to 2A may comprise any suitable type of absorbent structure that is capable of absorbing and / or retaining liquids (e.g., menstruation and / or urine). The main absorbent portion 22 can be manufactured in a wide variety of shapes (as seen from the side as in Figure 1 or as seen from the bottom as in Figure 1A). Non-limiting examples of shapes for the main absorbent portion when viewed from the bottom as in Figure 1A include ovoid, trapezoidal, rectangular, triangular, cylindrical, hemispherical or any combination of the above. Viewed from the side, as in Figure 1, the preferred shape for the main absorbent portion 22 is generally tapered with at least one curvilinear segment. In particularly preferred embodiments, the ends 34 of the device 20 have a sinusoidal or "S" shape. In the preferred embodiment shown in Figure 1, the caliper of the lower portion 28 is smaller than the caliber of the upper portion 26. This relationship is shown more clearly in Figure 1 B, which is a cross-sectional view of the Figure 1, taken along the transverse center line T. The main absorbent portion 22 can also be manufactured from a wide variety of liquid absorbent materials commonly used in absorbent articles such as crushed wood pulp which is generally referred to as air felt. Examples of other suitable absorbent materials include cotton fibers or cotton waste fibers, creped cellulose wadding, melt blown polymers including coform; chemically hardened, modified or cross-linked cellulosic fibers; synthetic fibers such as polyester fibers, pleated; peat moss; tissue including tissue wraps and tissue laminates; absorbent foams; absorbent sponges; superabsorbent polymers (in the form of fiber and particles); gelling absorbent materials; or any equivalent material or combinations of materials, or mixtures thereof. Preferred absorbent materials comprise folded tissues, cotton blocks, woven materials, non-woven wefts, needle-punched rayon, and thin foam layers. The main absorbent portion 22 may comprise a simple material. Alternatively, as shown in Figure 1A, the main absorbent portion 22 may comprise a combination of materials, such as a wrapping layer 46 surrounding a central wadding composed of an absorbent material 44 (as shown in Figure 2A) . In the embodiment shown in Figure 1, the main absorbent portion 22 is formed of a soft absorbent material such as rayon fibers or other suitable natural or synthetic fibers or laminates. The main absorbent portion 22 shown in Figures 1 to 2A is generally of an ovoid cross-sectional shape with tapered ends 34 having at least one curvilinear segment, as shown in Figures 1A and 2A. Figures 1 and 2A also show the ends 34 of the device 20 having a sinusoidal shape or "S" shaped ends 34. The ends 34 of the device 20 are tapered and comprise at least one curvilinear segment. In other words, there is at least one segment along the ends 34 where its shape as seen in the "y" direction is curvilinear. A part of the ends 34 may have a linear profile, or more than one curvilinear segment may be present. In the embodiment shown in Figure 1, each end 34 has two curvilinear segments oriented in opposite directions. The resulting device 20 shown in Figure 1 has ends 34 that are sinusoidal or "S" shaped when viewed from the side (i.e., observed in the "y" direction) as in Figure 1. Providing the device 20 with ends 34 having at least one curvilinear segment as shown in Figure 1, endows the interlabial absorbent device 20 of the present invention with several advantages as compared to devices without this feature. By providing the device 20 with tapered ends 34 having at least one curvilinear segment, it has more total absorbent area facing the bottom of the vestibule as compared to a device with vertically oriented ends in the "z" direction or with purely linear tapered ends. The preferred interlabial absorbent device 20 of the present invention improves on this advantage even more by providing sinusoidal or S-shaped ends 34. These ends 34 present about a 10% increase in the surface area facing the bottom of the vestibule as it is compared to an interlabial device with linear ends (even if these ends are tapered, but without the curvilinear segments provided by the "S" shape). The increase in the above-described surface area is particularly significant because the exposed ends 34 of the present invention are also the end sites of the fibers comprising the absorbent material 44, which fills the main absorbent portion 22. The ends 34 of the device 20 are, therefore, sites in which the deposited fluids (such as bodily discharges) will be absorbed by capillary action or wicking effect towards the inner portion of the main absorbent portion 22 of the interlabial absorbent device 20. interlabial devices without these tapered ends having a curvilinear segment 34, or in particular, these sinusoidal or "S" shaped ends 34 are more likely to allow fluids deposited near the ends of said device to leak without being absorbed. The tapered ends with a curvilinear segment 34, and in particular the "S" shaped or sinusoidal ends 34, can also provide an increase in comfort associated with the use of the device 20 as compared to devices with vertical ends. This is particularly true when the "S" or sinusoidal ends 34 are provided in combination with an arcuate joint pattern 94, described in more detail below. The main absorbent portion 22 of the embodiment shown in Figures 1 to 2A is the preferred form such that it comprises an upper portion 26 with a larger cross-sectional dimension relative to that of the lower portion 28. That is, as shown in Figure 1 B, the gauge (or width) of the upper portion 26 is preferably larger than the caliber of the lower portion 28. The upper portion 26 is preferably integral with the lower portion 28. However, in lesser embodiments Preferred the upper portion 26 and the lower portion 28 may comprise separate elements joined together by any suitable means known in the art. In the embodiment shown in Figures 1 to 2A (and also seen more clearly in Figure 1 B), the juncture of the upper portion 26 and the lower posterior 28 of the main absorbent portion 22 comprises a substantially abrupt change in the transverse dimension. thus forming a configuration in the form of a shoulder in said joint. In the embodiment shown in Figures 1 to 2A, the juncture of the upper portion 26 and the lower portion 28 of the absorbent main portion 22 is formed by the autogenous attachment method described in greater detail below. In a variation of the embodiment described above and shown in Figures 1 to 2A, the upper portion 26 may have a smaller cross-sectional dimension relative to the cross-sectional dimension of the lower portion 28. The absorbent main portion 22 may be made by any suitable process. A particularly preferred process for making the main absorbent portion 22 is described in more detail below. In the embodiment shown in Figures 1 to 2A, the interlabial absorbent device comprises a tow or rayon wick of core material that is wrapped with a non-woven, cover 46 web. Rayon is typically incompatible with conventional bonding techniques. The autogenous bonding method described below can be used to join the cover material 46 itself through the core material 44. Said joining method results in the creation of discrete intermittent bonding sites 94 as shown in Figures 1 to 2A.

Intermittent joints 94 created by the autogenous binding method described herein may be arranged in any desired pattern. Although any number of suitable joints 94 may be used, the device 20 is preferably provided with between two and eight binding sites 94. In a particularly preferred embodiment shown in Figure 2A, the joints 94 are arranged in an arcuate pattern in the portion lower 28 where said pattern is symmetrical about the transverse centerline T. The interlabial absorbent device having the attachment pattern shown in Figure 2A is more flexible in the direction of the arrows shown in Figure 3 than a similar interlabial device that has a continuous horizontal stitch line. There are several reasons for this. The binding method of the present invention (described below) can be used to form intermittent binding patterns which are more flexible than continuous bonding patterns. Furthermore, by providing a curve in the pattern of the binding sites 94, the binding sites 94 act as bending points so that the double interlabial absorbent device 20 such that the upper portion 26 thereof assumes a convex shape as shown in Figure 3. This would not be possible with a stitch pattern in the form of a continuous straight line. Such a stitch pattern will cause the interlabial absorbent device 20 to twist when an attempt is made to bend it to the configuration shown in Figure 3. The fact that the interlabial absorbent device is capable of flexing as shown in Figure 3 is important because that this is a form that it will take against the user's body when it is inserted into the interlabial space. The bonding pattern 94 shown in Figure 2A, together with the tapered ends 34, also allows the ends 34 of the interlabial absorbent device to crush as shown in Figure 4. This provides a more comfortable fit against the highly sensitive adjacent areas of the body. body of the user. These also allow the interlabial absorbent device 20 to conform better to the shape of the user's body in the interlabial space by widening the ends of the device and narrowing them in the center as shown in Figure 5. The use of discrete autogenous joints 94 provides the device interlabial absorbent 20 with locations of increased density of absorbent material 44. These high density locations will tend to pull or entrain deposited fluids due to capillary action or wicking action. Therefore, the joints 94 can be arranged in configurations, such as the arched configuration shown in Figure 2A to draw the fluids deposited towards the center of the interlabial absorbent device 20. The main absorbent portion of the interlabial absorbent device 20 described herein is both flexible as compressible. Flexibility and compressibility are important for the behavior of the product. If the interlabial absorbent device 20 (or a component thereof such as the main absorbent portion 22) is too flexible, the device is not conveniently or easily placed between the folds of the lips, if it is too rigid, the device is uncomfortable. and when the user is in a sitting position, the product can be forced against the clitoris causing discomfort. The discrete binding sites 94 can be used to control the compressibility and to optimize the compressibility of the localized areas of the interlabial device 20. It has been found during the development of the present invention that the increased comfort of the product can be obtained making an interlabial device 20 with a high compressibility ratio from center to end. That is, the central portion (ie, that part of the device 20 near the transverse center line T) must be more rigid or less compressible. This rigidity allows the increased ease of insertion of the device 20 and a better placement of the device 20 within the lips. Correspondingly, the end regions (i.e., the part of the device 20 at or near the ends 34) must be highly compressible or less rigid. This compression capability increases the comfort associated with the use of the device. The arcuate pattern of the binding site 94 in combination with the S-shaped ends 34 provides the interlabial absorbent device 20 of the present invention with highly compressible ends and a relatively rigid central region. Previous interlabial devices had central and extreme regions with the same or almost the same compressibility (ie, the compressibility ratio from center to end was low). Consequently, the choice of product rigidity was an exchange between the ease of insertion on the one hand, and the comfort of the product on the other hand. The present invention, using an arched pattern of joints 94 and S-shaped ends 34 allows the selection of the high compression capacity at the ends 34 for the convenience of the product simultaneously with the selection of the upper stiffness near the line transverse center T for improved handling and insertion of the device 20. The compressibility of the interlabial absorbent device 20 is measured using the Compressibility Test described in the Test Methods section, below. Preferably, the interlabial device 20 of the present invention has a lower central compression capacity (as measured using the Compressibility Test, described herein) of at least about 150 gramsf, more preferably, at least about 190 gramsf, and very preferably, at least about 250 gramsf. The end compressibility (as measured using the Compressibility Test, described herein) of the interlabial absorbent device 20 of the present invention is preferably less than about 50 gramsf. Preferably, the center to end compressibility ratio (as described in the Test Methods section below) is greater than about 4.0, more preferably greater than 5.0, and most preferably is greater than about 6.0 The arcuate pattern of the joints 94 shown in Figure 2A can be used to provide a nterlabial absorbent device with a signal of how the device should be stopped for placement during application. The arcuate pattern of joints 94 provides a relatively rigid region (with respect to the ends) to hold the device 20 for insertion. The arcuate pattern of junctions 94 also provides an appropriate visual driving signal of the device 20 for insertion (i.e., the user has a visual feedback that the upper portion 26 should not be inserted first and further). In addition to the arched pattern, the joints 94 can be placed in a number of virtually unlimited patterns. These unions can be used to create products that have a virtually unlimited number of possible geometric shapes. Another particularly preferred embodiment of alabellabel absorbent device 20 of the present invention is shown in Figure 2B. Figure 2B shows an interlabial absorbent device 20 with an arcuate pattern of intermittent joints 94 and S-shaped ends 34. The particularly preferred embodiment shown in Figure 2B is similar to those shown in Figures 1 to 2A, but has been optimized Various product features for even more improved operation. It has been found during the development of the present invention that the combinations of the different characteristics of the interlabial absorbent device 20 in the manner shown and described with respect to Figure 2B provides superior product comfort and superior performance. However, it should be noted that not all the characteristics of the absorbent device interlabial 20 of the present invention need to be practiced accurately in the manner shown and described with respect to Figure 2B in order to obtain at least some of the benefits of the claimed invention. The main absorbent portion 22 of the interlabial device 20 shown in Figure 2B has a length as measured along the upper surface of the upper portion 26 of approximately 48 mm. The length of the main absorbent portion 22 of the interlabial device 20, measured along the lower surface of the lower portion 28 is preferably approximately 72 mm. The lower portion 28 of the proximal absorbent device 20 shown in Figure 2B is ideally provided with four discrete binding sites 94. The use of four binding sites 94 instead of a larger number (as shown in Figure 2A ) allows the device 20 to maintain its desired flexibility characteristics while achieving some of the additional benefits described below. Each of these discrete bonding sites 94 are most preferably spaced about 10 mm apart from one another as measured in the longitudinal direction. Preferably, the attachment sites 94 are symmetrical about the transverse center line of the device 20. The two lower attachment sites 94 of the device 20 shown in Figure 2B are located approximately 6 mm from the lower surface of the device 20. The two upper bonding sites 94 are located above 10 mm from the lower surface of the liplabel absorbent device 20. The particularly preferred embodiment shown in Figure 2B differs from the preferred embodiment shown and described with respect to Figures 1 to 2A as shown in FIG. distinguished earlier. Except as noted, the particularly preferred embodiment shown in Figure 2B may be, and is preferably, constructed in a manner consistent with the description given above with respect to the preferred embodiment shown in Figures 1 to 2A. The description given above for the embodiment shown in Figures 1 to 2A with respect to the materials, acceptable processing methods, and how to use the device 20 are equally applicable to the preferred embodiment shown in Figure 2B. The advantages described above with respect to the preferred embodiment shown in Figures 1 to 2A resulting from the S-shaped ends 34 which is provided in combination with an arched pattern of discrete joining sites 94 is also provided for the preferred embodiment shown in Figure 2B. In addition to these advantages, the preferred embodiment shown in Figure 2B provides the additional benefit of using more fully the total capacity of the device 20. In other words, the preferred embodiment of the interlabial absorbent device 20 shown in Figure 2B will tend to distribute the fluids. deposited more fully towards the ends 34 of the device 20 while the device 20 is loaded. This is because the binding sites 94, which are regions of increased density of material as compared to other locations on the interlabial absorbent device 20, they are located closer to the ends 34 of the device in the embodiment shown in Figure 2B as compared to that shown in Figure 2A. Additionally, the binding sites 94 in the embodiment shown in Figure 2B are located more distant from the bottom of the device 20 than those shown in the embodiment of Figure 2A. This feature helps to reduce the transfer of fluid to the lower part of the device 20 and helps to reduce the opportunities for staining of the panties that result from the contact of the wearer's panties with the lower part of the device 20 as the device is worn. The pattern of discrete joints 94 included in the preferred embodiment shown in Figure 2B retains the ability to provide the signal of how the device 20 should be inserted. The pattern of joints 94 shown in Figure 2B, in combination with the S-shaped ends 34, also provides the device 20 with highly compressible ends and a central region relatively stiffer (with respect to said ends). It has been found during the development of the present invention that the end compressibility (as measured using the Compressibility Test) of the preferred embodiment shown in Figure 2B is slightly greater than that associated with the modalities shown in Figures 1 to 2A . Also the lower central compressibility (as measured using the Compressibility Test) of the preferred embodiment shown in Figure 2B is slightly less than that associated with the embodiment shown in Figures 1 to 2A. As a consequence, the preferred embodiment of Figure 2B will have a compressibility ratio from center to end slightly less than the embodiment of Figures 1 to 2A. However, the preferred scales of these parameters described above for the embodiment shown in Figures 1 to 2A is still applicable to the preferred embodiment shown in Figure 2B. It has been found during the development of the present invention that the preferred embodiment shown in Figure 2B provides a particularly advantageous optimization of localized stiffness and flexibility as well as the efficient use of the maximum capacity of the interlabial absorbent device 20. The interlabial absorbent device 20 may also comprise a pair of flexible extensions 24 which are attached to the main absorbent portion 22 of the interlabial absorbent device 20, as shown in Figures 6 and 7. In the embodiment shown in Figure 6, the flexible extensions 24 are of generally rectangular shape. Other shapes are also possible for flexible extensions 24 such as semicircular, trapezoidal, or triangular. The flexible extensions 24 can also have the same "S" shape or the sinusoidal shape as the "S" shaped ends 34 of the interlabial absorbent device 20. The flexible "S" shaped extensions are shown in Figure 7. in sinusoidal form. The flexible extensions 24 are preferably from about 20 mm to about 160 mm in length, more preferably from about 30 mm to about 130 mm in length, and most preferably from about 40 mm to about 115 mm in length. The flexible extensions 24 may have a length (measured in the x direction) that is shorter than the absorbent main portion 22, or these may have a length that is equal to or greater than the absorbent main portion 22 of the proximal absorbent device 20. The width of each of the flexible extensions refers to the distance from the junction of the flexible extension 24 to the main absorbent portion 22 (or the proximal end 24A of the flexible extension 24). To the far end (or free end) 24B of the flexible extension 24. The width of the flexible extensions 24 is preferably approximately equal to or greater than the height of the absorbent main portion as described above. The caliper of the flexible extensions is preferably less than or equal to about 3 mm, more preferably less than or equal to about 2 mm, and most preferably less than or equal to about 1 mm. Ideally, the gauge of the flexible extensions 24 and the main absorbent portion 22 are selected such that the gauge of the total interlabial absorbent structure 20 is less than or equal to about 8 mm. The flexible extensions 24 can be constructed of a tissue layer. A suitable tissue is a tissue laid with air available from the Fort Howard Tissue Company of Green Bry, Wisconsin, and having a basis weight of 35 pounds / 3000 feet. Another tissue spread with suitable air is available from Merfin Hygenic Products, Ltd., of Delta, British Columbia, Canada, which has a basis weight of 61 g / m2 and which has a designation number of grade 176. Flexible extensions 24 can optionally backed with a layer of material that is impermeable or semi-impervious to body exudates such as, polyethylene, polypropylene, or a polyvinyl alcohol. In the embodiments shown in Figures 6 and 7, the pair of flexible extensions 24 may comprise a sheet of simple material which is wrapped around the total bottom side of the device 20 and is fixed to the device 20 at least on the side of the center line longitudinal. The flexible extensions 24 can both be wrapped around the underside of the device 20 as shown in Figures 6 and 7 and backed with a layer of material that is impermeable or semi-impervious to body exudates., at least in the region of the lower portion 28 of the device 20. In this way, the flexible extensions 24 can act as a barrier to protect the garments of the wearer's body from becoming soiled when the interlabial absorbent device 20 is used. an alternative configuration, the pair of flexible extensions 24 may comprise separate sheets of material attached independently of the main absorbent portion 22. Preferably, the flexible extensions 24 are arranged symmetrically about the longitudinal center line L of the absorbent main portion. 22. The flexible extensions 24 can be attached to the upper portion 26 of the absorbent main portion 22 of the interlabial absorbent device 20. The term "attached", as used herein, encompasses configurations in which one element is directly attached to the other element by fix the element directly to the other element; configurations in which the element is indirectly secured to the other element by fixing the element to a member or intermediate members which in turn are fixed to the other element; and configurations in which one element is integral with the other element, that is, one element is essentially part of the other element. The flexible extensions 24 can be attached to the main absorbent portion 22 by any variety of means. For example, the flexible extensions 24 may be attached to the main absorbent portion 22 using any suitable adhesive centered around the longitudinal centerline L of the absorbent main portion 22 (ie, on the opposite sides of the longitudinal centerline L). This adhesive may extend continuously along the length of the main absorbent portion 22 or it may be applied in a "dotted" manner at discrete intervals. Alternatively, the flexible extensions 24 may be attached to the main absorbent portion 22 by stitching (such as with cotton or rayon yarn), technically joined, fusion bonding, or any other means known in the art for bonding these materials. As shown in Figures 6 and 7, the proximal ends 24A of the flexible extensions are fixed to the main absorbent portion 22. The flexible extensions 24 extend downward and outward from the absorbent main portion 22 toward a free end 24B which it is disjointed to the main absorbent portion. The flexible extensions 24 may be offset slightly away from the main absorbent portion 22 to tend to keep the extensions 24 in contact with the inner surfaces of the lips when the interlabial absorbent device 20 is in place. Additionally, the naturally moist surfaces of the lips will have a tendency to adhere to the material comprising the flexible extensions 24 tending more to keep them in contact with the inner surfaces of the lips. Preferably, the flexible extensions 24 must be able to move from a position where the free ends of the flexible extensions 24 are located adjacent the main absorbent portion 22 to a position where the flexible extensions 24 extend directly away from the absorbent main portion 22 in the transverse direction (as shown in Figure 6). The flexible extensions 24 should be of sufficient width and flexibility to allow the flexible extensions to cover the tips of the wearer's fingers as the interlabial absorbent device 20 is inserted into the interlabial space of the wearer. Figure 11 shows how a wearer can hold the main absorbent portion 22 of the interlabial absorbent device 20 while the flexible extensions 24 remain between the wearer's fingers and her body as the device 20 is inserted. Additionally, the flexible extensions 24 they must be able to move with the outer surfaces of the wearer's lips to maintain contact with the same. The flexible extensions 24 help to keep the main absorbent portion 22 in place at all of a scale of movements of the wearer such as the crouching. The flexible extensions 24 may be hydrophilic or hydrophobic. The flexible extensions 24 can be treated to make them less hydrophilic than the main portion 22. The hydrophilic capacity of a material is generally expressed in terms of its contact angle. In this way, the flexible extensions 24 can have a lead contact angle greater than the lead contact angle of the main portion 22, such that the fluid is preferentially directed toward and is absorbed by the main portion 22. Flexible extensions 24 can be either absorbent or non-absorbent. Preferably, the flexible extensions 24 have at least some absorbency. The majority of the fluid absorbed and retained by the interlabial absorbent device 20, however, it will preferably be retained in a final manner in the main portion 22, particularly within the absorbent material 44. For a more detailed description of the hydrophilic capacity and the contact angles see the following publications which are incorporated by reference herein: publication of the American Chemical Society entitled "Angle of contact, wettability and adhesion", edited by Robert F. Gould, and copyright of 1964; and the TRI / Princeton publications, Publication No. 459, entitled "A microtechnique for determining surface tension" published in April 1192, and Publication No. 468 entitled "Determination of contact angles within porous networks" published in January 1993, both edited by Dr. HG Heilweil. The strength and rigidity of the flexible extensions 24 are important characteristics of their design. If the flexible extensions 24 have a wet breaking strength of less than or equal to about 15 grams, they will tend to tear and may leave pieces that remain within the interlabial space of the wearer. Similarly, if the flexible extensions 24 are as rigid as a file manila folder, they will not provide sufficient flexibility to dynamically adjust the movements of the lips. The stiffness of flexible extensions is measured as a resistance to bending. Preferably, the flexible extensions 24 have a flexural strength of less than about 25 gm measured using the Three Point Bending Test. More preferably, the flexible extensions 24 have a flexural strength less than or equal to about 5 gm. A description of the Three Point Bending Test is contained in the Test Methods section, below. The flexible extensions 24 also have an inherent resistance, such that during application and use they do not tear. The wet strength for the flexible extensions should extend 15 grams, and preferably exceed 150 grams, and most preferably exceed 300 grams. The wet strengths given above are measured using the Wet Break Test described in more detail in the Test Methods section below. In the embodiment shown in Figure 8, the main absorbent portion 22 of the interlabial absorbent device 20 comprises a folded structure. In this embodiment, the main absorbent portion 22 preferably comprises a folded tissue web. The folded tissue web preferably has a higher strength than that of standard toilet paper without wet strength. Preferably, the main absorbent portion 22 comprises a tissue having a temporary wet strength greater than or equal to about 100 grams. In a preferred design this wet strength will decay to about 50% or less of the original strength for about 30 minutes.

As shown in Figure 8, the tissue web comprising the main absorbent portion 22 is bent into a folded structure comprising a plurality of folds 30 that are arranged in a laterally side-to-side relationship. The tissue web can be folded in such a way that it has any number of suitable folds. Preferably, the tissue web is folded in such a way that the total gauge (i.e., width) of the main absorbent portion 22 of this embodiment is between about 2 mm and less than or equal to about 7 mm. The folds in the folded tissue web are preferably connected or attached (or retained) in some suitable manner such that the folded sections maintain their folded configuration, and are not able to fully open. The folds may be connected by a variety of means including the use of threads, adhesives, heat-sealed tissues which contain a thermoplastic material, such as polyethylene. A preferred design uses the joining method described in greater detail below. The folded structure of the main absorbent portion 22 provides several advantages. An advantage provided by the folded structure is that the exudates can penetrate into the folds of the structure which presents a larger absorbent surface and more effective for acquisition than a flat surface. This is particularly important when dealing with potentially viscous fluids and particulate material such as cell debris and clots that can obstruct plugging the surface of the structure presented to the wearer's body. A second advantage of this design is that the caliber (or width) of the product can be controlled easily and conveniently by varying the number of folds. The structure shown in Figure 8 also provides a convenient central area for grasping the product and inserting it into the lips while the body / fingers in the insertion hand are protected from contact with the wearer's body.

As previously noted for the embodiments shown in Figures 1 to 2B, the flexural stiffness of the main absorbent portion 22 is also important for the comfort of the product with the folded structure shown in Figure 8. An advantage of the folded structure is that the number, thickness, and tightness of the folds controls the rigidity of the structure. The embodiment shown in Figure 8 preferably has the dimensions of the main absorbent portion 22 and the flexible extension 24 similar to those described above for the embodiments shown in Figures 2 to 2B. The width of the main absorbent portion 22 of the interlabial device 20 as measured in the transverse direction (direction y) is preferably between about 2 mm and less than or equal to about 7 mm. Preferably, in a preferred embodiment, the width of the main absorbent portion of the interlabial device 20 is approximately 4.5 mm. As shown in Figure 8, wherein the main absorbent portion 22 is of a uniform transverse dimension (ie, there is no abrupt change in the transverse dimension defining the juncture between the upper portion and the lower portion) the division between the upper portion 26 and lower portion 28 is considered to be at a height equal to approximately half the total height of the main absorbent portion 22. The ends of the absorbent main portion 22 of the device 20 shown in Figure 8 have at least one curvilinear segment and are preferably "S" shaped or sinusoidal as described above for the embodiment shown in Figure 1. The folded design shown in Figure 8 has the additional benefit of easily providing the flexible extensions 24. The extensions 24 can understand the same material as the main absorbent portion 22, or these may comprise a different material. The extensions 24 are attached to the main absorbent portion 22. The extensions 24 can be integral parts of the absorbent main portion 22 (i.e. the extensions 24 comprise integral extensions of the absorbent tissue material that is folded to form the absorbent main portion 22). .) The main absorbent portion 22 and the flexible extensions 24 of the interlabial absorbent device 20 shown in Figure 8 can be constructed from any of the materials and are provided with one of the same pattern of joints previously discussed for the embodiments shown in FIGS. Figures 1 to 2B. The embodiment shown in Figure 8 can be provided with several optional features. For example, there may be separate or raised bulge areas or voids between the pleats to improve the ability of the device 20 to move the exudates downwardly. Additionally, the folds on the part of the product that is in contact with the pelvic floor do not need to be of uniform height. For example, the material folded in the center could be superior and, therefore, easily crush under pressure. This arrangement can provide better fit and / or comfort. In another variation of the folded structure shown in Figure 8, the main absorbent portion 22 may comprise a plurality of individual layers joined in a face-to-face relationship. This structure can have all of the same characteristics described above for the folded structure. One benefit of using a plurality of individual layers is that the different layers may comprise different materials with different properties or characteristics. Each of the flexible extensions 24 may be integral with one of the individual layers or may be separately attached to the upper portion 26 of the absorbent main portion 22. Preferably, the individual layers are disposed in a side-by-side relationship of such so that the spaces between the layers are oriented in the z direction. The interlabial device 20 of any of the embodiments shown in the drawings may comprise other optional components. For example, the interlabial device 20 may comprise an upper sheet 42 positioned on and attached to all or part of its surface that faces the body of the device including the flexible extensions 24, and / or a back sheet 38 positioned on and attached to all or a portion of its back surface, including the flexible extensions 24. Preferably, if an upper sheet 42 and / or a back sheet 38 is used, these components are attached to at least the main absorbent portion 22. In an alternative embodiment, the The main absorbent portion can be wrapped at least partially by a top sheet. If a top sheet 42 is used, the top sheet must be docile to feel soft, and non-irritating to the wearer's skin. In addition, the top sheet must be permeable to liquid allowing liquids (eg, menstruation and / or urine) to easily penetrate through its thickness. A suitable top sheet can be manufactured from a wide range of materials such as woven and non-woven materials; polymeric materials such as thermoplastic films formed with openings, plastic films with openings, and hydroformed thermoplastic films; porous foams, cross-linked foams; crosslinked thermoplastic films; and thermoplastic canvases. Suitable woven and nonwoven materials may be composed of natural fibers (eg, wood or cotton fibers), synthetic fibers (e.g., polymer fibers such as polyester, rayon, polypropylene, or polyethylene fibers) from a combination of natural and synthetic fibers. A topsheet 42 suitable for use in the present invention is formed of rayon with a basis weight of about 18 g / m2 and is available from Veratec de Walpole, MA. This material is particularly suitable for use as a top sheet 42 because it is biodegradable. This material can also be used as an outer cover 46 if an outer cover 46 is desired and the top sheet 42 is not used. The top sheet may also comprise a film formed with openings. Films formed with openings are permeable to body exudates and, if properly perforated, have a reduced tendency to allow liquids to pass back through and re-wet the wearer's skin. In this way, the surface of the formed film that is in contact with the body remains dry, thus reducing the staining of the body and creating a more comfortable feeling for the user. Suitable formed films are described in U.S. Patent No. 3,929,135 entitled "Absorption structures having tapered capillaries", which was issued to Thompson on December 30, 1975; U.S. Patent No. 4,324,246 entitled "Disposable absorbent article having a stain resistant top sheet", which was issued to Mullane, et al. on April 13, 1982; U.S. Patent No. 4,342,314 entitled "Resilient plastic weft exhibiting fiber-like properties", which was issued to Radel, et al. on August 3, 1982; U.S. Patent No. 4,463,045 entitled "Macroscopically expanded three-dimensional plastic screen exhibiting non-glossy visible surface and fabric-like tactile printing" which was issued to Ahr, et al. on July 31, 1984; and in U.S. Patent No. 5,006,394"Multilayer Polymer Film" issued to Baird on April 9, 1991. The preferred top sheet for the present invention is the formed film described in one or more of the above patents and that sanitary napkins are marketed by The Procter & Gamble Company of Cincinnati, Ohio as the top sheet "DRI-WEAVE". Another upper sheet 30 suitable for the present invention is made in accordance with US Patents Nos. 4,609,518 and 4,629,643 both issued by Curro et al. On September 2, 1986 and December 16, 1986, respectively. This formed film is manufactured by Tredegar Corporation of Terre Haute, Indiana. In a preferred embodiment of the present invention, the body surface of the formed upper film sheet is hydrophilic to help transfer liquids through the upper sheet faster than if the body surface were not hydrophilic, to decrease the likelihood of the menstrual fluid flowing out of the topsheet instead of flowing into and being absorbed by the main absorbent portion 22. In a preferred embodiment, surfactant is incorporated into the polymeric materials of the formed film topsheet. Alternatively, the body surface of the topsheet can be made hydrophilic by treating it with a surfactant such as described in U.S. Patent No. 4,950,254 issued to Osborn. If a back sheet is used, the back sheet may be waterproof or semi-impervious to liquids (for example, menstruation and / or urine) and is preferably flexible. As used herein, the term "flexible" refers to materials that are docile and that will easily conform to the figure and general contour of the human body. The backsheet prevents the exudates absorbed and contained within the main absorbent portion 22 from wetting the articles that are in contact with the interlabial absorbent device 20 such as the wearer's undergarments. The backsheet also aids the main absorbent portion 22 to prevent the user's body from being soiled by the exudates. Additionally, the use of the backsheet may provide an improved surface for the user to grasp between the fingers as the interlabial absorbent device 20 is inserted or as the device is optionally removed with the fingers. The backsheet may comprise a woven or non-woven material, polymeric films such as polyethylene or polypropylene thermoplastic films, or composite materials such as a film-coated nonwoven material. Preferably, the backsheet is a polyethylene film having a thickness of about 0.012 mm to about 0.051 mm. An exemplary polyethylene film is manufactured by Clopay Corporation of Cincinnati, Ohio, under the designation P18-0410. The backsheet can allow the vapors to escape from the main absorbent portion 22 (ie, breathable) while still preventing the exudates from passing through the backsheet. If desired, the interlabial absorbent device 20 can be packaged in a single package, such as the package 50 shown in Figures 15 and 16. The individual package 50 can be composed of a number of suitable materials including films and flowable materials. and scatter. In Figures 15 and 16, the package 50 is made of a film that is frangibly sealed on the edges. The package 50 is provided with a tab of openings 52 which can be of any suitable configuration. Suitable methods for frangibly sealing packages are described in U.S. Patent No. 4,556,146 issued to Swanson and in U.S. Patent No. 5,462,166 issued to Minton, et al. Tabs suitable for such a package are described in U.S. Patent No. 5,413,568 issued to Roach, et al. As discussed previously, the interlabial absorbent device 20 of the present invention is designed to be placed within the interlabial space of a user. To use the interlabial absorbent device 20 of the present invention, the user holds the main absorbent portion 22 between her fingers. As shown in Figure 11, the flexible extensions 24 are extended to cover the tips of the wearer's fingers during insertion. This feature provides a hygienic insertion of the interlabial absorbent device 20 of the present invention. The interlabial device 20 is inserted with the upper portion 26 inserted first and more distant towards the interlabial space. The wearer can assume a crouched position during insertion to help separate the surface of the lips. Figure 9 shows a preferred embodiment of the interlabial absorbent device 20 of the present invention inserted into the interlabial space of a user W. The urinary genital members shown in Figure 9 include the bladder B, the vagina V, the urethra U, the clitoris C, the large intestine I, the anus A, the introitus of the vagina VI, the hymen ring H, the labia minora N, and the labia majora J. Figure 9 shows the relationship of these anatomical characteristics of the user W with with respect to the web-absorbing device 20 when the device is inserted appropriately for use. Once the interlabial absorbent device 20 is inserted, the flexible extensions 24 tend to adhere to the inner surfaces of the lips. When the user is standing, the walls of the laces close more tightly around the interlabial absorbent device 20. The interlabial device 20 is preferably retained at least partially in place by exerting a light pressure oriented laterally outwardly on the inner surfaces of the labia minora, labia majora, or both of the user. Additionally, the product can be retained by pulling the naturally wet labial surfaces to the fabric comprising the flexible extensions 24. Optionally, the flexible extensions 24 or other parts of the device may be provided with a biocompatible adhesive to aid adhesion from the device 20 to the internal surfaces of the user's lips. The strength of this adhesive must be selected to assist the interlabial absorbent device 20 in remaining in place, while still allowing reliable and comfortable removal of the device from the interlabial space of the wearer. The nterlabial absorbent device 20 can be carried as a "unique" product. Alternatively, it can be worn as a backing to a tampon, or in combination with a sanitary napkin, panty-hose, or incontinence pad for menstrual or incontinence use. If the interlabial absorbent device 20 is used with a sanitary napkin, the sanitary napkin can be of any thickness. Use with a sanitary napkin may be preferred at night to reduce back staining. The interlabial device 20 can be worn in conventional panties, or it can be used with short menstrual shorts. Numerous alternate embodiments of the interlabial absorbent device of the present invention are possible. For example, these products can be designed to be removed through urine, although an alternative extraction cord or loop can be used. These products can also be used with emollients and / or medicinal treatment. For example, an emollient suitable for use in the interlabial absorbent device 20 of the present invention is composed of about 50% petrolatum, about 39% cetearyl alcohol, and about 15% Ceteareth-10. These interlabial products can be constructed of materials that are biodegradable and / or which will fragment in water with agitation (as in a toilet). Preferably, the interlabial absorbent device 20 of the present invention is disposable in the toilet. The term "disposable in the toilet" as used herein includes the following features of an interlabial absorbent device: discharge capacity, dispersion capacity, settling capacity, and biodegradability. As used herein, the terms "capable of flowing and spreading" and "discharge capacity" refer to the ability of the product to pass through typical household, commercially available toilets and drainage pipes without causing occlusion or similar problem that may be directly associated with the physical structure of the product. It is recognized, however, that there may be many differences between the various types of toilets available. Therefore, for the purposes of the appended claims, a test is established to determine the discharge capacity of a catamenial product, such as an interlabial absorbent device, in the TEST METHODS section of this disclosure. In these and other embodiments, the interlabial absorbent device 20 may be provided with channels or areas of increased density of absorbent material 44. These regions of increased density may be arranged to directly assist the flow of bodily fluids toward the center of the device 20 to the capillary or wicking action provided by these density gradients. The interlabial absorbent device 22 can also to be constructed with a plurality of slits in the main absorbent portion 22 to allow folding of the product in multiple independent directions. Such a structure allows the product to respond more easily to the tensions associated with body movements. The upper surface of the structure may have one or more slits or have other preferred folding regions such that the product can easily adjust to vertical pressure against the pelvic floor., to help accommodate the non-linear surface of the pelvic floor between the clitoris and the perineum. The flexible extensions 24 of the above absorbent devices may also act as a spring in both of the wet and dry conditions such that the sides of the product tend to expand outwardly pressing against the side walls of the vestibule of the lips, in this way, keeping the product in place. In addition, it is preferred that the flexible extensions 24 maintain the ability to act as a "spring" when wet, such as when the product is saturated with liquid. Structures, such as polyurethane foams can provide these properties.

II. Method for Making the Paper Absorbent Device Figure 10 shows a preferred embodiment of a method and apparatus for making an interlabial absorbent device shown in the figures of the previous drawings. The method shown in Figure 10 preferably involves the manufacture of a plurality of individual interlabial absorbent devices from a continuous length of absorbent material (i.e., a piece of absorbent material having a length greater than the width). The absorbent material can be in any suitable continuous configuration. Suitable configurations include, but are not limited to, the configuration of: discrete cores which may be connected to a continuous frame, a frame, a folded or folded frame, wire, spun, ribbon, and thread. In preferred embodiment shown in the drawings, the absorbent material is provided in a form of a continuous tape 100. The continuous tape of absorbent material 100 is displaced in a longitudinal direction (ie, in the direction of its longitudinal dimension). This direction can also be referred to as the "machine direction" or MD: In the embodiment shown in Figure 10, the tape of the absorbent material 100 is preferably comprised of rayon fibers. The fibers in the ribbon 100 are preferably of a discrete length. However, it is also possible, (for example, if a yarn is used) for fibers that are of continuous length. The fibers in the ribbon 100 can be oriented randomly, or more preferably, oriented longitudinally in general. A cover material 102 is provided for the tape of the absorbent material 100. The cover material 102 is also preferably of a continuous length. The cover material 102 preferably comprises at least some thermoplastic material. The cover material 102 may be comprised of one or more layers of material. Suitable materials are described in the previous section of this description, such as cover 46 or upper sheet 42, and include, but are not limited to, thermoplastic films with openings or wefts or nonwovens or the like. In a particularly preferred embodiment shown, the cover material 102 comprises a nonwoven web of polypropylene having a basis weight of 35 g / yard2. A non-woven polypropylene weave is known as Grade 7535660-231 available from Veratec of Walpole, MA. In alternative embodiments, it may be desirable for the cover material 102 to comprise materials highly capable of flowing and spreading such as rayon and cellulose tissues. As shown in Figure 10, the continuous belt of absorbent material 100 is at least partially enclosed within the cover material 102. The cover material 102 preferably at least partially envelops the tape of the absorbent material 100 in such a way that the material of cover 102 has portions that are located on opposite sides of the tape of absorbent material 100. (The sides of the tape of absorbent material 100 are designated 100A and 100B in Figure 10). Preferably, the cover material 102 forms a tube around the absorbent material 100 and completely envelops the absorbent material 100. The cover material 102 can be formed in a tube around the continuous belt of the absorbent material 100 in any known manner to enclose an absorbent material 100. material in a tube of material. There are at least two main ways to form the tube relative to the tape of the absorbent material 100. The tube can be formed outside the cover material 102 first and the tape 100 can be inserted into the tube, or the material can be formed inside. of a tube around the tape of the absorbent material 100. In the first type of process, the tube can be formed from the cover material 102 by manipulating the cover material 102 into a cylindrical shape and forming an overlapped seam the long edge of the cylinder that is formed. The overlap joint can be formed by any suitable joining means. Suitable joining means include, but are not limited to adhesives, heat and / or pressure, and ultrasonic. In a preferred embodiment, the overlap joint is formed by ultrasound. The cylindrical tube is preferably inverted in such a way that the overlap joint will be on the inner side when the formation of the interlabial device is completed. This provides the advantage that the lap joint will not be in contact with the wearer's body when the interlabial device is worn, for improved comfort. Alternatively, the longitudinal side edges of the cover material 102 can be bent inwards and attached such that the overlap joint is inside the tube, and there is no need to invert the tube. Methods of forming a tube of material into which the absorbent material is inserted are described in U.S. Patent No. 4,095,542 issued to Hirschman on June 20, 1978 and U.S. Patent No. 4,995,150 issued to Gerstenberger. , and others on February 26, 1991. As discussed above, in an alternative embodiment, the cover material 102 can be formed in a tube by wrapping it at least partially around the tape of the absorbent material 100. In that embodiment, the material of cover 102 can be fed in the process in the machine direction. The cover material 102 can then be folded or wrapped around the tape of the absorbent material 100 in a conventional manner and sealed with a longitudinally oriented seam. The seam can be formed in any of the ways described above. As shown in Figure 10, a first portion 102A of the cover material 102 is preferably joined through the tape of the material 100 to a second portion 102B of the cover material. The apparatus used to join the tape covered with absorbent material preferably comprises a pair of cylindrical rolls 110 and 112. Preferably, at least one of the rolls, the roll 110, has a relief pattern on its surface. The patterned roller 110 is configured to have a cylindrical circular surface 115, and a plurality of protrusions or pattern elements (or "pattern element segments") 116 which extend outward from the surface 115. The relief pattern may be in any suitable configuration. This can be linear, curvilinear, or it can be composed of linear segments and curvilinear segments. The relief pattern can be continuous or intermittent. The pattern elements 116 may define a number of unlimited patterns and other types of designs. For example, it can define geometric shapes, arrows, words, etc. The seating surfaces 118 on the pattern elements 116 can also be provided in a wide variety of possible ways. Possible shapes for seating surfaces 118 include, but are not limited to, oval and circular. The pattern elements 116 have side walls 119 that are preferably not perpendicular to the surface 115 of the cylindrical roller. Preferably, the side walls 119 of the pattern elements 116 form an angle greater than 45 ° and less than 90 ° with the surface of the cylindrical roller. Modifying the orientation of the side walls 119 of the pattern elements 116 is necessary due to the thickness of the absorbent material between the materials that are bonded, and the desire to prevent tearing of the cover material 102. The relief pattern, in the embodiment of the apparatus shown, comprises a plurality of separate spaced pattern elements 116 having circular seating surfaces 118. In the embodiment of the method shown in FIG. 10, pattern elements 118 are arranged intermittently in a "half-moon" configuration " The pattern elements 118 are provided in an alternating pattern such that in every two applications of the bonding pattern, the joints 94 are formed on opposite sides of the longitudinal axis, A, of the tape covered with the absorbent material. The other roller 112 serves as an anvil member and thus can be referred to as the anvil roller 112. Preferably, the anvil roller 112 is smoothly smoothed. In other embodiments, however, both rolls 110 and 112 may have a relief pattern and / or pattern elements thereon. If this is the case, the pattern elements on the opposed rollers are preferably aligned with each other to compress the material to be joined therebetween. The pattern roller 110 and the anvil roller 112 define a biased grip space 114 therebetween. The pattern roller 110 and the anvil roller 112 are preferably inclined towards each other with a predetermined charge of the pattern member from about 140 MPa to about 1400 MPa. The pattern roller 110 and the anvil roller 112 are preferably driven in the direction at different speeds such that there is a differential of the surface velocity between them. The surface speed differential preferably has a magnitude of from about 2 to about 40% of the roll having the smaller surface speed, more preferably between about 2 and about 20% of the roll having the smaller surface speed. The anvil roller 112 is preferably operated at a surface speed that is greater than the surface speed of the pattern roller 110. A method for dynamically joining a laminate between a pair of rollers having a differential of the surface velocity therebetween is described in more detail in U.S. Patent No. 4,854,984 issued to Ball, and others on August 8, 1989. The method may further comprise the step of heating one or both of the rolls. If the rolls are heated, they are preferably heated to a surface temperature which is below the melting temperature of the thermoplastic material in the cover material 102. It is also possible, at high line speeds, for the joint to occur to the differential. of zero velocity (that is, with the grip space that defines the rollers having equal surface velocities). In parentheses, for simplicity and clarity of the invention, the apparatus 20 is described herein as comprising cylinders 110 and 112. However, the cylinders are only examples of the members defining the gripping space. Accordingly, it is not intended to limit the invention in this way to an apparatus comprising cylinders per se. In the same sense, the use of the term pattern element is not intended to limit the invention to binding patterns consisting of only discrete, discrete pattern elements for the exclusion of other patterns: for example, cross-linked patterns or patterns that they comprise continuous or elongated lines of union that are also possible. Figure 10 shows a particularly preferred binding process. The bonding process shown in the drawings penetrates through the tape of the absorbent material 100 and autogenously bonds the first portion 102A of the cover material to the second portion 102B of the cover material 102. The term "autogenous", as used herein , refers to the union without adhesives. However, the method described herein is not intended to be limited to one that precludes the adhesive buildup of this autogenous bond. It is also possible to use other types of joining processes and produce an interlabial device with the ends formed only. Preferably, however, to produce the interlabial device 20 shown in Figures 1 to 2A, an autogenous binding process is used. The joints 94 are arranged in a half-moon shape in an alternating pattern where each two applications of the joint pattern, the joints 94 are formed on opposite sides of the longitudinal axis, A, of the tape covered with the absorbent material.

The joining of the first and second portions 102A and 102B of the cover material 102 to each other at least partially encloses and segregates a part of the covered tape of the absorbent material 100 from the other part of the tape covered with the absorbent material. The joint causes portions of the cover material 102 that were on opposite sides of the absorbent material 100 to be in contact with each other, and pulls the cover material 102 more closely around these portions of the tape of the absorbent material to form the same. In this particular embodiment, the joining causes the portions of the covered tape of the absorbent material that will form the upper portion 26 and the lower portion 28 of the finished interlabial device 20 to have the largest and smallest desired widths, respectively, as measured at along the transverse center line of the finished product (shown in Figure 1 B). More specifically, the side with the joint will form the lower portion 28 of the interlabial device 20. The crescent connecting pattern forms alternating upper and lower portions on the opposite sides of the longitudinal axis A of the covered tape of the absorbent material. The joint, combined with the cutting step described below provides the ability to make an absorbent product that is formed asymmetrically about its longitudinal axis in both the width and the shape of its ends from a generally symmetrical continuous material length. This alternating pattern also has an advantage in processing the covered tape of the absorbent material. If the entire joint on one side of the longitudinal axis, A, of the covered tape of the absorbent material, this would create a high degree of stress on this particular side of the tape covered with the absorbent material. The alternating pattern ensures tension on both sides of the tape covered with the absorbent material in such a way that the attached covered tape of the absorbent material can be handled and processed more easily.

The bonding process described herein is not limited to the embodiments where the bonds are formed completely through the finished absorbent article. For example, in other embodiments, the absorbent material 100 may comprise at least one thermoplastic material, and the cover material 102 may be bonded to the thermoplastic material in the absorbent material 100. In still other embodiments, the bond may be formed through at least a part of the absorbent material, and the absorbent material can be folded to provide a double or greater thickness of the absorbent material. In such embodiment, the joint can only penetrate through one or more parts of the absorbent article without penetrating through the entire absorbent article. Many other modalities are possible. After the joining process, the covered and bonded tape of the absorbent material is preferably cut to form a plurality of individual interlabial absorbent devices. The apparatus used to cut the covered and attached tape of absorbent material comprises a pair of rollers 120 and 122. One of the rollers, the roller 120, has at least one, and preferably a plurality of blade elements 124 on its surface. The blade elements 124 are preferably configured to make a continuous cut in the generally transverse direction in the continuous and bonded web of the absorbent material. Preferably, as shown in Figure 10, the blade elements are configured to be a sinusoidal cut disposed symmetrically about the longitudinal axis of the covered and bonded tape of the absorbent material. The other roller 122 serves as an anvil member, and, in this manner, can be referred to as the anvil roller 122. The knife roller 120 and the anvil roller 122 also define a gripping space 126 therebetween.

As shown in Figure 10, the cutting step provides a cut in the generally transverse direction that alternates longitudinally through the covered and bonded tape of the absorbent material to cut it into individual interlabial devices, and provides a minimum of waste therebetween. Numerous alternate embodiments of the cutting step described herein are possible. For example, although the absorbent article described herein has curvilinear end edges, the method of the present invention can be used to make interlabial devices having a wider variety of formed end edges. For example, in other embodiments, the blade elements may be configured to form absorbent articles having end edges formed by completely rectilinear segments, fully curvilinear segments, or partially rectilinear segments and partially curvilinear segments. Furthermore, although the method of elaborating the interlabial device described herein preferably involves making a completely nested cut such that there is no waste between the adjacent interlabial devices, in another embodiment, the blade elements 124 may be configured to make any Cutting of desired shape along the ends of the interlabial devices. Some of these cuts can result in some wasted material being removed between each interlabial device. The process of the present invention forms a plurality of individual interlabial absorbent devices that are symmetrical about their longitudinal axis. After the cutting step, the individual interlabial devices 20 can then be sent on a conveyor 130 to a packing operation to pack them. If desired, other optional steps may be added to the method shown in Figure 10. For example, as shown in Figure 10A, one or more stages may be added in order to work out the modalities with the optional flexible extensions 24 shown in FIG. Figures 6 and 7. These additional steps will typically comprise a material supply step 134 for the optional flexible extensions 24, and a step of adding the material 134 for the flexible extensions to the main absorbent portion 22. The material 134 for the extensions flexible 24 can be added to (i.e., carried in or attached to) the main absorbent portion 22 (or more specifically, to the covered tape of the absorbent material that will form the main absorbent portion) in any suitable manner. The material 134 for the optional flexible extensions 24 can, as shown in Figure 10A, be brought into the process in the form of discrete pieces that have been cut to the desired size of the flexible extensions 24. These discrete pieces are preferably one size and configuration to be wrapped around the segment of the covered tape that will form the lower portion of the main absorbent portion to form both of the flexible extensions 24 as shown in Figures 6 and 7. Alternatively, two discrete pieces may be used. . These pieces can be fixed on each side of the covered tape to form the flexible extensions 24. In any case, the discrete pieces are then attached to the tape covered with absorbent material which will form the main absorbent portion of the individual interlabial devices. This can be done in any suitable way. For example, the material 134 for the flexible extensions 24 can be cut and separated slightly apart using a vacuum roller. In the embodiment shown in Figure 10A, the pieces cut and separated apart from the material 134 for the flexible extensions 24 are initially held at least temporarily against the covered tape of the absorbent material. This can be done by conventional means such as wrapping, by adhesive, by vacuum and the like. In the embodiment shown, the cut pieces 134 are then permanently attached to the covered tape of the absorbent material. The cut pieces 134 may be permanently attached to the covered tape of the absorbent material in any suitable manner. Suitable ways of permanently joining the cut pieces 134 to the covered tape of the absorbent material include, but are not limited to, adhesives, ultrasonics, and joints with heat and / or pressure. In the particularly preferred embodiment shown in Figure 10A, the cut pieces 134 are permanently bonded to the covered tape of the absorbent material using the same joining apparatus (roller 110 and 112) that was used to create the joints 94. As shown in FIG. Figure 10A, this is done simultaneously with the formation of the joints 94. The cut pieces 134 are then preferably folded in the desired orientation against the tape covered with absorbent material by a conventional bending mechanism located between the tie rolls 110 and 112 , and the cutting rollers 120 and 122. However, it is also possible to leave the joined pieces 134 unfolded and allow the consumer to bend them to the desired length. In other alternative embodiments, the material 134 for the optional flexible extensions 24 can be brought to the process in the form of one or more continuous webs that are cut into the flexible extensions 24 after the joining of the web or continuous webs to the web. cover of the absorbent material. In this alternative process, two material webs of the flexible extension 134, each of which has a width in the transverse direction of the machine (CD) greater than the CD width of the tape of the absorbent material are preferably used. One web will be placed on top of the web of absorbent material and another web will be placed on the bottom of the web of absorbent material. The two webs and the web of the absorbent material can then be carried through the joining process used to form the joints 94. In this embodiment, the continuous web or webs of the flexible extension material 134 can be cut at the cutting station. simultaneously with the cutting of the attached, covered tape of the absorbent material in the individual interlabial devices. This can produce an interlabial device similar to that shown in Figure 7. The addition of the flexible extensions 24 can be useful in serving other purposes than simply providing the complete interlabial device with flexible extensions 24. For example, if the Cover 102 was formed in a tube with the seam or overlap seam on the outside, the flexible extensions 24 may be useful when covering the seam on the cover above. The flexible extensions 24 may also comprise a waterproof material, which may, if wrapped around the underside of the absorbent main portion 22, serve as an impermeable barrier to the liquid in the complete interlabial device as shown in Figure 7. They are possible numerous alternative embodiments of the method of the present invention. For example, the method of the present invention is limited to the manufacture of liplabial devices having an absorbent main portion 22 formed from a strip of absorbent material (such as those shown in Figures 1 to 7). For example, in other embodiments, the main absorbent portion 22 of continuous threads of absorbent material (ie, a plurality of fibers of continuous length) can be made. In still other embodiments, the method of the present invention can be used to form interlabial devices having a folded absorbent main portion, such as the interlabial device shown in Figure 8. To form a folded, interlabial device, instead of a continuous belt of absorbent material, a bent weft is fed which comprises absorbent material towards the apparatus shown in Figure 10. In other embodiments, the method of the present invention can be varied to provide interlabial absorbent devices with characteristics unique For example, where the interlabial devices are made from a tube of absorbent material wrapped by a cover material, the overlap joint used to join the cover material in a cylindrical configuration can be altered to vary the properties of the interlabial device. For example, the overlap joint may be in the form of a continuous joint, or intermittent joints. Any of these types of joints can be in the form of straight lines, curved lines, arched lines, sinusoidal lines, or any other suitable configuration. The continuous straight line overlap joint will provide a flat cylindrical tube. However, the formation of the overlap joint with intermittent joints can provide a more comfortable overlap joint, the overlap joint must be in contact with the user's body. The dynamic bon method described in U.S. Patent No. 4,854,984 issued to Ball, and others may be used to form an overlap joint with intermittent joints, or joints in any other desired configuration. The formation of the overlap joint with a sinusoidal joint pattern can be used to provide the cylindrical tube of the absorbent material with alternating regions of greater and smaller diameter. The points of the overlap joint where the sinusoidal wave has a minimum amplitude forms regions where the tube has a smaller diameter. The sinusoidal overlap joint can, in this way, form a cylindrical structure "similar to a caterpillar". This can produce interlabial devices with additional ben axes which make the interlabial devices very flexible in their longitul dimension.

In the embodiments where the overlap joint is formed by the process described in the Ball patent and others, the process of forming the overlap joint can be combined with a cutting process to remove the excess material outside the joint. overlap. This combination of union by means of pressure and / or heat with cutting can be called "fusion / cutting". In addition, the binding pattern used to join through and form the interlabial device can be modified to provide the interlabial device with regions of different density (eg, greater) to absorb by capillary action or wicking the liquids towards the portions specific pre-determined features of the device. Providing capillary absorption or wicking lines in the interlabial device is believed to be more effective than providing them in absorbent pads such as sanitary napkins. The interlabial devices, due to the fact that these will remain within the interlabial space of the wearer during use, can not vary in their position relative to the body of a user to the limit that sanitary napkins can do. As a result, the lines and channels of capillary action or wicking effect will remain in the desired position in relation to the wearer's body, and will no longer move body exudates in the desired direction or directions more surely. The method described here provides many unique benefits. As discussed above, the method described herein provides the ability to make an absorbent product that is formed symmetrically about its longitudinal axis both in width and in the shape of its ends from a continuous length of generally symmetrical absorbent material. The method described herein is capable of making such asymmetrically alternating shaped products with little or no waste between the adjacent products.

The method described here also has particular advantages when compared to sewing processes. A sewing process is very slow, and undesirable for use in high speed manufacturing lines, and would be the limiting part of the total process speed. The method of the present invention, on the other hand, can be used in a manufacturing line that runs at high speeds (eg, 700 to 1000 feet per minute), which is not possible with the stitch processes. The method of the present invention is also capable of forming a limited number of possible joint patterns, and is not limited to the formation of generally straight, continuous line bonds, such as sewing processes.

TEST METHODS Absorbent capacity The absorbent capacity can be determined as follows. The test is performed on samples that have been conditioned by leaving them in a room at a relative humidity of 50% and at 73 ° F for a period of two hours before the test. The test must be carried out under similar conditions. The item is weighed to 0.1 grams closer. The article is then immersed in a beaker of sterile 0.9% saline (obtainable from Baxter Travenol Company of Deerfiled, IL), such that the article is fully submerged and is not flexed or otherwise bent or twisted. The article is submerged for 10 minutes. The article is removed to the saline solution and placed horizontally on a wire mesh screen that has 0.64 cm by 0.64 cm openings for 5 minutes to allow the saline solution to drain from the article. Both sides of the article are covered with absorbent blotting paper, such as filter paper # 631 available from Filtration Science Corp., Eaton-Dikeman Division of Mount Holly Springs, PA. A uniform load of 17.6 grams per square centimeter is placed on the article to release the excess fluid. The absorbent blotting paper is replaced every 30 seconds until the amount of fluid transferred to the blotting paper is less than 0.5 grams in a period of 30 seconds. Next, the article is weighed to the nearest 0.1 gram and the dry weight of the item is subtracted. The difference in grams is the absorbent capacity of the article.

Three Point Bending Test The Three Point Bending Test is performed on samples that have been conditioned by leaving them in an environment at 50% relative humidity and at 73 ° F for a period of 2 hours before the test. This test must be performed under similar conditions. The Three Point Bending Test uses an INSTRON Model 4502 tension and compression tester which is available from Instron Corporation of Canton, Massachusetts. A 10 N load cell is used and fixed to the INSTRON machine according to the manufacturer's instructions. The test also uses a special scroll "T" bar and a special bra for the test sample. As shown in Figure 12, the "T" bar 1101 comprises a pair of 6.40 mm diameter metal bars perpendicularly mounted together. The drive rod 1102 is approximately 125 mm long and the push rod 1103 is approximately 75 mm long. Preferably, the end of the drive rod 1102 is tapered to fit the circumference of the push rod 1103 and the two are glued, welded, and / or screwed together. The opposite end of the driving rod 1102 is mounted to the sliding unit of the INSTRON machine. The test sample holder 1104 comprises a template base 1105 for positioning and supporting a pair of support rods 1108. The template base 1105 comprises a base 1105 and twelve rectangular supports 1107 mounted in parallel on the base 1106. The base 1106 and supports 1107 are each preferably made from the LEXAN plate (plexiglass) from about 10 mm to about 13 mm thick. A support rod 1108 of the same materials as the "T" bar and approximately 150 mm long is mounted on each support 1107 of the template base 1105. The support rods 1108 are mounted to leave 10 mm of open space between them (measured at the point on each rod that is closest to the other). As shown in Figure 12, the "T" rod 1101 is centered between the support rods 1108. The INSTRON machine is fixed at a crosshead speed of 2.0 inches per minute (50.8 mm / min). The INSTRON machine is set in such a way that the slide unit will travel 10 mm down and back for each sample tested. Before testing a sample, the T-rod 1101 is lowered until it rests directly on the top of one of the support rods 1108. The vertical position of the T-rod 1001 is "zeroed" when the load as it rests on the support rod 1108 is approximately 1 gramf. The T-rod 1101 is then raised to 5 mm from this zero position and is centered between the support rods 1108. The sample 1000 to be tested is a piece of a material taken from one of the flexible extensions. The sample 1000 taken from one of the flexible extensions should have a dimension of approximately 25 mm in the longitudinal direction LD and a dimension in the transverse direction of approximately 10 mm. The sample is positioned in such a way that the push rod 1103 is running parallel to the side of the sample that was oriented in the transverse direction TD. The T 1001 rod is then allowed to move through a full 10 mm cycle (ie, 10 mm down and 10 mm back). Consequently, the T-rod 1101 will contact the sample 1000 after approximately 5 mm and the sample will bend an additional 5 mm. The flexural strength is the peak force required to bend the sample as the T-bar travels through a full 10-mm cycle.

Proof of Compressibility Summary The compressibility test is performed on samples that have been conditioned by leaving them in an environment at 50% relative humidity and at 73 ° F for a period of 2 hours before the test. This test must be performed under similar conditions. The Compressibility Test uses an INSTRON Model 4502 tension and compression tester which is available from Instron Corporation of Guangzhou, Massachusetts. A 10 N load cell is used and fixed to the INSTRON machine according to the manufacturer's instructions. The test also uses a special displacement "T" bar described above for the Three Point Bending Test and a plate type vise as a sample holder. The sample holder is a standard vise comprising a pair of plates whose surfaces are disposed opposite each other. The plates should be larger and taller than the sample being tested.

The compressibility test can be performed in an interlabial absorbent device 20 made in accordance with the above description. The product to be tested may have flexible extensions or it may be made without flexible extensions. The test routine consists of first measuring the compressibility of the lower center, then measuring the compressibility of the end of each end. Finally, the compressibility of the upper center of each product is measured. The compressibility of the lower center and the average compressibility of the ends are used to compute the compressibility ratio from the center to the end.

Test Procedure 1. The product to be tested is first placed inside the vise with the upper portion between the vise plates and the bottom portion (ie, the bottom) free of sticking up the vise plates . The device must be placed inside the vise so that approximately 15 mm is allowed to protrude above the top surface of the vise plates. The tightening of the vise must be sufficient to hold the product firmly so that it will not slip, but it does not need to be significantly tightened to retain the product in place. A confining pressure of approximately 1 psi is adequate. 2. The INSTRON machine is fixed at a crosshead speed of 2.0 inches per minute (50.8 mm / min). The INSTRON machine is set in such a way that the slide unit will move 5 mm down and 5 mm backward for each sample tested. The sample is placed as described above, such that the push rod 1103 will push down approximately half the way along the length of the sample (ie, along the transverse center line, over the tending to compress it.

Before testing a sample, the T-rod 1101 is lowered until it rests directly on the upper part of the sample. The length of the rod 1101 is perpendicular to the length of the sample. The vertical position of the T-rod 1001 is "zeroed" when the load like this rests on the support rod 1108 is approximately 1 gram. The T-rod 1101 is allowed to move through a complete 5 mm cycle (ie, 5 mm down and 5 mm back). Consequently, the T-bar 1101 will be in continuous contact with the sample during its stroke and will compress the sample by approximately 5 mm. The compressive strength is the peak force required to compress the sample as the T-bar moves through the entire cycle (ie, 5 mm down and 5 mm back). Record the lower central compressibility as the peak force required to compress the sample as described in step # 3 when the push rod 1103 is oriented to compress the lower part of the device along its transverse center line. Without removing the product from the vise, adjust the position of the sample relative to the T-rod 1101 such that the push rod 1103 will now compress one end of the sample to approximately 5 mm from the end edge. The push rod 1103 must still be oriented in the transverse direction, although it is no longer oriented above the transverse center line. "Reset" the position of the push rod 1103 above the sample as described above in step # 3. Allow the T-1101 rod to complete a 5 mm down stroke and 5 mm up stroke cycle. Record the peak force as the first compressibility of the end. Repeat the procedure in step # 5 for the other end of the sample. Record this peak force as the second compressibility of the end. 7. Average the first and second compressibility results. Record this value as the compressibility of the endpoint. 8. Take the ratio of the compressibility of the lower center line to the end (ie, divide the compressibility of the lower center of step # 4 between the compressibility of the end of step # 7). Record this value as the compressibility ratio from the central to the extreme. 9. Remove the product from the vise and replace it as described in step # 1 except that approximately 15 mm of the top of the device should be left protruding from the top of the vise plates.

. Repeat steps 2, 3 and 4 as described except that the T-rod 1101 will be compressing the top of the device along the transverse center line. Record this result as the compressibility of the upper center. 11. Repeat the total test sequence (steps 1 to 10) with at least 5 different samples of the same type.

Test for Resistance to Breakage Revision A test specimen, held between annular fasteners, is subjected to the increasing force applied by a 0.625 inch diameter polished stainless steel ball. The resistance to rupture is that force that causes the sample to fail. The resistance to rupture can be measured on wet or dry samples.

Apparatus Rupture Tester Tension test instrument Intelect-ll-STD, No. 1451-24PGB or the Thwing-Albert rupture tester are both suitable. Both instruments are available from Thwing-Albert Instrument Co., Philadelphia, PA. The instruments must be equipped with a 2000 gram load cell. If wet breakage measurements are to be made, the instruments must be equipped with a load cell protection and water protection for the front panel. Room Condition The temperature and humidity must be controlled to remain within the following limits: Temperature: 73 + 3 ° F (23 ° C + 2 ° C) Humidity: Relative Humidity of 50 + 2% Paper Cutter Scissors can be used or another equivalent Tray To soak the samples for the wet break suitable for the sample size Water solution to soak the samples for the wet break that must be balanced at the temperature of the conditioned room Stopwatch Suitable for soaking time measurement Sample preparation 1) Cut the sample to an appropriate size for the test (minimum sample size 4.5 inches x 4.5 inches). If the sample to be tested is too small (for example, a flexible extension with overall dimensions less than 4.5 inches x 4.5 inches), a larger sample of the same material should be used to determine the wet breaking strength. Prepare a minimum of five samples for each condition to be tested. 2) If you are going to make measurements of the break in wet, place an appropriate number of samples cut into a tray filled with water at a balanced temperature.

Equipment layout 1) Arrange the break tester according to the manufacturer's instructions. If a ll-STD tension test instrument is to be used, the following is appropriate: Speed: 12.7 centimeters per minute Breakage sensitivity: 20 grams Peak load: 2000 grams 2) Calibrate the load cell according to the breaking strength expected Measurements and report 1) Operate the rupture tester according to the manufacturer's instructions to obtain a measurement of the breaking strength for each sample. 2) Record the breaking strength for each sample and calculate an average and a standard deviation for the breaking strength for each condition. 3) Report the average and standard deviation for each condition in the next gram. Report the average and standard deviation for each group of four samples. This concludes the test.

Proof of Download Capacity Summary As distinguished above, the terms "capable of flowing and spreading" or "discharge capacity" refers to the ability of the product to pass through typical, commercially available household toilets and facilities drainage system. sanitary without causing obstruction or similar problems that may be directly associated with the physical characteristics of the product. For the purpose of the appended claims, the catamenial products are evaluated for their discharge capacity through the relative facility of the toilet rate and the evacuation of the siphon and subsequent transport through a simulated sanitary system. The discharge capacity of such a device must be measured by the following test procedure. The test procedure is designed to simulate two days of normal toilet use for a family of four (two men, two women). The test used a discharge sequence that simulates the following conditions: male urination visits, female urination visits (including post-urinal drying with paper), waste of catamenial products (ie, the nterlabial device or other device that is going to try) with toilet paper and bowel evacuation visits. The amount of paper to be used for each paper discharge is a normal discharge of 2 strips of 7 sheets. Normal loading is based on consumer research regarding typical habits and practices. The test was designed to simulate the conditions of a product that will be found if it is discharged through a conventional toilet and into a municipal sewer or septic tank. The samples were evaluated for: 1) clear of the toilet and stump rate, 2) blockage of the drainage line, and 3) disintegration during discharge.

Apparatus A suitable apparatus for the discharge capacity test is shown in the plan view in Figure 13. The apparatus includes: A 13.2-liter, water-saving whirlpool siphon, referred to as 210 (additional toilets can also be attached to the pipe layout shown in Figure 13, to evaluate the behavior of test samples using different unloading mechanisms such as pressure, commercial toilets). approximately 18 meters of 10 cm acrylic pipe (as seen in Figure 13, the pipe is generally assembled in a square configuration, which has linear runs 211, 212, 213, 215, 217, 219, 221 approximately (3 meters) long, a cast iron T 223 slightly downstream of the toilet 210 which is open to the atmosphere for ventilation, 5 angled 90 degrees cast iron pipes 212, 214, 216, 218 and 220; a stump 222 placed vertically (Figure 14) of approximately 4.57 meters from the terminal end of the pipe and approximately 2.5 cm long, and A grating (Tyler No. 4 sieve) to capture the solid effluent for the evaluation of the disintegration.

The apparatus used for this method is set to be equivalent to A112.19.2M-1990 ANSI Standard for Chinese ceramic accessories. The pipe is installed to provide a drop of 2 cm per meter of pipe length.

Materials Paper Product used in the Test: CHARMIN® standard toilet paper manufactured by The Procter & Gamble Company of Cincinnati, Ohio. Synthetic Fecal Material: Prepared to the method according to the method described below Test download sequence The test download sequence simulates 2 days of normal toilet use for a family of 4 (2 men, 2 women, based on the habits and practice of the consumer investigated). The sequence of 34 total downloads consists of 14 downloads with an empty rate, 8 downloads with paper only, 6 downloads with paper and a catamenial product and 6 downloads with paper and simulated faecal matter (SFM). When this is used, the SFM is placed at the rate just before the addition of the paper, the SFM load of 160 degrees + 5 grams consists of 2 pieces of 2.5 cm x 10 cm and a piece of »2.5 cm x 5 cm . The folded paper strips (or the catamenial product) are placed at the rate at 10-second intervals. 10 seconds later the strip or final cathemenal product is placed in the rate, the toilet is discharged. The download sequence is described below as a series of two routines combined in the following order: Routine No.1 (A was performed 6 times for a total of 30 downloads) 1) Paper discharge only - Capture reading of drainage line taken 2 minutes after the water reaches the simulated obstruction, wait a minute additional, and move to step 2. 2) Download with the empty rate. Take a blocking reading of the drain line 2 minutes after the water reaches the stump point and move to step 3. 3) Discharge with paper and catamenial product. Take a drain line lock reading 2 minutes after the water reach the stump point, wait 1 additional minute and move to step 4. 4) Empty discharge rate. Take a drainage line blockage reading 2 minutes after the water reaches the stump point and move to step 5. 15 5) Discharge with paper and simulated faecal matter (SFM). Take a reading of the blockage of the drain line 2 minutes after the water reaches the stump point, wait an additional minute.

Routine No. 2 (To be done once) 20 1) Paper discharge only: Take a reading of the blockage of the drain line 2 minutes after the water reaches the stump point, wait an additional minute, and move to the step 2. 2) Download with the empty rate. Take a reading of the blockage of the drain line 2 minutes after the water reaches the stump point and move to step 3. 3) Download with paper only. Take a reading of the blockage of the drain line 2 minutes after the water reaches the stump point, wait an additional minute, and move to step 4. 4) Unload with the empty rate. Take a reading of the blockage of the drain line 2 minutes after the water reaches the point of the stump. The total number of discharges per sequence is 34. If, at any point in the discharge sequence, the product remains in the cap or the siphon after discharge, the paper and / or the catamenial product thrown into the drain line manually and the download sequence will continue. After completing each test load, the drain pipe will be cleared before beginning the subsequent test. The above-described download sequence is repeated three times for each test product.

Data Report The degree of blockage of the drain line is determined by measuring the length of standing water completely behind the obstruction. Graduations are marked every 30 cm on the drain pipe upstream of the extrusion. Each standing length that the water recedes corresponds to 0.6 cm or 6.25% of the blockade at the point of extrusion. The residues of the test product that exist in the drain pipe are also collected. The following data is recorded for each evaluation: 1) Incidence of failure (%) of the catamenial product to clear the siphon and the rate in a discharge. 2) Incidence of failure (%) of the catamenial product to clear the siphon and the rate in two discharges. 3) Incidence of the product on the simulated stump. 4) Maximum level (%) of the blockage of the drain line 5) Accumulated level (%) of the blockage of the drain line during the simulated test period of two days.

Preferably, the products described herein will completely clear the bowl at least 70% of the time of two fewer discharges, more preferably at least 80% of the time of one discharge, and most preferably at least about 90% of the time in one discharge, and most preferably at least about 95% of the time in a discharge. The products described herein will preferably have a maximum block level of the drain line of less than or equal to about 80%. The products described herein will preferably have an accumulated level of blockage of the drain line during the similar test period of two days less than or equal to about 50%.

Preparation of Synthetic Fecal Material I. Materials Needed: • Synthetic faecal material Felcone (900 grams); (Available from Silicone Studio, Valle Forge, PA as a dry concentrate BFPS-7) • Running water at 100 ° C (6066 grams) II. Equipment needed: • Mixer (Available from Hobart Corp., Troy, OH, as model A200) • Extruder (Available from Hobart Corp., Troy, OH as Model 4812) • Disposable centrifugal tubes with screw caps (50 ml) (Available WVR Scientific, Chicago, IR, Catalog No. 21-008-176) • Water bath to control the temperature at 37 ° C. Preparation: 1. Drain the water at 100 ° C in the mixing bowl of the mixer and add the dry concentrate of Feclone. 2. Mix at low speed for one minute. 3. Mix at medium speed for two minutes. 4. After the material has been mixed well, transfer it to the extruder. 5. Use an ice pick, puncturing a small hole in the tip of each spin tube. 6. Extrude the Feclone in the centrifuge tubes. 7. Cover the centrifuged tubes and store in the refrigerator. 8. Before use, place the tubes in the water bath at 38 ° C.

This concludes the test. The disclosure of all patents, patent applications (and any of the patents issued thereon, as well as any of the corresponding published foreign patent applications), and the publications mentioned throughout this description are hereby incorporated by reference here. However, it is not expressly admitted that any of the documents incorporated by reference herein, teach or disclose the present invention.

Although the particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the invention.

Claims (9)

1. A method for making a plurality of interlabial absorbent devices, said method characterized in that said interlabial absorbent devices are made from a continuous length of absorbent material, said method comprising the steps of: a) providing a continuous length of absorbent material; b) moving the continuous length of absorbent material in a longitudinal direction; and c) making a continuous cut in the generally transverse direction in said length of absorbent material, wherein the cut in the generally transverse direction alternates longitudinally through the length of the absorbent material to provide a minimum of waste between the interlabial devices.

The method according to claim 1, wherein step (c) of making said continuous cut in the generally transverse direction comprises making an approximately sinusoidal cut in a symmetrical manner disposed around the center line of the continuous length of the absorbent material .

The method according to claim 1 or 2, wherein said continuous length of absorbent material has a longitudinal axis, and a thickness, wherein the thickness of said continuous length of absorbent material varies on opposite sides of the longitudinal axis in an alternating pattern where along the longitudinal axis where there are regions of greater or lesser thickness on the opposite sides of the longitudinal axis.

The method according to any one of the preceding claims, wherein said continuous length of absorbent material comprises one of the following types of components: a tape of absorbent material, a yarn of absorbent material, or a folded weft of absorbent material.

5. A method for making a plurality of interlabial absorbent devices, said method characterized in that said interlabial absorbent devices are symmetrical about a transverse axis and asymmetric about a longitudinal axis, and said interlabial devices are made with minimal waste, said method comprising the steps of : a) provide a continuous length of absorbent material; b) moving the continuous length of absorbent material in a longitudinal direction; c) providing a cover material for wrapping the continuous length of absorbent material; d) enclosing at least partially the continuous length of absorbent material in said cover material such that the cover material is located on opposite sides of the length of the absorbent material; e) joining a first portion of the cover material to a second portion of the cover material which is located on opposite sides of the length of the absorbent material, said joint penetrating through the absorbent material and being provided in an alternating pattern wherein each two applications of the bonding pattern, the joints are formed on opposite sides of the longitudinal axis of the length of the absorbent material; and f) making a continuous cut in the generally transverse direction in said length of absorbent material, wherein the cut in the generally transverse direction alternates longitudinally through the length of the absorbent material to provide a minimum of waste between the interlabial devices.

The method according to claim 5, wherein step e) of joining the first portion of the cover material to the second portion of the cover material comprises providing intermittent joints arranged in a curvilinear pattern.

7. The method according to claim 5 or 6, wherein step e) of joining the first portion of the cover material to the second portion of the cover material comprises the joint using ultrasound. The method according to claim 5 or 6, wherein step e) of joining the first portion of the cover material to the second portion of the cover material comprises continuously joining in a dynamic process employing pressure. The method according to claims 5, 6, 7 or 8, wherein step e) of joining the first portion of the cover material to the second portion of the cover material comprises forming the length of the absorbent material in the regions which have asymmetric gauges around the longitudinal axis of the length of the absorbent material.