Disposable diaper with folded absorbent batt

• US 4,670,011 A
• Filed: 04/22/1985
• Issued: 06/02/1987
• Est. Priority Date: 12/01/1983
• Status: Expired due to Term

• Current Assignee: McNeil-PPC Incorporated (Johnson & Johnson)
• Original Assignee: Personal Products Co. (Johnson & Johnson)
• Inventors: Mesek, Frederick K.
• Primary Examiner(s): NOT, DEFINED
• Assistant Examiner(s): Krab, A.
• Application Number:
  US06/726,040
• Time in Patent Office: 771 Days
• Field of Search: 604/378, 604/385, 604/379, 604/380
• US Class Current: 604/378
• CPC Class Codes: A61F 13/15634 Making fibrous pads between sheets or webs
• CPC Class Codes: A61F 13/5323 having absorbent material located in discrete regions, e.g. pockets
• CPC Class Codes: A61F 13/53427 having an e-folded cross-section
• CPC Class Codes: A61F 13/53708 the layer having a promotional function on liquid propagation in at least one direction
• CPC Class Codes: A61F 2013/530562 being arranged in discontinuous pattern
• CPC Class Codes: A61F 2013/53765 characterized by its geometry

Abstract

An improved absorbent unit for a disposable diaper, or the like, wherein a fibrous batt is initially generally rectangularly shaped, and is cut so as to define side flaps which are folded over into overlapping relationship with one another in the central portion of the batt to define a multiple layer crotch region for increased liquid storage capacity. The batt is provided with a thickened densified skin at one side thereof for increased strength and stability, and for transporting liquid into remote areas of the batt. In a further embodiment, a quantity of highly liquid-sorbent superabsorbent material is provided in discrete spaced-apart regions between upper and lower fibrous webs of the diaper batt, with a network of densified wicking embossments and at least one integral densified wicking layer provided for promoting efficient wicking and transport of liquid within the absorbent structure.

Claims

1. An absorbent unit for use in an absorbent article, comprising:

a highly porous, cellulosic fibrous batt, said batt comprising first upper and second lower fibrous webs superposed to define a web interface therebetween, said fibrous batt being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, said superabsorbent material being disposed in discrete, spaced apart regions to define relatively superabsorbent-free areas at said web interface, said first and second fibrous web having relatively densified, liquid-wicking embossments in said superabsorbent-free areas adjacent said discrete superabsorbent regions to promote wicking of liquid, at least one of said first and second fibrous webs having an integrally formed, relatively densified, paper-like liquid wicking layer provided at the surface thereof at said web interface for further promoting said wicking of liquid, at least a portion of said wicking layer being in physical contact with at least a portion of said superabsorbent material to promote liquid transfer therebetween.

2. An absorbent unit as set forth in claim 1, wherein

each of said upper and lower fibrous webs is provided with an integrally formed, relatively densified paper-like wicking layer at said web interface.

3. An absorbent unit as set forth in claim 1, wherein

each said discrete region of superabsorbent material is bounded by said liquid-wicking embossments formed in first and second fibrous webs.

4. An absorbent unit as set forth in claim 1, wherein

said densified compacted wicking layer is provided on said first upper web at said web interface,

said batt including another paper-like densified compacted cellulosic fibrous wicking layer provided at the upper surface of said first upper web.

5. An absorbent unit as set forth in claim 1, wherein

said discrete regions of superabsorbent material extend longitudinally of said fibrous batt, and said liquid-wicking embossments extend longitudinally of said fibrous batt in spaced apart parallel relation to each other between and on respective opposite sides of said discrete regions of superabsorbent material.

6. An absorbent unit as set forth in claim 5, including

a pair of transversely extending, relatively densified embossments formed in said first and second webs of said fibrous batt, said transverse embossments being provided at respective opposite longitudinal ends of said discrete regions of superabsorbent material and said parallel longitudinal embossments, so that each said discrete region of superabsorbent material is bounded by a pair of said longitudinal embossments and by said transverse embossments.

7. An absorbent unit as set forth in claim 1, including

means for preventing degradation of said fibrous batt attendant to wetting and swelling of said discrete regions of superabsorbent material.

8. An absorbent unit for use in an absorbent article, comprising:

a highly porous, cellulosic fibrous batt, said batt comprising first and second lower fibrous webs superposed to define a web interface therebetween, said fibrous batt being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, said superabsorbent material being disposed in discrete, spaced apart regions to define relatively superabsorbent-free areas at said web interface, said first and second fibrous webs having relatively densified, liquid-wicking embossments in said superabsorbent-free areas adjacent to but spaced from said discrete superabsorbent regions to promote wicking of liquid, said densified embossments comprising integrated fibrous material of said first and second webs for joining said webs to each other for stabilizing said absorbent unit.

9. An absorbent unit as set forth in claim 8, wherein

at least a portion of said fibrous batt includes a paper-like, densified compacted cellulosic fibrous wicking layer formed integrally with one of said first and second webs to further promote said wicking of liquid.

10. An absorbent unit as set forth in claim 9, wherein

said densified compacted wicking layer is provided on said surface of said one of said first and second webs at said web interface.

11. An absorbent unit as set forth in claim 10, wherein

said densified compacted wicking layer is provided on said first upper web at said web interface,

said batt including another paper-like densified compacted cellulosic fibrous wicking layer provided at the upper surface of said first upper web.

12. An absorbent unit as set forth in claim 8, wherein

said discrete regions of superabsorbent material extend longitudinally of said fibrous batt, and said liquid-wicking embossments extend longitudinally of said fibrous batt in spaced apart parallel relation to each other between and on respective opposite sides of said discrete regions of superabsorbent material.

13. An absorbent unit as set forth in claim 12, including

a pair of transversely extending, relatively densified embossments formed in said first and second webs of said fibrous batt, said transverse embossments being provided at respective opposite longitudinal ends of said discrete regions of superabsorbent material and said parallel longitudinal embossments, so that each said discrete region of superabsorbent material is bounded by a pair of said longitudinal embossments and by said transverse embossments.

14. An absorbent unit as set forth in claim 8, including

means for preventing degradation of said fibrous batt attendant to wetting and swelling of said discrete regions of superabsorbent material.

57. An absorbent unit as set forth in claim 14 wherein said batt is generally I-shaped and includes widened end portions at opposite ends of said body portion.

58. An absorbent unit as set forth in claim 14 wherein a densified wicking section is disposed between said first and second densified layers, and another densified wicking section is disposed between said first and third densified layers.

15. An absorbent unit for use in an absorbent article, said absorbent unit comprising:

a highly porous, cellulosic fibrous batt, said batt comprising first upper and second lower fibrous webs superposed to define a web interface therebetween, said fibrous batt being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, at least one of said first and second fibrous webs having an integrally formed, relatively densified, paper-like liquid-wicking layer provided at the surface thereof at said web interface for promoting wicking and transport of liquid from a region of introduction into said absorbent unit, at least a portion of said wicking layer being in physical contact with at least a portion of said superabsorbent material to promote liquid transfer therebetween.

16. An absorbent unit as set forth in claim 15, wherein

each of said first upper and second lower fibrous webs includes an integrally formed, relatively densified, paper-like wicking layer at the surface thereof at said web interface.

59. An absorbent unit as set forth in claim 16 wherein said densified layers and sections are continuous with one another.

17. An absorbent unit for use in an absorbent article, said absorbent unit comprising:

a highly porous, cellulosic fibrous batt, said batt comprising first upper and second lower fibrous webs superposed to define a web interface therebetween, said fibrous batt being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, said superabsorbent material being disposed in discrete, spaced apart regions to define relatively superabsorbent-free areas at said web interface, at least one of said first and second fibrous webs having an integrally formed, relatively densified, paper-like liquid-wicking layer provided at the surface thereof at said web interface for promoting wicking and transport of liquid from a region of introduction into said absorbent unit, at least a portion of said wicking layer being in physical contact with at least a portion of said superabsorbent material to promote liquid transfer therebetween.

18. An absorbent unit as set forth in claim 17, wherein

said discrete regions of superabsorbent material extend longitudinally of said fibrous batt.

19. An absorbent unit as set forth in claim 17, wherein

each said discrete region of superabsorbent material is bounded by relatively densified embossments formed in said upper and lower fibrous webs.

20. An absorbent unit as set forth in claim 17, wherein

said upper and lower fibrous webs include relatively densified liquid-wicking embossments in said superabsorbent-free areas adjacent said discrete regions of superabsorbent material.

21. An absorbent unit for use in an absorbent article, comprising:

a highly porous, cellulosic fibrous batt, said batt comprising first upper and second lower fibrous webs superposed to define a web interface therebetween, said fibrous batt being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, said superabsorbent material being disposed in discrete, spaced apart regions to define relatively superabsorbent-free areas at said web interface, each of said first and second fibrous webs having an integrally formed, relatively densified, paper-like liquid-wicking layer provided at the surface thereof at said web interface to promote wicking of liquid within said absorbent unit, at least a portion of said wicking layer being in physical contact with at least a portion of said superabsorbent material to promote liquid transfer therebetween.

22. An absorbent unit as set forth in claim 21, wherein

each said discrete region of superabsorbent material is bounded by relatively densified embossments formed in said upper and lower fibrous webs.

23. A disposable diaper, comprising:

a first outer layer in the form of a moisture-impervious backing sheet;

a highly porous, cellulosic fibrous batt, said batt having a generally I-shaped configuration formed from an initially generally rectangular member and having end portions and a central portion including a medial section, said batt comprising first upper and second lower fibrous webs superposed to define a web interface therebetween, said medial section being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, said superabsorbent material being disposed in discrete, spaced apart regions to define relatively superabsorbent-free areas at said web interface, said first and second fibrous webs having relatively densified, liquid-wicking embossments in said superabsorbent-free areas adjacent to but spaced from said discrete superabsorbent regions to promote wicking of liquid, said densified embossments comprising integrated fibrous material of said first and second fibrous webs for joining said webs to each other; and

an outer second layer in the form of a moisture-pervious facing sheet positioned in superposed relationship with respect to said fibrous batt on the side opposite said backing sheet.

24. A disposable diaper as set forth in claim 23, wherein

at least a portion of said medial section includes a paper-like, densified compacted cellulosic fibrous wicking layer formed integrally with one of said first and second webs to further promote said wicking of liquid.

25. A disposable diaper as set forth in claim 24, wherein

said densified compacted wicking layer is provided on said surface of said one of said first and second webs at said web interface.

26. A disposable diaper as set forth in claim 23, wherein

said discrete regions of superabsorbent material extend longitudinally of said fibrous batt, and said liquid-wicking embossments extend longitudinally of said fibrous batt in spaced apart parallel relation to each other between and on respective opposite sides of said discrete regions of superabsorbent material.

27. A disposable diaper as set forth in claim 26, including

a pair of transversely extending, relatively densified embossments formed in said first and second webs of said fibrous batt, said transverse embossments being provided at respective opposite longitudinal ends of said discrete regions of superabsorbent material and said parallel longitudinal embossments, so that each said discrete region of superabsorbent material is bounded by a pair of said longitudinal embossments and by said transverse embossments.

28. A disposable diaper as set forth in claim 23, including

means for inhibiting leakage from liquid from longitudinal end portions of said diaper.

29. A disposable diaper as set forth in claim 28, wherein

said leakage inhibiting means comprises a pair of moisture-impervious strips provided at respective opposite ends of said fibrous batt between said fibrous batt and said facing sheet.

30. A disposable diaper, comprising:

a first outer layer in the form of a moisture-impervious backing sheet;

a highly porous, cellulosic batt, said batt having a generally I-shaped configuration formed from an initially generally rectangular member and having end portions and a central portion, said central portion including a medial section flanked by a flap section at each side thereof, said flap sections being folded into overlapping relationship with said medial section, said batt comprising first upper and second lower fibrous webs superposed to define a web interface therebetween, said medial section being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, said superabsorbent material being disposed in discrete spaced apart regions, said fibrous batt including a paper-like densified compacted cellulosic fibrous wicking layer integrated with one of said first and second webs at said web interface to promote wicking of liquid, at least a portion of said wicking layer being in physical contact with at least a portion of said superabsorbent material to promote liquid transfer therebetween; and

a second outer layer in the form of a moisture-pervious facing sheet positioned in superposed relationship with respect to said fibrous batt on the side opposite said backing sheet.

31. A disposable diaper as set forth in claim 30, including

means for inhibiting leakage of liquid from longitudinal end portions or said diaper.

32. A disposable diaper as set forth in claim 30, including

a plurality of relatively densified, liquid-wicking embossments formed in said upper and lower fibrous webs of said batt adjacent to and between said discrete regions of superabsorbent material to further promote said wicking of liquid.

33. A disposable diaper as set forth in claim 32, wherein

said discrete regions of superabsorbent material extend longitudinally of said fibrous batt.

34. A disposable diaper as set forth in claim 33, wherein

said liquid-wicking embossments are provided in said medial section in the form of a plurality of spaced apart, parallel longitudinal embossments on respective opposite sides of each said discrete region of superabsorbent material.

35. A disposable diaper as set forth in claim 34, wherein

said liquid-wicking embossments are provided in said fibrous batt so that each said discrete region of superabsorbent material is bounded by said embossments.

36. A disposable diaper as set forth in claim 30, including

at least one discrete region of highly liquid-sorbent superabsorbent material provided in each said flap section at said interface between said first and second fibrous webs.

37. A disposable diaper as set forth in claim 30, wherein

each of said upper and lower fibrous webs is provided with an integrated, relatively densified compacted fibrous wicking layer at the surface thereof at said web interface.

60. A disposable diaper as set forth in claim 34, wherein

the lateral-most ones of said longitudinal liquid-wicking embossments are respectively spaced approximately 0.75 inches inwardly of respective fold lines where said flap sections are folded into overlapping relationship with said medial section.

38. A disposable diaper, comprising:

a first outer layer in the form of a moisture-impervious backing sheet;

a highly porous, cellulosic fibrous batt, said batt having a generally I-shaped configuration formed from an initially generally rectangular member and having end portions and a central portion, said central portion including a medial section flanked by a flap section at each side thereof, said flap sections being folded at respective fold lines into overlapping relationship with said medial section, said batt comprising first upper and second lower fibrous webs superposed to define a web interface therebetween, said medial section being provided with a quantity of highly liquid-sorbent, superabsorbent material positioned at said web interface, said superabsorbent material being disposed in a plurality of longitudinally extending, spaced apart discrete regions separated by areas which are relatively free of superabsorbent material, said fibrous batt including a plurality of relatively densified wicking embossments extending longitudinally of said batt in spaced parallel relation to provide said wicking embossments on respective opposite sides of each said discrete region of supreabsorbent material, said fibrous batt including a densified compacted fibrous wicking layer formed integrally with one of said first and second webs at said web interface whereby said embossments and said wicking layer promote wicking of liquid, at least a portion of said wicking layer being in physical contact with at least a portion of said superabsorbent material to promote liquid transfer therebetween; and

a second outer layer in the form of a moisture-pervious facing sheet positioned in superposed relationship with respect to said batt on the side opposite said backing sheet.

39. A disposable diaper as set forth in claim 38, wherein

said densified compacted wicking layer is provided on said first upper fibrous web at said web interface, said fibrous batt including another densified compacted wicking layer formed integrally with said first fibrous web at the surface thereof opposite said first-said wicking layer.

40. A disposable diaper as set forth in claim 38, including

at least one discrete region of highly liquid-sorbent superabsorbent material provided in each said flap section, each said flap section including relatively densified liquid-wicking embossments bounding the discrete region of superabsorbent material therein.

41. A disposable diaper as set forth in claim 38, wherein

each of said fold lines between said flap sections and said medial section are relatively uncompacted and uncompressed to abate wicking of liquid into and along said fold lines.

42. A disposable diaper as set forth in claim 38, including

means for inhibiting leakage from the longitudinal end portions of said diaper.

61. A disposable diaper as set forth in claim 41, wherein

the lateral-most ones of said longintudinally extending wicking embossments are respectively spaced approximately 0.75 inches inwardly of the relatively uncompacted fold lines between said flap section and said medial section.

43. A disposable diaper comprising:

a first outer layer in the form of a moisture-imperious backing sheet;

a highly porous, loosely compacted, cellulosic fibrous batt formed of cellulosic fibrous material, said batt having formed integrally therewith a paper-like, densified compacted cellulosic fibrous layer positioned in superposed relationship with respect to the backing sheet, said densified compacted fibrous layer being formed of a compacted integral portion of said fibrous material of which said fibrous batt is formed for integration into said batt, the batt being smaller than the backing sheet and spaced inwardly from the longitudinal sides thereof, said batt having a generally I-shaped configuration and formed from an initially generally rectangular member having end portions and a central portion, said central portion including a medial section flanked by a flap section at each side thereof, said flap sections being folded into overlapping relationship with one another, whereby the central portion of said batt includes (1) a first densified layer adjacent said first outer layer, (2) a first loosely compacted layer adjacent to said first densified layer, (3) a second loosely compacted layer adjacent to said first loosely compacted layer, (4) a second densified layer adjacent to said second loosely compacted layer, (5) a third loosely compacted layer adjacent to said second densified layer, and (6) a third outwardly facing densified layer, said inwardly folded flap sections thereby defining said generally I-shaped configuration and providing increased liquid holding capacity in the central portion of said absorbent batt; and

a second outer layer in the form of a moisture-pervious facing sheet positioned in superposed relationship with respect to the batt on the side opposite the backing sheet.

44. A disposable diaper as set forth in claim 43 wherein said medial section and flap sections are substantially equal in size.

45. A disposable diaper as set forth in claim 44 wherein said flap sections are defined by spaced lines of cutting extending inwardly from the longitudinal side edges of the batt, said lines of cutting each extending about one third the width of said batt.

46. A disposable diaper as set forth in claim 45 wherein the liner of cutting are perpendicular to the longitudinal side edges of the batt and parallel with one another.

47. A disposable diaper as set forth in claim 43 wherein said densified layer includes longitudinally extending lines of greater thickness dimension.

48. A disposable diaper comprising:

a first outer layer in the form of a moisture-impervious backing sheet;

a highly porous, loosely compacted, cellulosic fibrous batt formed of cellulosic fibrous material, said batt having formed integrally therewith a paper-like, densified compacted cellulosic fibrous layer positioned in superposed relationship with respect to the backing sheet, said densified compacted fibrous layer being formed of a compacted integral portion of said fibrous material of which said fibrous batt is formed for integration into said batt, the batt being smaller than the backing sheet and spaced inwardly from the longitudinal sides thereof, said batt having a generally I-shaped configuration and formed from an initially generally rectangular member having end portions and a central portion, said central portion including a medial section flanked by a flap section at each side thereof, said flap sections being folded inwardly over said medial section to position the densified layer on each flap section above the loosely compacted portion of said medial section to thereby define said generally I-shaped configuration and to provide an upwardly facing wicking layer and increased liquid holding capacity in the central portion of said absorbent batt; and

a second outer layer in the form of a moisture-pervious facing sheet positioned in superposed relationship with respect to the batt on the side opposite the backing sheet.

49. A disposable diaper as set forth in claim 48 in which said flap sections are folded into overlapping relationship with one another whereby the central portion of said batt includes (1) a first densified layer adjacent said first outer layer, (2) a first loosely compacted layer adjacent to said first densified layer, (3) a second loosely compacted layer adjacent to said first loosely compacted layer, (4) a second densified layer adjacent to said second loosely compacted layer, (5) a third loosely compacted layer adjacent to said second densified layer, and (6) a third outwardly facing densified layer;

and wherein said first and second outer layers have reduced width midportions aligned with the central portion of said batt.

50. A disposable diaper as set forth in claim 48 wherein said medial section and flap sections are substantially equal in size.

51. A disposable diaper as set forth in claim 50 wherein said flap sections are defined by spaced lines of cutting extending inwardly from the longitudinal side edges of the batt, said lines of cutting each extending about one third the width of said batt.

52. A disposable diaper as set forth in claim 51 wherein the lines of cutting are perpendicular to the longitudinal side eges of the batt and parallel with one another.

53. A disposable diaper as set forth in claim 48 wherein said densified layer includes longitudinally extending lines of greater thickness dimension than said densified layer.

54. A disposable diaper comprising:

a first outer layer in the form of a moisture-impervious backing sheet;

a highly porous, cellulosic fibrous batt formed of cellulosic fibrous material, said batt having formed integrally therewith a paper-like, densified compacted cellulosic fibrous layer, said densified compacted fibrous layer being formed of a compacted integral portion of said fibrous material of which said fibrous batt if formed for integration into said batt, the batt being smaller than the backing sheet and spaced inwardly from the longitudinal sides thereof, said batt being formed from an initially generally rectangular member with said densified compacted fibrous layer being spaced from the upper surface of said member, said batt having an end portion and a central portion, said central portion including a medial section flanked by a flap section at each side thereof, said flap sections being folded inwardly over said medial section to position the densified layer on each flap section above the loosely compacted portion of said medial section to provide increased liquid holding capacity in the central portion of said absorbent batt; and

a second outer layer in the form of a moisture-pervious facing sheet positioned in superposed relationship with respect to the batt on the side opposite the backing sheet.

55. A disposable diaper comprising:

a first outer layer in the form of a moisture-impervious backing sheet;

a highly porous, loosely compacted, cellulosic fibrous batt formed of cellulosic fibrous material, said batt having formed integrally therewith a paper-like, densified compacted cellulosic fibrous layer positioned in superposed relationship with respect to the backing sheet, said densified compacted fibrous layer being formed of a compacted integral portion of said fibrous material of which said fibrous batt is formed for integration into said batt, the batt being smaller than the backing sheet and spaced inwardly from the longitudinal sides thereof, said batt being formed from an initially generally rectangular member having an end portion and a body portion, said body portion including a medial section flanked by a flap section at each side thereof, said flap sections being folded into overlapping realtionship with one another whereby the body portion of said batt includes (1) a first densified layer adjacent said first outer layer, (2) a first loosely compacted layer adjacent to said first densified layer, (3) a second loosely compacted layer adjacent to said first loosely compacted layer, (4) a second densified layer adjacent to said second loosely compacted layer, (5) a third loosely compacted layer adjacent to said second densified layer, and (6) a third outwardly facing densified layer, said inwardly folded flap sections providing increased liquid holding capacity in the body portion of said absorbent batt; and

a second outer layer in the form of a moisture-pervious facing sheet positioned in superposed relationship with respect to the batt on the side opposite the backing sheet.

56. An absorbent unit for use in an absorbent article comprising:

a highly porous, loosely compacted, cellulosic fibrous batt formed of cellulosic fibrous material, said batt having formed integrally therewith a paper-like, densified compacted cellulosic fibrous layer, said densified compacted fibrous layer being formed of a compacted portion of said fibrous material of which said fibrous batt is formed for integration into said batt, said batt being formed from an initially generally rectangular member having an end portion and a body portion, said body portion including a medial section flanked by a flap section at each side thereof, said flap sections being folded into overlapping relationship with one another, whereby the body portion of said batt includes (1) a first densified layer at one side thereof, (2) a first loosely compacted layer adjacent to said first densified layer, (3) a second loosely compacted layer adjacent to said first loosely compacted layer, (4) a second densified layer adjacent to said second loosely compacted layer, (5) a third loosely compacted layer adjacent to said second densified layer, and (6) a third densified layer at the side of said batt opposite said one side, said inwardly folded flap sections providing increased liquid holding capacity in the body portion of said absorbent batt.