Disposable diaper with folded absorbent batt
First Claim
1. A method of manufacturing a disposable diaper, comprising the steps of:
- forming first and second fibrous webs of highly porous cellulosic fibrous material;
depositing a quantity of highly liquid-sorbent superabsorbent material on said second fibrous web on at least a medial section thereof to provide a plurality of spaced apart discrete regions of superabsorbent material;
positioning facing surfaces of said first and second fibrous webs in superposed relation to define a web interface therebetween at which said discrete regions of superabsorbent material are provided to thereby form a fibrous batt having a medial section corresponding to the medial section of said second fibrous web;
joining said first and second fibrous webs to each other, including forming a plurality of densified compacted wicking embossments between and adjacent to, but spaced from, said discrete regions of superabsorbent material to promote wicking of liquid, said joining step being performed so that said densified embossments comprise integrated fibrous material of said first and second fibrous webs for joining said webs to each other to integrate said fibrous webs for stabilizing said fibrous batt formed therefrom; and
providing a first outer backing sheet and a second moisture-pervious facing sheet on respective opposite sides of said fibrous batt in superposed relation therewith.
1 Assignment
0 Petitions
Accused Products
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.
264 Citations
26 Claims
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1. A method of manufacturing a disposable diaper, comprising the steps of:
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forming first and second fibrous webs of highly porous cellulosic fibrous material; depositing a quantity of highly liquid-sorbent superabsorbent material on said second fibrous web on at least a medial section thereof to provide a plurality of spaced apart discrete regions of superabsorbent material; positioning facing surfaces of said first and second fibrous webs in superposed relation to define a web interface therebetween at which said discrete regions of superabsorbent material are provided to thereby form a fibrous batt having a medial section corresponding to the medial section of said second fibrous web; joining said first and second fibrous webs to each other, including forming a plurality of densified compacted wicking embossments between and adjacent to, but spaced from, said discrete regions of superabsorbent material to promote wicking of liquid, said joining step being performed so that said densified embossments comprise integrated fibrous material of said first and second fibrous webs for joining said webs to each other to integrate said fibrous webs for stabilizing said fibrous batt formed therefrom; and providing a first outer backing sheet and a second moisture-pervious facing sheet on respective opposite sides of said fibrous batt in superposed relation therewith. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of forming an absorbent unit for use in an absorbent article, comprising the steps of:
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forming first and second fibrous webs of highly porous cellulosic fibrous material; depositing a quantity of highly liquid-sorbent superabsorbent material on said second fibrous web on at least a medial section thereof to provide a plurality of spaced apart discrete regions of superabsorbent material and to define relatively superabsorbent-free areas; positioning facing surfaces of said first and second fibrous webs in superposed relation to define a web interface therebetween at which said discrete regions of superabsorbent material are provided to thereby form a fibrous batt having a medial section corresponding to the medial section of said second fibrous web; joining said first and second fibrous webs to each other, including forming relatively densified, liquid-wicking embossments in said first and second fibrous webs at said superabsorbent-free areas adjacent said discrete superabsorbent regions to promote wicking of liquid along the relatively densified embossments; and providing at least one of said first and second fibrous webs with an integrated, relatively densified paper-like liquid wicking layer at the surface thereof at said web interface, said providing step being performed so that the embossments on said at least one fibrous web are joined to said wicking layer for further promoting wicking of liquid along the relatively densified wicking layer, 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. - View Dependent Claims (11, 12, 13, 14, 15)
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16. A method of forming an absorbent unit for use in an absorbent article, comprising the steps of:
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forming first and second fibrous webs of highly porous cellulosic fibrous material; depositing a quantity of highly liquid-sorbent superabsorbent material on said second fibrous web on at least a medial section thereof to provide a plurality of spaced apart discrete regions of superabsorbent material and to define relatively superabsorbent-free areas; positioning facing surfaces of said first and second fibrous webs in superposed relation to define a web interface therebetween at which said discrete regions of superabsorbent material are provided to thereby form a fibrous batt having a medial section corresponding to the medial section of said second fibrous web; and joining said first and second fibrous webs to each other, including forming relatively densified liquid-wicking embossments in said first and second fibrous webs at said superabsorbent-free areas adjacent to but spaced from said discrete superabsorbent regions to promote wicking of liquid, said joining step being performed so that said densified embossments comprise integrated fibrous material of said first and second webs for joining said webs to each other for integrating and stabilizing said absorbent unit. - View Dependent Claims (17, 18, 19, 20)
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21. A method of forming an absorbent unit for use in an absorbent article, comprising the steps of:
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forming first and second fibrous webs of highly porous cellulosic fibrous material; depositing a quantity of highly liquid-sorbent superabsorbent material on said second fibrous web on at least a medial section thereof to provide a plurality of spaced apart discrete regions of superabsorbent material; positioning facing surfaces of said first and second fibrous webs in superposed relation to define a web interface therebetween at which said discrete regions of superabsorbent material are provided to thereby form a fibrous batt having a medial section corresponding to the medial section of said second fibrous web; joining said first and second fibrous webs to each other; and providing at least one of said first and second fibrous webs with an integrally formed, relatively densified, paper-like wicking layer at the surface thereof at said web interface for promoting wicking and transport of liquid along said relatively densified wicking layer from a region of introduction of liquid 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. - View Dependent Claims (22, 23, 24, 25, 26)
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Specification