Disposable diaper with folded absorbent batt

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.

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.

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.

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.

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.

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.

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.

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.