Prefolded and sewn diaper and fabric therefor having improved wear-resistance and moisture-holding characteristics

Claim 1

A woven prefolded and sewn diaper having a multilayer center panel and side panels on each side thereof and being formed from an unfolded diaper blank comprising two plies of material superimposed on each other and extending throughout the length and width of said diaper blank and having opposed selvage edges joining said plies together and opposed cut edges, said unfolded diaper blank being characterized by providing increased fabric density and a less open construction than conventional gauze diaper material in a first one of said plies for increased wear resistance and providing less fabric density and a more open construction than conventional gauze diaper material in the second of said plies for increased moisture-holding characteristics while retaining a combined fabric density, weight, warp end count and filling pick count for both said plies within the ranges of conventional gauze diapers, said first ply of material having a warp end count throughout greater than a conventional range of 37-39 for providing the aforesaid characteristics, said second ply of material having a warp end count throughout less than a conventional range of 37-39 for providing the aforesaid characteristics, and said diaper blank being folded in such a manner so that said first ply of material forms the entire outside surface of said prefolded and sewn diaper for combating wear therealong and said second ply of material forms inside layers of said prefolded and sewn diaper for providing greater moisture-holding characteristics internally thereof.