Absorbent pad structure, diaper construction utilizing same and methods of manufacture thereof

Claim 1

Absorbent pad structure combining high wicking and moisture transport capability with high liquid absorptive capacity to provide high surface dryness impression and high softness impression comprising, in combination, an air laid pad of generally uniform weight basis consisting essentially of disintegrated cellulose pUlp lap contained within a paper tissue envelope defining therewith means for providing structural integrity thereto, together with means for providing regions having high liquid absorptive capacity spaced apart throughout the pad, and means for providing enhanced capillary wicking and thereby providing high liquid transport of absorbed moisture within the pad to portions of the pad remote from the point of moisture application, wherein said means for providing regions of high liquid absorptive capacity comprises a bi-laterally staggered array of spaced apart generally circular tufts formed by undensified regions of relatively low density, and said means for providing enhanced capillary wicking comprises a bi-laterally extending pattern of intersecting non-linear higher density regions densified essentially only by the application of selective pressures thereto surrounding, separating and extending between each of said low density tufts, said non-linear densified high density regions comprising between approximately twenty and fifty percent of the area of said pad to thereby enable said staggered array of spaced apart generally undensified generally circular tufts and said bilaterally extending pattern of intersecting non-linear higher density regions together to define means for providing both high dryness impression and high softness impression without substantial stiffening of the pad.