US4960477A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Disposable diaper with folded absorbent batt
Assignee: Kenvue Brands LLC
•
Filing: 1989-01-24
•
Granted: 1990-10-02
•
Expires: 2009-01-24
Abstract
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.
Inventors
- 👤 Frederick K. Mesek
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 20:25
CPC Classifications
A; A61; A61F; A61F13/00; A61F13/15; A61F13/53; A61F13/531; A61F13/532; A61F13/5323; A61F13/15577; A61F13/15617; A61F13/15634; A61F13/534; A61F13/53409; A61F13/53427; A61F13/537; A61F13/53708; A61F2013/530481; A61F2013/53051; A61F2013/530547; A61F2013/530562; A61F2013/53765; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1007; Y10T156/1023; Y10T156/1039; Y10T156/1041
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
206 words
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.
Claim 2
Independent Claim
206 words
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.
Claim 3
Dependent Claim
32 words
A method of manufacturing a disposable diaper as set forth in claim 1, including providing a densified compacted wicking layer integrated with at least one o: said first and second fibrous webs.
Claim 4
Dependent Claim
28 words
A method of manufacturing a disposable diaper as set forth in claim 2, including providing said densified compacted wicking layer at said web interface of said fibrous batt.
Claim 5
Dependent Claim
53 words
A method of manufacturing a disposable diaper as set forth in claim 1, including cutting said fibrous batt to form a pair of flap sections at respective opposite sides of said medial section of said batt, and folding said flap sections at respective fold lines into overlapping relationship with said medial batt section.
Claim 6
Dependent Claim
32 words
A method of manufacturing a disposable diaper as set forth in claim 4, including providing a densified compacted wicking layer integrated with at least one of said first and second fibrous webs.
Claim 7
Dependent Claim
23 words
A method of manufacturing a disposable diaper as set forth in claim 5, including providing said densified wicking layer at said web interface.
Claim 8
Dependent Claim
45 words
A method of manufacturing a disposable diaper as set forth in claim 3, including providing said densified wicking layer on said first upper web at said web interface, and providing another densified compacted wicking layer on the opposite outer surface of said first upper web.
Claim 9
Dependent Claim
68 words
A method of manufacturing a disposable diaper as set forth in claim 1, including depositing said superabsorbent material on said second fibrous web to provide a plurality of said discrete regions extending longitudinally of said fibrous batt in spaced apart parallel relation, and forming said densified compacted wicking embossments in longitudinally extending spaced apart parallel relation on respective opposite sides of each said discrete region of superabsorbent material.
Claim 10
Dependent Claim
63 words
A method of manufacturing a disposable diaper as set forth in claim 4, including forming a plurality of said diapers in continuous end-to-end relation, and severing said diapers from each other, including advancing said continuous plurality of diapers with tensioning pull roller means configured to avoid compaction of said fold lines of said flap sections of the fibrous batt of each said diaper.
Claim 11
Independent Claim
247 words
A method of forming an absorbent unit for use in an absorbent article, 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 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.
Claim 12
Independent Claim
247 words
A method of forming an absorbent unit for use in an absorbent article, 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 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.
Claim 13
Dependent Claim
33 words
A method of forming an absorbent unit in accordance with claim 10, including providing each of said first and second fibrous webs with an integrated, relatively-densified paper-like wicking layer at said web interface.
Claim 14
Dependent Claim
28 words
A method of forming an absorbent unit in accordance with claim 10, including forming said relatively densified, liquid-wicking embossments to bound each said discrete region of superabsorbent material.
Claim 15
Dependent Claim
47 words
A method of forming an absorbent unit in accordance with claim 10, including providing said densified wicking layer on said first upper web at said web interface, and forming said batt with another paper-like, densified fibrous wicking layer at the upper surface of said first upper web.
Claim 16
Dependent Claim
61 words
A method of forming an absorbent unit in accordance with claim 10, including depositing said superabsorbent material to form said discrete regions to extend longitudinally of said fibrous batt, and forming said liquid-wicking embossments to extend longitudinally of said fibrous batt in spaced parallel relation to each other between and on respective opposite sides of said discrete regions of superabsorbent material.
Claim 17
Dependent Claim
42 words
A method of forming an absorbent unit in accordance with claim 14, including 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 to form a disposable diaper.
Claim 18
Independent Claim
192 words
A method of forming an absorbent unit for use in an absorbent article, 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 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.
Claim 19
Independent Claim
192 words
A method of forming an absorbent unit for use in an absorbent article, 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 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.
Claim 20
Dependent Claim
40 words
A method of forming an absorbent unit in accordance with claim 16, including forming at least one of said first and second webs with an integrally formed, paper-like, densified compacted cellulosic fibrous wicking layer to further promote wicking of liquid.
Claim 21
Dependent Claim
61 words
A method of forming an absorbent unit in accordance with claim 17, including depositing said superabsorbent material to form said discrete regions to extend longitudinally of said fibrous batt, and forming said liquid-wicking embossments to extend longitudinally of said fibrous batt in spaced parallel relation to each other between and on respective opposite sides of said discrete regions of superabsorbent material.
Claim 22
Dependent Claim
28 words
A method of forming an absorbent unit in accordance with claim 16, including forming said relatively densified, liquid-wicking embossments to bound each said discrete region of superabsorbent material.
Claim 23
Dependent Claim
42 words
A method of forming an absorbent unit in accordance with claim 16, including 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 to form a disposable diaper.
Claim 24
Independent Claim
199 words
A method of forming an absorbent unit for use in an absorbent article, 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; 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.
Claim 25
Independent Claim
199 words
A method of forming an absorbent unit for use in an absorbent article, 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; 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.
Claim 26
Dependent Claim
29 words
A method of forming an absorbent unit in accordance with claim 21, including depositing said superabsorbent material to form said discrete regions to extend longitudinally of said fibrous batt.
Claim 27
Dependent Claim
38 words
A method of forming an absorbent unit in accordance with claim 21, including forming relatively densified, liquid-wicking embossments in said first and second webs so that said discrete regions of superabsorbent material are bonded by said liquid-wicking embossments.
Claim 28
Dependent Claim
38 words
A method of forming an absorbent unit in accordance with claim 21, including providing each said first and second fibrous webs with an integrally formed, relatively densified, paper-like wicking layer at the surface thereof at said web interface.
Claim 29
Dependent Claim
42 words
A method of forming an absorbent unit in accordance with claim 21, including 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 to form a disposable diaper.
Claim 30
Dependent Claim
28 words
A method of forming an absorbent unit in accordance with claim 25, wherein said first outer backing sheet is provided in the form of a moisture-impervious backing sheet.
References Cited (Backward Citations)
DE489308C
Cited
US2644454A
Cited
US3017304A
Cited
US3381688A
Cited
US3344789A
Cited
US3670731A
Cited
US3612055A
Cited
US3768480A
Cited
US3938522A
Cited
US3903889A
Cited
US3888257A
Cited
US4102340A
Cited
US4105033A
Cited
US3965904A
Cited
US4232674A
Cited
US4055184A
Cited
US4186165A
Cited
US4145464A
Cited
US4079739A
Cited
FR2402594A1
Cited
US4251643A
Cited
US4269188A
Cited
US4381783A
Cited
US4327728A
Cited
WO1980001455A1
Cited
US4364992A
Cited
US4425127A
Cited
US4333463A
Cited
US4410324A
Cited
US4381782A
Cited
US4372312A
Cited
US4389211A
Cited
US4461621A
Cited
US4411660A
Cited
US4518451A
Cited
US4519800A
Cited
US4576596A
Cited
US4500316A
Cited
JPH047113A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-10-01 | 1994-04-02 | 1994-10-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-10-01 | 1998-04-02 | 1998-10-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-10-01 | 2002-04-02 | 2002-10-02 | $7700.00 | Window Closed / Lapsed |