Abstract A disposable multi-layer diaper of high absorptive capacity and improved feel is provided which comprises as a first layer, to be brought into contact with an infant''skin, a porous, fibrous, nonwoven bonded facing web of controlled wettability made of short cellulosic fibers and long fibers at a given overall concentration. The outer face of the facing layer is characterized by a blend of long and short fibers, with the concentration of long fibers being in excess of the overall concentration, while the inner face of the facing layer is also characterized by a blend of long and short fibers, with the concentration of short fibers being in excess of the overall concentration. The outer face of the facing layer has a sufficient amount of long fibers to give the diaper improved feel and wearing characteristics. The concentration of short cellulosic fibers gradually, and preferably substantially uniformly, increases from the outer face to the inner face of the facing layer to provide a gradually increasing degree of wettability for preferentially drawing the urine away from the outer face, through the facing layer and into a second layer, in juxtaposition to the facing layer. The second layer is a highly porous, loosely compacted completely cellulosic batt having greater wettability than that of the facing web. A third layer, integral with the second, is a paper-like, densified, highly compacted layer of the same cellulosic material as the second layer but of substantially smaller average pore size and which is selectively thickened in certain areas. The final layer is an impervious backing sheet adhered to the densified layer over a widely distributed area of adhesion.
A diaper as set forth in claim 1 wherein said staple length fibers are rayon fibers.
Claim 2
Dependent Claim
16 words
A diaper as set forth in claim 1 wherein said staple length fibers are polyester fibers.
Claim 3
Dependent Claim
53 words
A diaper as set forth in claim 1 wherein said staple length fibers are present at an overall concentration from about 10 to about 40 percent by weight and are present at said outer major face in a concentration of from about 5 to 20 percent by weight higher than said overall concentration.
Claim 4
Dependent Claim
183 words
A multi-layer diaper comprising: a porous facing layer in the form of a nonwoven web formed of staple length fibers and short cellulosic fibers at an overall concentration of staple length fibers from about 2 to about 55 percent by weight and an overall concentration of short fibers from about 45 to about 98 percent by weight, said web having an outer major face characterized by a concentration of staple length fibers in excess of said overall concentration and an inner major face characterized by a concentration of short cellulosic fibers in excess of said overall concentration, the intermediate portion of said web between said faces being characterized By a transition whereby the concentration of said staple length fibers gradually decreases from said outer major face to said inner major face and the concentration of said short cellulosic fibers gradually decreases from said inner major face to said outer major face; a highly porous, loosely compacted, cellulosic fibrous batt in face-to-face juxtaposition with the inner face of said facing layer; and a water-impervious backing sheet adhered to the outer surface of said batt.
Claim 5
Dependent Claim
53 words
A diaper as set forth in claim 5 wherein said staple length fibers are present at an overall concentration from about 10 to about 40 percent by weight and are present at said outer major face in a concentration of from about 5 to 20 percent by weight higher than said overall concentration.
Claim 6
Dependent Claim
22 words
A diaper as set forth in claim 6 wherein the transition of each type of fibers between said faces is substantially uniform.
Claim 7
Dependent Claim
16 words
A diaper as set forth in claim 5 wherein said staple length fibers are rayon fibers.
Claim 8
Dependent Claim
16 words
A diaper as set forth in claim 5 wherein said staple length fibers are polyester fibers.
Claim 9
Dependent Claim
210 words
A multi-layer diaper comprising: a porous facing layer in the form of a nonwoven web formed of staple length fibers and short cellulosic fibers at an overall concentration of staple length fibers from about 2 to about 55 percent by weight and an overall concentration of short fibers from about 45 to about 98 percent by weight, said web having an outer major face characterized by a blend of staple length fibers and short cellulosic fibers with the concentration of staple length fibers being in excess of said overall concentration, and said web having an inner major face characterized by a blend of short cellulosic fibers and staple length fibers with the concentration of short cellulosic fibers being in excess of said overall concentration, the intermediate portion of said web between said faces being characterized by a transition whereby the concentration of said staple length fibers gradually decreases from said outer major face to said inner major face and the concentration of said short cellulosic fibers gradually decreases from said inner major face to said outer major face; a highly porous, loosely compacted, cellulosic fibrous batt in face-to-face juxtaposition with the inner face of said facing layer; and a water-impervious backing sheet adhered to the outer surface of said batt.