CA2104959C

CA2104959C - Absorbent product

Info

Publication number: CA2104959C
Application number: CA002104959A
Authority: CA
Inventors: Harry J. Chmielewski; John R. Cook; David G. Unrau; Migaku Suzuki
Original assignee: Paragon Trade Brands LLC
Current assignee: Paragon Trade Brands LLC
Priority date: 1991-02-26
Filing date: 1992-02-26
Publication date: 1998-07-07
Anticipated expiration: 2012-02-26
Also published as: WO1992014430A1; CA2104959A1; US5281207A; MX9200798A

Abstract

An absorbent product, for use in absorbent articles, comprising an absorbent layer (32) and a wicking layer (34) of densified hydrophilic material. The absorbent layer comprises resilient hydrophilic fibers (36) and superabsorbent material (38). The absorbent layer includes at least one area comprising a bulky fibrous structure having high void regions (40) of low fiber density randomly distributed in the structure.

Description

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ABSORBENT PRODUCT

FIELD OF THE INVENTION
S The ~leSelll invention relates to a new and i~llpl~ved absorbent product co.... .......... .........~ E hydrophilic fibers and superabsorbent material, and more particularly, to an absorbent product having a bulky fibrous structure wherein the fibers are loosely entangled, with high void regions of low fiber density distributed in the bulky structure.
BACKGROUND OF THE INVENTION
Disposable absorbent products have been known for some time, including such products as disposable diapers, sanitary napkins, wound dressings, bandages, incontinent pads, and the like. Such products generally incorporate absorbent structures cont~ining superabsorbent material which absorbs and retains even under loads large quantities of liquids. In order for superabsorbent material to function, the liquid being absorbed in the absorbent structure must be transported to the superabsorbent material. In other words, the superabsorbent material must be placed in a position to be contacted by liquid.
Furthermore, as the superabsorbent material absorbs the liquid, it must be allowed to swell. If the superabsorbent material is prevented from swelling, it will cease absorbing liquids. Hence if the superabsorbent material is to function in diapers and sanitary napkins wherein the liquid to be absorbed is placed in a small void area, the structure of the absorbent layer containing superabsorbent materials, generally co~ ised of a mixture of hydrophilic fibers and superabsorbent materials, appears to be critical.
'' Over the years a number of techniques have been disclosed in an attempt to provide absorbent structures which make efficient use of the superabsorbent material. U.S. Patent Number 4,673,402 to Weisman et al.
30 discloses a dual-layer absorbent core wherein an absorbent acquisition layer ove~l~y~ a lower fluid storage area which is preferably placed in the front two-~ 1 ~D 4 ~ 5 2 thirds section of the absorbent core. U.S. Patent Number 4,834,735 to Alemany et al. ~ clnses an absorbent member wherein there is formed a liquid acquisitionzone having a relatively low concentration of superabsorbent material in the front area of typical liquid deposition. U.S. Patent Number 4,699,823 discloses an absorbent layer wherein superabsorbent particles are disposed to form a substantially con~ uous, non-sle~wi~e, positive concentration gradient of superabsorbent in a thickness direction of the layer. The aforementioned prior art has been directed toward forming a concentration gradient of superabsorbent within the absorbent structures to improve a liquid diffusion process in the absorbent structures while reducing possibilities for gel blocking to take place.
The gel blocking occurs when superabsorbent particles are sufficiently close together that as they swell a layer of gel is formed and additional liquid can not penetrate that layer. These approaches are however not very effective in it.lpl~vi"g rewet properties of the absorbent structure. The term rewet describes a phPn~mennn that occurs when some ~les~ule is exerted onto an absorbent layer, liquids absorbed in that layer flow or strike back to and rewet the top surface of the layer.
U.S. Patent Numbers 4,608,292 and 4,701,237 to Lassen disclose an absorbent web wherein apertures are formed within the web to increase the available area for liquid absorption by superabsorbent. ~nother example of such an approach is disclosed in U.S. Patent Number 4,676,784 to Erdman et al.
Although the apertures are effective in that they provide passages for liquids to go through, they also permit liquids to strike back to a top surface of the structure, which produce a poor rewet property.
SUMMARY OF THE INVENTION
The present invention provides a new and improved absorbent r product which pos~çsses good strike-through or high liquid acquisition rate and rewet properties.
The absorbent product in accordance with the present invention comprises an absorbent layer and a densified hydrophilic material layer. The WO 92/14430 Pcr/US92/01544 ~ 2 ~

absorbent layer comprises from about 10 to about 80% by weight of hydrophilic resilient fibers and from 20 to about 90% by weight of superabsorbent material.
The absorbent layer includes at least one area co~ g a bulky fibrous structure having high void regions of low fiber density. The high void regions are 5 randomly distributed in the bulky fibrous structure. The superabsorbent material is ~rerel~bly disposed within a lower portion of the absorbent layer to provide the area with a bulky fibrous top layer where substantially less superabsorbent material exists. The densified hydrophilic material or wicking layer is formed of suitable hydrophilic material such as wood or synthetic pulp fibers.
The bulky fibrous structure with a plurality of high void regions of lower fiber density provides good strike-through and rewet properties. The tlçn~ified hydrophilic material enhances a planar liquid transport within the absorbent product.

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of a disposable diaper in the unfolded condition showing the top side thereof.
Figure 2 is a cross-sectional view taken along lines 2-2 of Figure 1.
Figure 3 is an enlarged cross-sectional view of the absorbent product 20 in accordance with the principles of the present invention.
Figure 4 is a plan view of an absorbent layer formed from a resilient fibrous web cont~ining superabsorbent material before stretching.
Figure S is a plan view of the absorbent layer of Fig. 4 after stretching the resilient fibrous web containing superabsorbent material after 25 stretching.
Figure 6 is a cross-sectional view of another configuration of an absorbent product for use in disposable diaper in accordance with the present mventlon.
Figure 7 is a photograph which shows the dirrelellce in bulk 30 between-stretched and unstretched web portions.

.

sQ~ 4 Figure 8 is a schem~tir plan view which shows one process embo~liment for manufacturing the absorbent product in accoldance with the present invention.
Figure 9 is a schematic elevated view which shows another process S embo-liment for manufacturing the absorbent product in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The absorbent product of the present invention will be described herein in relation to its use for disposable absorbent articles. As used in the present disclosure, the term disposable absorbent article is intended to refer to an article that is worn by an individual for absorbing and conlail,illg urine and/or fecal matter. A ~lerelled embodiment of a disposable absorbent article, a disposable diaper, is shown in Figure 1. It is to be understood that disposable diapers may be ap~lo~liately sized for use by infants or babies, and can furtherbe sized for use by incontinent adults. It will be further understood that the present invention is also applicable to other disposable absorbent articles such as sanitary napkins, tampons, incontinent pads, wound dre~ing~, absorbent wipes, and the like.
Referring to the drawings, there is illustrated in Figures 1-3 an exemplary disposable diaper 10 embodying an absorbent product in accordance with the principles of the present invention. Diaper 10 includes a facing or topsheet 12 formed of liquid pervious material, with the facing sheet being adaptedfor positioning adjacent to the wearer of the diaper. The diaper further includes an absorbent product 14, which in the illustrated embodiment, is generally rectangular, but which may be otherwise shaped, such as hourglass-shaped, T-shaped, I-shaped, or otherwise conlouled.
Disposable diaper 10 further includes a backsheet 16 positioned on the side of the absorbent product 14 which is opposite the facing sheet 12. The backsheet ~pically co~ ises a liquid-impervious material, such as plastic film or sheet. Diaper 10 may be provided with a double standing gather 18 consi~ling ~ 2104gS~

of an inner gather 20 and an outer gather 22. Double st~n~ling gather 18 is ~lere,~bly formed at the leg openings from a sheet of non-woven hydrophobic material 24 that is sub~lalllially impermeable to liquid while having vapor permeability characteristics, e.g. a fibrous non-woven fabric treated with silicone 5 resin. Inner gather 20 is ~lerelably elasticized by a monofilament rubber element 26 extending the length thereof and outer gather 22 is ~rer~ bly elasticized by a plurality of monofilament rubber elements 26 extending the length thereof.
Sheet 24 is ~rerelably glued to backsheet 16 by lines of hot melt adhesive.
As will be recognized by those f~mili~r with the art, several dirrel ellt 10 types of facing materials may be used for topsheet 12. For example, these sheets may colllplise a non-woven web made of a mixture of fibers consisting predominantly of inexpensive, short, cellulosic fibers, such as wood pulp fibers or cotton linters, with the rem~in~ler of the lllixLule being textile length fibers. The non-woven webs may also be formed from polyester, polyethylene, poly~lo~ylene, 15 nylon, rayon, or the like. The facing sheet may be a l~min~te of one or more non-woven fabrics, each having tliffçring physical properties.
~ order to secure the diaper in position, adhesive tape fasteners 28, as are well known in the art, are provided on the rearward portions of the diaper.
Each of these fasteners 28 include a tab-like element having pressure-sensitive 20 adhesive thereon which, when brought into contact with a landing area associated with the forward, outer waist portion of the diaper, secures the diaper in position.
The diaper may also be provided with elasticized waistband 30, as is well known in the art.
Referring to Figure 3, in accordance with a preferred embodiment, 25 absorbent product 14 COlllpliSCS an absorbent layer 32 and a densified hydrophilic layer of fibrous material 34. The absorbent layer 32 coml)lises a resilient bully fibrous structure 36 with superabsorbent material 38 distributed within the fibrous structure. The superabsorbent material 38 is ~lerelably in the form of a plurality of particles or globules of superabsorbent material disposed in a random and 30 intermittent arrangement throughout the fibrous structure. The particles or globules are of a size and spacing so that they do not interfere with the ~ZVO 92/14430 PCI'/US92/01544 ~Q~$~9 absorption of liquid by adjacent particles upon expansion of the resilient fibrous structure.
The bulky fibrous structure 36 is preferably formed from resilient synthetic staple fibers, such as polyethylene, poly~lo~ylene, polyester, nylon, 5 bicomponent fibers, and the like. Meltblown fibrous webs are also suitable. The fibrous structure includes a plurality of high void regions 40 of low fiber density randomly distributed in the structure. Notably, this structure combined with superabsorbent material has been found to provide good strike-through and rewet properties in that the bulk combined with high void regions of the fibrous 10 structure effectively and rapidly acquires li~uids and temporarily holds the liquid and effectively prevents liquid under pressure from going back to a top surface of the fibrous structure. The fibrous web, before combination with superabsorbent material, generally has a basis weight less than about 3 oz./sq. yd.
and ~lefel~bly about 1.5 oz./sq. yd.
The term high void regions of low fiber density, as used herein, is intended to refer to a fibrous region with undefined boundary where subst~nti~lly less resilient fibers exist as part of the bulky fibrous structure.
The provision of high void regions of low fiber density is prerelably accomplished by ~Llelcllillg a stretchable resilient fibrous web. By stretching, fiber 20 entanglements or fiber bondings in random locations of the web are loosened or broken to form less dense fiber areas in the web. When released from stretching forces, the web springs back to some degree due to its resilience with the result that it gains bulk and some fibers are repositioned in the less dense fiber areas to form high void regions of low fiber density in the bulky fibrous structure. The 25 superabsorbent material 38 may be thereafter combined with the fibrous structure 36 in any number of ways. However, the most efficient way may be to provide a resilient fibrous web with superabsorbent material incorporated therein followed by stretching and releasing of the web. Generally, the resilient fibers are carded or air-laid to form a parallel, cross-parallel, or random web which, if 30 needed, is then stabilized. Stabilization may be achieved by heat-through bonding, adhesive bon~ling, heat embossing, and the like. The stabilizing process WO 92/14430 PCI/US92/01~44 ~ s~

is selected accordillg to the fibers used and the process used to form the web.
Other suitable procedures for forming a web include wet-laying, spun-bonding, melt-blowing, and other known techniques.
The superabsorbent material is combined with the resilient fibrous Layer 32 in an amount from about 20% to about 90% by weight based on the combined weight of fibers and superabsorbent by means suitable to distribute thesuperabsorbent materials therein trying to ~ interference by adjacent superabsorbent materials upon swelling. If the superabsorbent material is a powder, it may be sprinkled onto the fibrous web either in dry form or the web may be moistened. If the superabsorbent material is in granular form, it may be desirable to slightly moisten the superabsorbent material before placing it in contact with the web. The superabsorbent material will contain particles which range in size from about 0.005 mm in diameter to globules that are continuous along fibers for a distance up to several inches.
Another method of placing the superabsorbent material in the web is s~l~yillg a monomer solution on the web or saturating the web with a monomer solution followed by polymerization of the monomer. One typical way to polymerize the monomer is by use of irradiation. It is desirable to place thesuperabsorbent material somewhat evenly throughout the fibrous web. However, even if the superabsorbent material is powder-like and in the form of a layer, it tends to function better than such a layer has in previously known products. It may be desirable to place more superabsorbent material in one area than in another and/or to place the superabsorbent material in the structure in predetellllilled patterns. Any superabsorbent material which absorbs large amounts of liquids is suitable for use in the absorbent layer of the present invention.
In accordance with a most preferred embodiment of the invention, droplets of the superabsorbent material are dispersed within the web by movinn the web through a droplet-flicking zone and flicking droplets of the super-30 absorbent material, in a liquid carrier, onto one side or opposite sides of the web as the web is moved through the droplet-flicking zone. On either side of the ~ -8- 2~ ~4959 fibrous web, a rotating brush has bristles, picking up the material, in the liquid carrier, and flicking droplets thereof as the brush rotates. The superabsorbent material is polymerized and cross-linked in situ.
The superabsorbent m~t-?ri~l present in an i~ y dispersed form 5 in the resilient fibrous web is generally a water-insoluble but water-swellable polymeric substance capable of absorbing water in an amount which is at least 10times the weight of the substance in its dry form. The superabsorbent m~t~ri~l iS in the form of particles which may be in shape of fibers, spheres, bits of film, globules, or the like.
In one type of superabsorbent material, the particles or fibers may be described chemically as having a backbone of natural or ~ylllheLic polymers withhydrophilic groups or polymers cont~inin~ hydrophilic groups being chemically bonded to the backbone or an intim~te a-1mixtllre therewith. Included in this class of lmaterials are such modified natural and regenerated polymers as polysacch~ri~les 15 including, for example, cellulose and starch and rege~ ç~l cellulose which are modified being carboxyaLkylated, phosphonoaLkylated, sulphoaLkylated or phosphorylated to render them highly hydrophilic. Such modified polymers may also be crosslinked to improve their water-insolubility.
These same polysacch~ritles may also serve, for example, as the 20 backbone onto which other polymer moieties may be bonded by graft copolymerization techniques. Such grafted polysacch~ritles and their method of m~mlf~ctllre are described in U.S. Pat. No. 4,105,033 to Chatterjee et al. and may be described as polysaccharide chains having grafted thereon a hydrophilic chain. The plcr~rled hydrophilic chains are hydrolyzed polyacrylonitrile chains and copolymers 25 of polyacrylamide and polysodium acrylate.
In addition to modified natural and regenerated polymers, the hydrocolloid particle component may comprise wholly ~ylllh~Lic hydrophilic ~ ~ .
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particles. Fx~mples of those now known in the art are polyacrylonitrile fibers which may be modified by grafting moieties thereon such as polyvinyl alcohol chains, polyvinyl alcohol itself, hydrophilic polyurethane, poly(alkyl phosphonates), partially hydrolyzed polyacrylamides (e.g., poly(N-N-dimethyl 5 acrylamide)), slllfnn~te-l poly~lylelle, or a class of poly(alkylene oxide). These highly hydrophilic synthetic polymers may be modified by other chemical treatments such as cross-linking or hydrolysis. Further examples known in the art are the non-ionic hydrophilic polymers such as polyoxyethylene, polu~ylul u~ylene and llli~lules thereof which have been suitably cross-linked, either chemically or 10 by irradiation. Still another more recent type is a derivative of isobutylene-maleic anhydride copolymer.
IIydlo~uhilic polymers formed from water-soluble acrylate monomers, such as sodium, potassium, ammonium (or combination of cations), acrylate, may be placed on the fibrous web by spraying or otherwise placing a 15 solution thereon followed by polymerization and cross-linking, for example, by irradiation.
In addition, naturally occurring material such as gums, may be used.
For instance, guar gum is suitable.
After application of the superabsorbent material, the resilient 20 fibrous Layer 32 is subjected to stretching at a ~lerelable draw ratio of from about 50% to about 150%. For better bulk recovery after release, the web is preferably stretched in a direction that crosses fiber orientation in the web. The typical stretching direction is the CD (cross direction of other formation direction of web) for a parallel web, the MD (parallel to direction of web formation) for 25 a cross-parallel web and the CD and/or MD for a random web. In a practical stretching operation, a resilient fibrous web containing superabsorbent materialmay be fed in a culllilluous or discrete form to a stretching station where a conventional stretcher stretches the web to a predetermined length.
Notably, this stretching has been found to increase absorbency peL
30 gram of superabsorbent material in the web in that bits of film-like particles are Wo 92/14430 Pcr/US92/01544 9 ~

broken into smaller particles and more suitable spacing between adjacent particles can be obtained.
Furthermore, by stretching a selected area of the web, the final structure can be formed to COlll~lisc a relatively lower density area which S colles~onds to the stretched area and a relatively higher density area which corresponds to the ullsLletclled area. This selective arrangement of density gradient within the structure is very effective in deeigning absorbent products for use in disposable absorbent articles.
Recovery of the web in length has been found to be dependent on 10 the basis weights of the web and superabsorbent material, the hy~lelesis characteristics of the web, the draw ratio, and the like. Accoldingly, it is necess~ry to select an a~lopliate combination of the material properties and process parameters to delelmine a target length to be desired for the final bulky fibrous structure 36.
The ~leneified hydrophilic material or wicking layer 34 is colll~ ed of hydrophilic fibers, such as rayon fibers, cellulosic fibers, peat moss, acrylic fibers, synthetic pulp fibers, meltblown fibers treated to be hydrophilic, or i~Luies thereof. The cellulosic fibers include tissue, wood pulp fibers, cotton linters, and the like. The wood pulp fibers generally are those that are used to20 form the fluff or fibrous batt layer in conventional absorbent products such as disposable diapers, sanitary napkins, etc. Other cellulosic fibers that might beused are rayon fibers, flax, hemp, jute, ramie, cotton and the like. The fibers or peat moss or llli~lules thereof are placed in such a way as to form a layer in which the particles are close to one another so as to provide a higher capillary25 pleS:iUle to promote wicking of liquid in the plane of the layer. The wicking layer 34 can be ~rerolllled and placed next to the absorbent layer 32 or the wicking layer particles can be air-laid, mechanically entangled therewith, or wet-laid onto the absorbent layer. The wicking layer 34 may desirably be lightly-compressed against at least the sllelclled area of the absorbent layer 32 in order to effect 30 stabilization thereof. In some cases, they may be lightly-colll~lessed in thepresence of moisture to form a composite so as to provide higher stabilization of ~ 210~3~

the layer 34. The wicking layer 34 is pler~l~bly positioned substantially coextensive with at least the expansive surface of the stretched area of the absorbent layer 32 and has a total basis weight of from about 3 oz./sq. yd. to about 17 oz./sq. yd., more prefel ~bly from about 4 oz./sq. yd. to about 5 10 oz./sq. yd.
Figures 4 and 5 show another configuration of the absorbent layer 32 of the present invention for use in a disposable diaper. The resilient fibrous web 50 with superabsorbent material distributed in its bottom side is clamped atits one transverse end section 51 and center transverse section 52 to be stretched 10 in an arrow direction at a draw ratio of more than 100%. After release of tension, the semi-hourglass shaped web is formed which includes about front one third section of higher density 53 and about rear two thirds section of~=lower de~4 which co l~liSCS a bulky fibrous structure with high void regions of low fiber density. Application of a wicking layer 34 to this absorbent layer 32 yields 15 the absorbent product 14 suitable for use in disposable diaper, as shown in Figure 6. The front and rear end sections of higher density have been found to functionin protecting liquid leakage thelelhrough by gel-blocking after full absorption of liquid. Figure 7 is a photograph which shows a bulk gain of the stretched portion of the web on its right side. The unsllelclled portion is shown on its left side.
20 For this specific embodiment, the stretched portion has been observed to gain a bulk increase of 56% against 23% decrease in a basis weight over the unstretchedportion. Accordingly, about 20% increase in thickness has been observed.
It has been found that at least 15% improvement in rewet values and at least 5% improvement in strike-through values over the initial unstretched 25 substrate can be achieved by stretching it by about 100%.
Figures 8 and 9 show typical schematic process flows for manufacturing the absorbent product for use in an absorbent diaper in accordance with the present invention.
In Figure 8, a resilient fibrous parallel web 60 containing 30 superabsorbent material on its top side is continuously fed to a stretching station 61 such as a pin tender where the fibrous web 60 is CD-stretched to a ~ -12~ 959 predetermined length. Here, the stretched area of the web can lbe selectively adjusted by ch~ngin~ positions of clamping or gripper means that grasp the web for stretching.
The web 60 exiting from the stretching station 61 passes a tension-release zone 62 where it gains some bulk recovery and formation of randomly-distributed high void 5 regions of low fiber density. A pulp fiber applicator 63 casts pulp fibers onto a top surface of the ~lbrous web 60 so that a wicking layer may be added to the bulky fibrous structure layer. The two layers are lightly-colllyl~ssed by a nip roll 64 for combination and then cut into individual absorbent product pieces 65 by a cutter roll 66. A moi~l~u~er may be inserted between the stretching station 61 and the nip roll 10 64, if n~e~le-l, to cause the softened surface of the superabsorbent m~teri~l to provide the adhesion to the wicking layer thereby dimensionally-stabilizing the untentioned web. The individual piece 65 is next carried to a diaper assembly station where it is incorporated between a liquid-permeable topsheet and a liquid-impermeable bac~h~et so as for the wicking layer to face the backsheet.
In FIG. 9, the resilient fibrous parallel web 70 cont~ining superabsorbent material on its one side is continuously fed by a driven feed roll 71 onto a vacuum roll 72 where the web 70 is transversely cut into individual pieces 73 of a predetermined width by a knife roll 74. The individual piece 73 is picked up by a pair of spaced apart lldl~rel wheel assemblies 75, 76 from the vacuum roll 72.20 These wheels are placed inclined to each other so that the (1i~t~nre between them is greatest at the pick-up point and least at the release point. The individual piece 73 is held by each Lldl~reL wheel from the pick-up point to the release point during about 180 degrees rotation of the wheels to be CD-stretched to a predeLe~ ed length. The stretched individual piece 73 is then passed the release zone to the pulp fiber 25 applicator as described with l~rer~llce to FIG. 8. It will be readily understood that the stretch area of the fibrous web can be readily controlled by adjusting the angle of inclination of the two Lldl~rel wheels and/or the ~ t~nre between the two wheels.

C

Claims

What is claimed is:

1. An absorbent product comprising an absorbent layer having upper and lower sides and comprising from about 10% to about 80% by weight of hydrophilic resilient fibers and from about 20% to about 90% by weight of superabsorbent material, said absorbent layer including at least one area comprising a prestretched bulky fibrous structure having high void regions of lower fiber density than an unstretched region randomly distributed therein;
said high void regions of lower fiber density formed from stretching of the fibrous structure which results in resilient fiber breakage and loosening, thereby forming less dense fiber areas in the absorbent layer; and a densified hydrophilic material placed adjacent to and at least coextensive with said at least one area of the absorbent layer to promote planar liquid transport within said absorbent layer.

2. The absorbent product as defined in claim 1 wherein said superabsorbent material is primarily disposed in the lower side of said absorbent layer.

3. The absorbent product as defined in claim 1 or 2 wherein said at least one area of said absorbent layer has a concentration of superabsorbent material equal to or lower than an average superabsorbent material concentration of said absorbent layer.

4. The absorbent product of claim 1, 2 or 3 wherein said superabsorbent material in said at least one area has an increased absorbency per gram of superabsorbent material as compared to an average absorbency per gram elsewhere in said absorbent layer.

5. The absorbent product as defined in claim 1, 2, 3, or 4 wherein said absorbent layer is a non-woven web.

6. The absorbent product as defined in claim 5 wherein said non-woven web is a polyester web.

7. The absorbent product of claim 5 or 6 wherein said non-woven web has an original size and, said non-woven web is stretched 50% to 150% of its original size at said at least one area.

8. The absorbent product of claim 1, 2, 3, 4, 5, 6, or 7 wherein said densified hydrophilic material is underneath said absorbent layer.

9. A disposable diaper including an absorbent product positioned between a substantially liquid impermeable backsheet and a liquid permeable topsheet, said absorbent product comprising:
an absorbent layer having upper and lower sides and comprising from about 10% to about 80% by weight of hydrophilic resilient fibers and from about 20% to about 90% by weight of superabsorbent material, said absorbent layer including at least one area comprising a prestretched bulky fibrous structure having high void regions of lower fiber density than an unstretched region randomly distributed therein;
said high void regions of lower fiber density formed from stretching of the fibrous structure which results in resilient fiber breakage and loosening, thereby forming less dense fiber areas in the absorbent layer; and a densified hydrophilic material placed adjacent to and at least coextensive with said at least one area of the absorbent layer to promote planar liquid transport within said absorbent layer.

10. The disposable diaper as defined in claim 9 wherein said at least one area is a central section of the absorbent product.

11. The absorbent product of claim 9 or 10 wherein said non-woven web has an original thickness and, said at least one area of said non-woven web has a thickness 20% greater than said original thickness after said stretching.

12. The disposable diaper as defined in claim 9, 10 or 11 wherein said absorbent product is divided into a front section comprising one-third of the absorbent product and a rear section comprising two-thirds of the absorbent product, and said at least one area is primarily located in said rear section.

13. The disposable diaper as defined in claim 9, 10 11 or 12 wherein said at least one area of said absorbent layer has a concentration of superabsorbent material equal to or lower than an average superabsorbent material concentration of said absorbent layer.

14. The disposable diaper of claim 9, 10, 11, 12 or 13 wherein said superabsorbent material in said at least one area has an increased absorbency per gram of superabsorbent material as compared to an average absorbency per gram elsewhere in said absorbent layer.

15. The disposable diaper as defined in claim 9, 10, 11, 12, 13 or 14 wherein said superabsorbent material is primarily disposed in the lower side of said absorbent layer.

16. The disposable diaper of claim 9, 10, 11, 12, 13, 14 or 15 wherein said absorbent layer is a non-woven web.

17. The disposable diaper of claim 16 wherein said non-woven web is a polyester web.

18. The disposable diaper of claim 16 or 17 wherein said non-woven web is stretched at a draw ratio of about 50% to 150% at said at least one area.

19. The absorbent product of claim 16, 17, or 18 wherein said non-woven web has an original thickness, and said at least one area of said non-woven web has a thickness 20% greater than said original thickness after said stretching.

20. An absorbent product comprising an absorbent layer having upper and lower sides and comprising from about 10% to about 80% by weight of hydrophilic resilient fibers and from about 20% to about 90% by weight of superabsorbent material, said absorbent layer including at least one area comprising a prestretched bulky fibrous structure having high void regions of lower fiber density than an unstretched region randomly distributed therein;
said high void regions of lower fiber density formed from stretching of the fibrous structure which results in resilient fiber breakage and loosening, thereby forming less dense fiber area in the absorbent layer.

21. The absorbent layer of claim 20 wherein said superabsorbent material is primarily disposed on one side of said layer.

22. The absorbent layer of claim 20 or 21 wherein said at least one area of said absorbent layer has a concentration of superabsorbent material equal to or lower than an average superabsorbent material concentration of said absorbentlayer.

23. The absorbent layer of claim 20, 21 or 22 wherein said absorbent layer is a non-woven web.

24. The absorbent layer of claim 23 wherein said non-woven web is a polyester web.

25. The absorbent layer of claim 23 of 24 wherein said non-woven web is stretched at a draw ratio of about 50% to about 150% at said at least one area.

26. The absorbent layer as defined in claim 23, 24 or 25 wherein said non-woven web has an original thickness, and said at least one area of said non-woven web has a thickness 20% greater than said original thickness after said stretching.