UNITED STATES PATENT [19] [11] PATENT NUMBER: 5,360,422
BROWNLEE ET AL. [45] DATE OF PATENT: NOV. 1, 1994
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[54] WASHABLE DIAPER WITH LIQUID IMPERVIOUS CHANNEL FOR RETAINING DISPOSABLE
ABSORBENT INSERT
[75] Inventors: James R. Brownlee, West Vancouver; William E. Lasby, White
Rock, both of Canada
[73] Assignee: Caring Products International, Inc. Vancouver, Canada
[21] Appl. No.: 970,880
[22] Filed: Nov. 3, 1992
RELATED U.S. APPLICATION DATA
[63] Continuation-in-part of Ser. No. 944,279, Sep. 14, 1992, which is a
continuation-in-part of Ser. No. 921,579, Jul. 30, 1992, abandoned.
[51] Int. Cl.(5) .................................................... A61F 13/15
[52] U.S. Cl. .............................................. 604/385.2; 604/387;
604/393; 604/397
[58] Field of Search ...................................... 604/385.2; 386-387;
604/393-398, 400
[56] References Cited
U.S. PATENT DOCUMENTS
2,026,158 12/1935 Bennett ....................................... 128/290
2,319,138 5/1943 Kneibler ........................................ 2/234
2,369,773 2/1945 Brenner ......................................... 2/224
2,381,222 8/1945 Stone ........................................... 2/43
2,476,585 7/1949 Cohen ........................................... 2/43
2,522,009 9/1950 Wohlman ...................................... 128/288
2,532,029 11/1950 Medoff ....................................... 604/394
2,556,800 6/1951 Donovan ...................................... 604/394
2,575,163 11/1951 Donovan ...................................... 604/394
2,854,979 10/1958 Turner ....................................... 604/394
2,890,701 6/1959 Weinman ...................................... 604/394
2,893,393 7/1959 Pressley ..................................... 604/394
2,896,627 7/1959 Harwood ...................................... 128/290
2,952,259 9/1960 Burgeni ...................................... 128/290
3,224,448 12/1965 Diebold ...................................... 128/529
3,400,718 9/1968 Saijo ........................................ 604/394
3,800,797 4/1974 Tunc ........................................ 128/290 R
3,886,941 6/1975 Duane et al. .................................. 128/287
4,044,769 8/1977 Papajohn ..................................... 128/288
4,215,692 8/1980 Levesque ...................................... 604/904
4,301,550 11/1981 Carver ......................................... 2/408
4,352,356 10/1982 Tong ......................................... 128/288
4,421,512 12/1983 Papajohn ..................................... 604/396
4,496,359 1/1985 Pigneul ...................................... 604/387
4,579,556 4/1986 McFarland .................................. 604/385.2
4,617,022 10/1986 Pigneul et al. ................................ 604/394
4,619,862 10/1986 Sokolowski et al. ............................. 119/172
4,676,196 6/1987 Lojek et al. .................................. 119/171
4,695,279 8/1987 Steer ........................................ 604/397
4,964,857 10/1990 Osborn ....................................... 604/395
5,019,068 5/1991 Perez et al. .................................. 604/386
5,069,672 12/1991 Wippler et al. ................................ 604/387
5,167,653 12/1992 Igaue et al. ................................ 604/385.2
FOREIGN PATENT DOCUMENTS
292464 8/1929 United Kingdom -
358765 10/1931 United Kingdom -
436869 10/1935 United Kingdom -
855020 11/1960 United Kingdom -
878455 9/1961 United Kingdom -
888827 2/1962 United Kingdom -
1143419 2/1969 United Kingdom -
1178212 1/1970 United Kingdom -
85/03430 8/1985 WIPO
PRIMARY EXAMINER--Randy C. Shay
ATTORNEY, AGENT, OR FIRM--Kenyon & Kenyon
[57] ABSTRACT
The present invention provides a washable diaper having a waterproof interior
channel the walls of which are formed from the leg cuffs, for holding a
removable absorbent insert, whether disposable or re-usable.
23 Claims, 6 Drawing Sheets
[Diagram of the washable diaper]
U.S. PATENT NOV. 1, 1994 SHEET 1 OF 6 5,360,422
[Figure 1 is a perspective view of
the infant diaper of the invention]
U.S. PATENT NOV. 1, 1994 SHEET 2 OF 6 5,360,422
[Figure 2 is a plan view of an absorbent
insert cover of the invention]
[Figure 3 is a perspective view of the
absorbent insert of the invention]
U.S. PATENT NOV. 1, 1994 SHEET 3 OF 6 5,360,422
[Figure 4 is a cross-section taken
along line 4--4 of Figure 1]
[Figure 5 is a cross-section taken
along line 5--5 of Figure 1]
[Figure 6 is a cross-section taken
along line 6--6 of Figure 1]
U.S. PATENT NOV. 1, 1994 SHEET 4 OF 6 5,360,422
[Figure 7 is a partial perspective view
of a preferred construction of the
waterproof channel of the invention
attached to the body of the diaper]
[Figure 8 is a cross-section taken along
line 8--8 of Figure 7, showing a first
embodiment of the means of attachment]
U.S. PATENT NOV. 1, 1994 SHEET 5 OF 6 5,360,422
[Figure 9 is a cross-section taken along
line 8--8 of Figure 7, showing a second
embodiment of the means of attachment]
[Figure 10 is a cross-section taken along
line 8--8 of Figure 7, showing a third
embodiment of the means of attachment]
[Figure 11 is a cross-section taken along
line 8--8 of Figure 7, showing a fourth
embodiment of the means of attachment]
U.S. PATENT NOV. 1, 1994 SHEET 6 OF 6 5,360,422
[Figure 12 is a cross-section taken along
line 8--8 of Figure 7, showing a fifth
embodiment of the means of attachment]
[Figure 13 is a cross-section taken along
line 8--8 of Figure 7, showing a sixth
embodiment of the means of attachment]
1
WASHABLE DIAPER WITH LIQUID
IMPERVIOUS CHANNEL FOR RETAINING
DISPOSABLE ABSORBENT INSERT
CROSS-REFERENCE TO RELATED
APPLICATIONS
This application is a continuation-in-part of copending application Ser.
No. 07/944,279 filed Sep. 14, 1992 entitled COMBINATION WASHABLE DIAPER WITH
DISPOSABLE ABSORBENT INSERT which is in turn a continuation-in-part of
co-pending application Ser. No. 07/921,579 filed Jul. 30, 1992 entitled
ABSORBENT INSERT FOR DIAPERS AND INCONTINENT GARMENTS.
TECHNICAL FIELD
This invention relates to the construction of infant diapers.
BACKGROUND ART
A problem with existing infant diapers is that when disposable diapers
are used, and the diaper is wetted or soiled even slightly, the entire diaper
is discarded at considerable expense and causing considerable waste. Fitted
cloth diapers are less popular than disposable diapers due to their expense
and the time and labour required to wash them, while non-fitted cloth diapers
are difficult to fit to the infant, and also involve considerable labour to
wash them. There is therefore a need for an infant diaper which combines the
convenience of disposable diapers with the economy and environmental benefits
of cloth diapers.
DISCLOSURE OF INVENTION
The present invention therefore provides a washable diaper having a
waterproof interior pocket for holding a removable absorbent insert, whether
disposable or re-usable. The insert may be bio-degradable and/or flushable.
In the preferred form of the invention the waterproof interior channel is
formed as a unitary welded channel having flanges running lengthwise along
either side thereof which can in turn be stitched to the outer fabric shell of
the diaper (or the crotch area of some other type of garment) without reducing
the liquid imperviousness of the channel.
BRIEF DESCRIPTION OF DRAWINGS
In drawings which disclose a preferred embodiment of the invention:
FIG. 1 is a perspective view of the infant diaper of the invention;
FIG. 2 is a plan view of an absorbent insert cover of the invention;
FIG. 3 is a perspective view of the absorbent insert of the invention; and
FIG. 4 is a cross-section taken along line 4--4 of FIG. 1;
FIG. 5 is a cross-section taken along line 5--5 of FIG. 1;
FIG. 6 is a cross-section taken along line 6--6 of FIG. 1;
FIG. 7 is a partial perspective view of a preferred construction of the
waterproof channel of the invention attached to the body of the diaper;
2
FIG. 8 is a cross-section taken along line 8--8 of FIG. 7, showing a first
embodiment of the means of attachment;
FIG. 9 is a cross-section taken along line 8--8 of FIG. 7 showing a second
embodiment of the means of attachment;
FIG. 10 is a cross-section taken along line 8--8 of FIG. 7 showing a third
embodiment of the means of attachment;
FIG. 11 is a cross-section taken along line 8--8 of FIG. 7 showing a
fourth embodiment of the means of attachment;
FIG. 12 is a cross-section taken along line 8--8 of FIG. 7 showing a fifth
embodiment of the means of attachment; and
FIG. 13 is a cross-section taken along line 8--8 of FIG. 7 showing a sixth
embodiment of the means of attachment.
BEST MODE(S) FOR CARRYING OUT THE
INVENTION
FIG. 1 illustrates a novel reusable diaper 10 to be used, in place of
existing disposable or fitted diapers, with a disposable or washable absorbent
insert 80 (FIG. 4). It is constructed of an hour-glass shaped body 12 of a
two-ply tight woven, breathable, water repellant 100% polyester micro-fibre
fabric. The two panels 12', 12" (FIG. 4) are reverse stitched in that the
outer edges are stitched together, and then the entire body is turned inside
out. (In most instances where the term "stitched" is used herein it will be
understood that equivalent processes such as serging, binding, gluing of sonic
welding may also be used.) A top stitch is provided around the edges of rear
end 14. A third waterproof interior ply 16 is provided forming a center
waterproof channel or pocket 8. This third ply is a nylon fabric with a
waterproof coating such as a polyurethane or polyvinyl chloride material and is
connected to the top ply 12' of body 12 by stitching along lines 13, 15,
forming raised waterproof side walls 17, 18 of the same polyurethane or
polyvinyl chloride-coated nylon material. Walls 17, 18 are hemmed along their
upstanding edges 20 with live rubber strips under tension and extending from
edge 24 of panel 22 on the rear of the diaper to the lower edge of similar
panel 22 on the front of the diaper. Edges 20 are stitched to the edges 24 of
panels 22 at points 23 spaced inwardly from lines 13, 15.
The sides of body 12 are elasticized with elastic strips 21 stitched
under tension between the outer and inner plies of material of the body 12 and
stitched along lines 26 spaced inwardly from either leg-contacting edges 28 to
create a soft edge. To provide the desired cupping of the diaper, the elastic
strip along line 26 should also be spaced from the walls 17, 18.
Closure tabs 25 and 27 are provided with patches 29 of the hook portion of
hook-and-loop fasteners which engage strips of the loop portion 71 on the
front face 73 of the diaper. Alternatively, the hook-and-loop fasteners could
be replaced with a double hook-and-eye metal fastener (two hooks and two eyes
would be used, side by side, to prevent rotation of the fastener about the
point of fastening). A metal hook-and-eye fastener has advantages over
hook-and-loop fasteners in terms of durability under exposure to extreme heat
and chemicals such as chlorine.
Elastic strips are stitched under tension between the two plies of body 12
at 75 to permit the tabs to stretch and apply pressure when attached. A third
layer 87 of
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3
stiffening fabric may also be stitched between the two plies of body 12
in the area of tabs 25, 27 and front face 73 to provide a stiffening and
smoother appearance.
For easier cleaning of the garment, as will be described in further
detail below, the panels 22 at either end of the diaper are preferably sewn
through the waterproof layer 16 and the two-ply body 12 along semicircular
lines 77 at both ends. A waterproof channel or pocket 8 is thus formed
along the central axis of the garment with its lower surface formed by
waterproof fabric 16 and bordered at either end by stitch lines 77 and panels
22, and along either side by walls 17, 18.
To use the diaper, an absorbent insert 80 is inserted into pocket 8.
Such insert is sized to fit snugly in pocket 8 and may be a disposable
insert, or it may be a reusable, washable insert. In respect of a
disposable insert 80, such insert may be manufactured from a super-absorbent
polymer, including air-laid thermal-bonded materials of the type available
for adult incontinence pads manufactured by Merfin Hygienic Products Ltd.
The insert may be not only disposable but also flushable and biodegradable.
("Flushable" means the insert disintegrates in water to a particular size
which can be handled by a municipal sewage system.) For example a product
marketed under the trademark PRIMA by Johnson & Johnson Inc. provides a
bio-degradable absorbent pad for sanitary napkins and the like composed
partly of peat moss. In such an application, an unused absorbent insert is
inserted in pocket 8 with its ends under panels 22. The diaper is then
placed on the infant in the usual way. Once the insert has been wetted or
soiled, the insert is removed from the pocket 8 and either flushed down the
toilet or placed in a waste disposal container. If the diaper 10 has been
wetted or soiled it can be rinsed, and periodically will require washing.
Stitching 77 may be used to prevent waste from getting in to square interior
corners which would make cleaning more difficult.
Re-usable inserts may also be used in the invention and FIG. 2
illustrates an absorbent insert cover 30 which may be used to hold the
absorbent insert 80 (whether disposable or washable) for insertion into
pocket 8. The cover 30 is formed of a single piece of waterproof coated
nylon 34, so that it is water impervious. A polyurethane or PVC coated
nylon, washable and resistant to heat, bleach, detergent and ultra-violet
radiation is suitable. It has a front opening 36 to receive and expose the
absorbent insert, for example of the type illustrated as 32. The cover 30
has live (natural) rubber strips approximately 1 cm. in width hemming the
edges 38, 40 of opening 36 which cross over at ends 42, 44 to provide a
flatter profile. The cover is a one-piece construction so that edges 46, 48
are seamless to prevent leaking. Ends 50, 52 are waterproof seams formed by
sonic welding or other waterproof seam means. As optional strip 54 of fast
wicking spun polyester mesh is stitched at either end thereof to the inner
edge (bottom) of rubber hem 38, 40 where they met the nylon backing material
34. Strip 54 does not stretch along its length, but may across its width in
the longitudinal direction of the cover 30. As with the inserts, dimensions
of the cover will vary according to the particular size of diaper.
FIG. 3 illustrates one embodiment of the absorbent reusable insert 32
which may be used alone or in the cover 30. Insert 32 is formed of three
layers 60 of brushed polyester, and two layers 62 of absorbent felt. The
two felt layers 62 are slightly narrower than the
4
polyester layers 60, and are secured to the central polyester layer 61 by
stitching along either longitudinal edge which extends through only felt
layers 62 and layer 61. The three-piece sandwich thus formed is then in turn
contained between layers 63, 65 by stitching which extends only through the
outer edges of layers 61, 63, 65. This creates a softer outer edge of the
insert. Sharp edges are further avoided by staggering the ends of layers 62.
Another form of insert 32 which can be used in the invention is a single
layer of absorbent felt material covered with a non-wicking "stay dry"
material such as polyester. The felt layer may be 100% rayon, a blend of
rayon and polyester, or a microporous acrylic such as that sold under the
trademark SUPERSORB. As an alternative to the felt layer, a multiple layer
of cotton fabric, of a flannelette or bird's eye weave, may be used.
When used in cover 30, insert 32 is inserted to fit smoothly in the
interior of cover 30, and cover 30 is inserted into pocket 8 of the diaper
10 with opening 36 pointing towards the interior of the garment. Due to the
curvature of the garment, the dimensions of edges 38, 40 and the tightening
action of strip 54, the edges 38, 40 are caused to be raised in relation to
insert 30. This causes a damming effect on liquid within cover 30. The
waterproof container formed by cover 30 allows time for the liquid to be
absorbed by the absorbent insert. Squeezing of cover 30 may cause liquid to
exit from insert 32 but it will still be retained in cover 30 and re-absorbed
into the insert when pressure is released. After the insert has been
wetted, the garment is removed, the cover slipped out of the garment, the
cover is rinsed or washed in warm water, the insert is replaced with a clean
insert (or the insert in question is washed), and the cover is replaced in
the garment. The waterproof cover allows the saturated inserts to be
removed with minimum contact of the user's hands.
The cover 30 permits any number of inserts to be inserted into the
cover depending on the user's needs. In each case, the cover is readily
inserted like a cassette, regardless of the number of absorbent inserts.
The low friction coating of the cover makes this insertion easier. Thus by
using the cover 30 of the invention and either a reusable or disposable
insert, soiling of diaper 10 is further reduced and the diaper can be
re-used a number of times without washing. The user simply inserts the
cover with the desired type and number of inserts in the crotch area of the
diaper, opening inwardly, and puts the diaper on the infant in the usual
way. The cover 30 (and insert) need not be hour-glass shaped as shown, but
rather can have straight, parallel sides.
FIG. 7 through 13 illustrate a preferred manner of forming the
waterproof channel and attaching it to the fabric body 12 of the diaper. In
the embodiment shown in FIG 7 and 8, the body 12 is preferably formed again
of a layer 100 of a tight woven, breathable, water repellant 100% polyester
fabric, woven from a micro-fibre or a high multi-filament count polyester
yarn. This provides a soft comfortable finish to the diaper. The center
waterproof channel or pocket 108 is formed again of a nylon fabric 109 with
a waterproof coating such as a polyurethane or polyvinyl chloride material
and is formed with unitary walls 117, 118 by forming flanges 120, 122 and
sonic welding along lines 123, 125 to weld the upper ply of the flange to
the lower ply along the lower edge of the wall. The ends of the channel 108
are folded over to form panel 132 which may be stitched to the underlying
material 109 along semicircular line 133
5,360,422
5
to prevent waste from getting in to square interior corners which would make
cleaning more difficult. Walls 117, 118 are again hemmed along their
upstanding edges 130 with live rubber strips under tension and are connected
to panel 132 at stitches 136 and extend to the lower edge of a similar panel
on the other end of the channel (not shown).
The material 109 can then be connected to the body 100 by stitching through
flanges 120, 122 along lines 127, 129 without the stitches extending through
the central channel 108. In this way the water impervious central channel 108
can be secured to a non-waterproof outer shell by stitching without affecting
the water imperviousness of the central channel.
FIGS. 9 through 13 illustrate other methods of achieving the same
functional result as in FIG. 8. In FIG. 9, a central rectangular channel 139
of liquid impermeable material is welded or glued at seams 140 to two parallel
strips 141, 142 of the same material. The outer edges of strips 141, 142 are
then stitched to the underlying fabric body 100 along lines 148. In FIG. 10,
strips 141, 142 are replaced with a sheet 143 which extends beyond the edges
of the central channel 139. In FIG. 11, the central channel 139 is formed by
welding or gluing two L-shaped walls 144, 145 to sheet 143, with the outer
edges of sheet 143 being stitched to the underlying fabric. In FIG. 12, the
lower horizontal portions of walls 144, 145 extends outwardly to form part of
the outer flanges, so the welding will run along lines 147 and stitching to
the underlying body along 148. Of course if the outer body material 100 is
suitable, the channel 139 may be welded directly to it as in FIG. 13, but
generally it will be preferable to have a soft fabric for outer shell 100
which is not compatible with welding.
Since the waterproof channel in the embodiments shown in FIG. 7-13 forms
an independent element separate from the diaper, it could similarly be
attached to the crotch area of other types of garments to permit insertion of
an absorbent pad, such as underwear, bathing suits and the like.
As will be apparent to those skilled in the art in the light of the
foregoing disclosure, many alterations and modifications are possible in the
practice of this invention without departing from the spirit or scope
thereof. Accordingly, the scope of the invention is to be construed in
accordance with the substance defined by the following claims.
What is claimed is:
1. An incontinence garment comprising a pliant body for removable fitting
to a wearer, said body having an interior and an exterior surface and a front
and back portion and a crotch area, said garment comprising opposed
elastically contractible leg cuffs extending between said front and back
portions, said garment also comprising a non-absorbent, liquid impervious
channel secured to said interior surface in the crotch area of said body
extending between said front and back portions and opening to the interior of
said body, said channel being adapted for removably receiving an absorbent
insert and comprising a liquid impervious central section and two opposed
generally upstanding liquid impervious walls along opposed edges of said
central section, the garment further comprising an absorbent insert removably
contained in the liquid impervious channel.
2. The garment of claim 1 wherein said pliant body is a fabric.
6
3. The garment of claim 1 wherein said upstanding walls project upwardly
from said elastically contractible cuffs.
4. The garment of claim 1 wherein said walls include inner edges and are
provided with elasticized hems along said inner edges.
5. The garment of claim 4 wherein a panel extends across either end of
said channel between said hems forming a recess.
6. The garment of claim 5 wherein said panel is secured to said liquid
impervious layer by a curved end stitch.
7. The garment of claim 1 wherein said channel comprises flanges extending
along either edge thereof and said channel is secured to said interior
surface of said body along said flanges.
8. The garment of claim 8 wherein said walls of said channel and said
flanges are formed by sonic welding of said liquid impervious walls to said
liquid impervious central section along the lower edges of said walls.
9. The garment of claim 1, further comprising a cover for said absorbent
insert, said cover being adapted for placement in said channel, said cover
comprising a liquid impervious material forming an elongated pocket, said
pocket including a front face and having an opening across a major portion of
the front face, said pocket having an edge of said opening and a raised rim
extending around said edge.
10. The garment of claim 1, wherein said insert comprises two absorbent
layers, a central web having an outer edge, and two outer layers having
edges, and wherein said two absorbent layers are secured to either face of
said central web, and said two outer layers secured to each other and the
outer edge of said central web along the edges of said outer layers.
11. The garment according to claim 1 wherein the pliant body is not
waterproof.
12. The garment according to claim 1 wherein said two opposed walls extend
along opposite sides of said central section between said front and back
portions of the garment.
13. The garment according to claim 1 wherein said central section is
generally rectangular in shape and is disposed generally longitudinally in
the garment, extending between the front and back portions of the garment.
14. An incontinence garment comprising a washable fabric body for
removable fitting to a wearer, said body having an interior and an exterior
surface and a front and back portion and a crotch area, said garment
comprising a non-absorbent, liquid impervious channel secured to said
interior surface in the crotch area of said body extending longitudinally
between said front and back portions and opening to the interior of said
body, said channel having a central section adapted for removably receiving
an absorbent insert and two opposed generally upstanding, longitudinally
extending walls along opposed edges of said central section, the garment
further comprising an absorbent insert removably contained in the liquid
impervious channel.
15. The garment of claim 14 wherein said insert is non-washable.
16. The garment of claim 14, wherein said insert is composed of a
bio-degradable material.
17. The garment of claim 16, wherein said insert is composed of a
bio-degradable material containing peat moss.
5,360,422
7
18. The garment according to claim 14 wherein the fabric body is not
waterproof.
19. The garment according to claim 14 wherein said walls are provided with
elasticized hems along upper edges of the walls.
20. A non-absorbent, liquid impervious channel adapted for being secured to
an interior crotch area of a garment, said channel having a central section
adapted for removably receiving an absorbent insert and two opposed,
generally upstanding walls comprising opposed elastically contractible leg
cuffs extending along opposed edges of said central section wherein said
chan-
8
nel further comprises flanges extending along either edge thereof adapted
for being secured to said garment.
21. The channel of claim 20 wherein said walls are provided with hems and
wherein the channel includes opposite ends and further comprising two panels
extending across the ends of said channel between said hems forming recesses
at either end thereof.
22. The liquid impervious channel according to claim 20 wherein the channel
is adapted for being secured to the crotch area of a garment that is not
waterproof.
23. The liquid impervious channel of claim 20 wherein said walls are
provided with elasticized hems along upper edges of the walls.