U.S. patent application number 10/907382 was filed with the patent office on 2005-07-21 for graphic viewable through encasement of vacuum-packed diaper.
This patent application is currently assigned to DIAPEROOS, LLC. Invention is credited to Snell, Alan Kay.
Application Number | 20050155892 10/907382 |
Document ID | / |
Family ID | 34753887 |
Filed Date | 2005-07-21 |
United States Patent
Application |
20050155892 |
Kind Code |
A1 |
Snell, Alan Kay |
July 21, 2005 |
GRAPHIC VIEWABLE THROUGH ENCASEMENT OF VACUUM-PACKED DIAPER
Abstract
A single disposable absorbent article is vacuum-packed in an
interior space of an air impermeable encasement. The encasement
includes a sheet of material having an interior surface and an
exterior surface, a portion of the sheet of material being
transparent and defining a viewing region. The single disposable
absorbent article is disposed in a folded configuration within the
encasement and includes a graphic disposed on an outer surface
thereof. Moreover, the single disposable absorbent article is
folded and disposed in the encasement in a configuration such that
at least a portion of the graphic is viewable through the
transparent portion of the encasement.
Inventors: |
Snell, Alan Kay; (Idaho
Falls, ID) |
Correspondence
Address: |
TILLMAN IVSAN, PLLC
PO BOX 471581
CHARLOTTE
NC
28247
US
|
Assignee: |
DIAPEROOS, LLC
520 Elliot Street Suite 200
Charlotte
NC
|
Family ID: |
34753887 |
Appl. No.: |
10/907382 |
Filed: |
March 31, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10907382 |
Mar 31, 2005 |
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10907333 |
Mar 29, 2005 |
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10907333 |
Mar 29, 2005 |
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10665169 |
Sep 18, 2003 |
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60451433 |
Mar 4, 2003 |
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60660792 |
Mar 11, 2005 |
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Current U.S.
Class: |
206/524.8 ;
206/438; 206/440 |
Current CPC
Class: |
A61F 2013/8497 20130101;
G07F 11/62 20130101; A61F 13/15747 20130101; A61F 13/84 20130101;
B65D 85/07 20180101; B65D 77/02 20130101; B65B 63/02 20130101; A61F
13/55115 20130101; B65D 2203/00 20130101; B65D 81/2023 20130101;
B65B 63/028 20130101; A61F 13/5511 20130101; B65B 31/024
20130101 |
Class at
Publication: |
206/524.8 ;
206/438; 206/440 |
International
Class: |
B65D 081/20 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 7, 2004 |
WO |
PCT/US04/29286 |
Claims
What is claimed is:
1. A package enclosing a single disposable absorbent article, the
package comprising a sheet of material having an interior surface
and an exterior surface, the sheet of material having at least one
viewing region and being configured to provide an interior space,
the single disposable absorbent article having a folded
configuration, an unfolded configuration, a body facing surface and
a garment facing surface, the garment facing surface having a
graphic disposed on at least a portion thereof, the single
disposable absorbent article being in a folded configuration and
situated within the interior space of the package in a manner such
that at least a portion of the graphic is situated in the viewing
region.
2. The package of claim 1, wherein the package is vacuum-packed.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to
U.S. patent application Ser. No. 10/907,333, filed Mar. 29, 2005,
which is hereby incorporated herein by reference, and which
application is: (1) a continuation-in-part of and claims priority
to U.S. patent application Ser. No. 10/665,169, filed Sep. 18,
2003, which is hereby incorporated herein by reference, and which
application is a nonprovisional of and claims priority to U.S.
Provisional Patent Application No. 60/451,433, filed Mar. 4, 2003,
which is hereby incorporated herein by reference; and (2) a
nonprovisional application of and claims priority to U.S. Patent
Application No. 60/660,792, filed on March 11, 2005, which is
hereby incorporated herein by reference. Moreover, the '169
application published on Sep. 9, 2004, as Patent Application
Publication No. U.S. 2004/0176735 A1, which publication also is
incorporated herein by reference.
BACKGROUND
[0002] The present invention relates generally to disposable
packaged diapers and related infant and incontinent adult care
accessories. More particularly, the present invention relates to a
reduced size packaged diaper, and related infant and incontinent
adult care accessories and kits.
[0003] Diapers are generally a necessity for very young children
and incontinent adults. Individuals incapable of controlling the
release of bodily waste in a manner sufficiently reliable to enable
the use of restroom facilities, and those caring for such
individuals, typically need to carry extra disposable diapers and
changing accessories. This is typically because it is difficult to
predict when a diaper worn by an individual may need to be changed.
Caretakers of babies and others requiring diapers often carry
spare, clean diapers for this reason.
[0004] Many of the following discussions and examples are directed
to use of diapers in infant care. However, it will be apparent that
many of the same considerations apply to use of diapers for
non-infant, incontinent persons.
[0005] Storage and carriage of clean diapers is often inconvenient.
For instance, disposable diapers are generally rather bulky items
not given to easy storage or carriage in a purse, pocket, or
otherwise about the person. In addition, the problem can be
acerbated in that diapers can be subject to expansion from the
typically somewhat compressed state in which they are normally
provided to consumers, especially in circumstances where the
diapers are subject to contact with other items within a storage
bag. For example, many disposable diapers are provided in a bi-fold
configuration meant to minimize the space taken in storing the
diaper. However, after being removed from their original packaging,
bi-fold diapers often unfold or otherwise expand to consume an even
larger storage space. Thus, disposable diapers can become more
bulky and difficult to carry than when in their nominal, packaged
condition.
[0006] In addition, it is often the case that it is not sufficient
to simply change a soiled diaper and replace it with a clean
diaper. For instance, cleaning of the individual who wore the
diaper may need to be performed with diaper accessories, such as
moist wipes. Also, it may be necessary to apply ointment or powder
to the individual wearing the diaper to treat or prevent incidents
of diaper rash or other skin conditions. Due to these
considerations, caretakers of individuals requiring diapers often
carry clean diapers and diaper changing accessories in a dedicated
container, is often referred to as a "diaper bag." By doing so,
when it becomes necessary to change a diaper, all of the materials
needed by the caretaker are available in one location.
[0007] While a conventional diaper bag provides a dedicated
container in which diapers and diaper accessories can be stored and
carried, the requirement of carriage of a diaper bag often adds to
the difficulty of a caretaker's responsibility. For example,
parents of young children often must carry a purse or briefcase for
the parent's own needs. In addition to this, the parent may need to
carry the young child; and, of course, the child's diaper bag. This
can leave the parent with no free hands for other tasks.
[0008] While conventional clean diapers and diaper changing
accessories can be stored and carried in other carrying containers
such as purses, backpacks, briefcases, etc., the bulky nature of
conventional disposable diapers results in the diapers occupying a
relatively large space within the carrying container. In addition,
diaper changing accessories such as moist wipes, ointment, powder,
etc., add to the space consumed by conventional clean diapers and
can be difficult to locate among other items stored in the
backpack, purse, case, or the like.
[0009] Where the diapers being carried by the caretaker are for
bottle feeding infants, the problems discussed above are further
exacerbated by the need to carry materials for feeding the baby. In
addition to the accoutrement necessary to attending to changing the
baby's diaper, things such as bottles, nipples, containers of
formula or milk, etc., generally must also be carried.
SUMMARY OF THE INVENTION
[0010] It has been recognized that it would be advantageous to
develop a packaged diaper that requires a relatively small amount
of storage space. In addition, it has been recognized that it would
be advantageous to develop a diaper and related accessory kit that
consumes a relatively small amount of space while providing
substantially all of the materials necessary to change an
individual's diaper. It has also been recognized that it would be
advantageous to develop an infant care kit that consumes a
relatively small amount of space while providing substantially all
of the materials necessary to feed the infant and change the
infant's diaper.
[0011] The invention provides a packaged diaper, including a
diaper, having a first, nominal size, and a second, reduced size,
the reduced size of the diaper being convenient for carriage and
storage of the diaper. An encasement can also be provided, in which
the diaper can be disposed in the second, reduced size. The
encasement can confine the diaper so that the diaper is retained in
its reduced size by the encasement and so that the diaper is
returned to its nominal size upon opening of the encasement.
[0012] In accordance with another aspect of the invention, a
packaged diaper is provided, including a diaper, having a first,
nominal configuration characterized by a nominal length, width and
height, and a second, reduced configuration characterized by a
second, reduced length, width and height. The reduced length can be
between about 2 inches to about 4 inches, the reduced width can be
between about 1.0 inch to about 2.5 inches, and the reduced
thickness can be between about 0.5 inches to about 1.5 inches. An
encasement can also be provided, in which the diaper can be
disposed and retained in the second, reduced configuration.
[0013] In accordance with another aspect of the invention, a
packaged diaper is provided, including a diaper, having a first,
nominal size and shape, and a reduced, substantially cylindrical
size and shape. The reduced, substantially cylindrical shape can
have a diameter between about 0.5 inches to about 1.5 inches and a
length between about 2 inches to about 4 inches. An encasement can
also be provided, in which the diaper can be disposed and retained
in the reduced, substantially cylindrical shape.
[0014] In accordance with another aspect of the invention, a
packaged diaper is provided, including a diaper having a first,
nominal volumetric configuration characterized by a nominal length
and width of the diaper, and a second, reduced volumetric
configuration characterized by a reduced length and width of the
diaper. An encasement can also be provided, the encasement formed
of a substantially air impermeable material. The diaper can be
disposed in the encasement in the second, reduced volumetric
configuration and the encasement can be at least partially
evacuated of air so as to contain the diaper in at least a partial
vacuum state. Differential pressure within and without the
encasement can maintain the second, reduced volumetric
configuration of the diaper and the encasement can be sealed to
confine the diaper so that the diaper is returned to its nominal
volumetric configuration upon opening of the encasement.
[0015] In accordance with another aspect of the invention, a method
of packaging a diaper is provided and includes the steps of: a)
folding the diaper at least once along both a lengthwise and a
crosswise aspect of the diaper; b) disposing the folded diaper
within an encasement comprised of a substantially air impermeable
material; c) evacuating air from the encasement and the folded
diaper; and d) sealing the encasement to maintain a vacuum created
within the encasement and the folded diaper.
[0016] In accordance with another aspect of the invention, a method
of packaging a diaper is provided and includes the steps of: a)
volumetrically reducing a size of the diaper to a size convenient
for carriage and storage of the diaper; b) disposing the
volumetrically reduced diaper within an encasement; and c)
maintaining the volumetrically reduced size of the diaper with the
encasement.
[0017] In a more detailed aspect, the encasement can facilitate
this by virtue of its hoop strength and/or by means of a pressure
differential acting upon the encasement.
[0018] In accordance with another aspect of the invention, a diaper
changing kit is provided and includes a packaged diaper in
accordance with one or more previously set forth aspects of the
invention, at least one diaper accessory, and a container in which
the packaged diaper and the diaper accessory can be disposed. In a
more detailed aspect, the accessory can be one or more of: a) a
moistened wipe; b) baby powder; c) a medicament; d) a swab; e) a
lotion; and, a disposal bag for a dirty diaper. In another more
detailed aspect the container can be configured to have a first,
oversized size and shape and a second smaller size and shape, and
to also function as a disposal container for a dirty diaper.
[0019] In accordance with another aspect of the invention, an
infant care kit is provided and includes a diaper, a diaper
accessory, a portion of infant food and an infant feeding assembly.
The infant feeding assembly can have a hollow body and a nipple
portion couplable thereto. The diaper, diaper accessory, and
portion of infant food can each be disposed in the infant feeding
assembly. The infant feeding assembly can be configured to: i)
contain each of the diaper, at least one diaper accessory and at
least one portion of infant food; and ii) upon removal of the
diaper and diaper accessory, receive the portion of infant food
within the hollow body and deliver the infant food to an infant
with the food delivery device. In a more detailed aspect a warming
pack can also be provided for warming the infant food.
[0020] In accordance with another aspect of the invention, a
packaged diaper is provided and includes a diaper, having a first,
nominal size, and a second, reduced size, the reduced size of the
diaper being convenient for carriage and storage of the diaper. A
restraint can also be provided, in which the diaper can be disposed
in the second, reduced size. The restraint can confine the diaper
so that the diaper is retained in its reduced size by the restraint
and so that the diaper is returned to its nominal size upon opening
of the restraint.
[0021] In accordance with another aspect of the invention, a
packaged diaper is provided and includes a densified diaper
volumetrically reduced to a second reduced volume and increased
density from a first greater volume and lesser nominal density. The
reduction of the diaper can entail reduction in one or more
dimensions. An encasement can also be provided in which the diaper
can be disposed in the second reduced volume. The encasement can
confine the diaper so that the diaper is retained in the reduced
volume by the encasement.
[0022] In accordance with another aspect of the invention, an
expandable diaper is provided and includes a diaper being reduced
to a second, reduced size from a first, nominal size, the reduced
size of the diaper being reduced in at least two dimensional
directions relative to the nominal size. An encasement can also be
provided in which the diaper can be disposed in the second, reduced
size. The encasement can confine the diaper so that the diaper is
retained in the reduced size by virtue of the encasement.
[0023] In accordance with another aspect of the invention, a
packaged diaper is provided and includes a diaper, having a first,
nominal size, and a second, reduced size, the reduced size of the
diaper being convenient for carriage and storage of the diaper. A
restraint can also be provided in which the diaper can be disposed
in the second, reduced size. The restraint can confine the diaper
so that the diaper is retained in its reduced size by the restraint
and so that the diaper is returned to its nominal size upon opening
of the restraint.
[0024] In addition to the foregoing, one or more other aspects of
the present invention as found in the provisional patent
application incorporated by reference above each relates to a
method for miniaturizing a diaper. In this respect, a preferred
such method comprises: folding a diaper within a jig; transferring
the folded compressed diaper from the jig using a clamping
apparatus; inserting the folded compressed diaper into a pliable
bag; and vacuum sealing the bag thereby further miniaturizing the
diaper within the bag. The miniaturized finished product preferably
fits into a conveniently sized box for eliminating the bulky nature
of carrying bulky diapers within a purse or other carrying case.
Furthermore, the finished product is condensed down to a firm and
hard exterior surface, and may be disguised in appearance, for
example, to look like a candy bar instead of a baby diaper or an
adult diaper. The miniaturization process can be readily adapted to
mechanical application for automatic manufacturing assembly line
runs.
[0025] Additional features and advantages of the invention will be
apparent from the detailed description which follows, taken in
conjunction with the accompanying drawings, which together
illustrate, by way of example, features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1A is a top view of a diaper in a nominal configuration
in accordance with an embodiment of the present invention;
[0027] FIG. 1B is a side view of the diaper of FIG. 1A;
[0028] FIG. 2A is a top view of a diaper in a volumetrically
reduced configuration in accordance with an embodiment of the
present invention;
[0029] FIG. 2B is a side view of the diaper of FIG. 2A;
[0030] FIG. 3A is a perspective view of a diaper in accordance with
an embodiment of the invention;
[0031] FIG. 3B is a perspective view of the diaper of FIG. 3A in
the process of folding the diaper along a lengthwise aspect of the
diaper;
[0032] FIG. 3C is a perspective view of the diaper of FIG. 3B in
the process of folding the diaper along a crosswise aspect of the
diaper;
[0033] FIG. 3D is a perspective view of the diaper of FIG. 3C being
disposed within an encasement;
[0034] FIG. 3E is a perspective view of the diaper of FIG. 3D held
under vacuum within the encasement of FIG. 3D;
[0035] FIG. 4 is an end view of a packaged diaper having a reduced
volume in a substantially cylindrical shape in accordance with one
aspect of the invention;
[0036] FIG. 5 is a perspective view of a diaper kit in accordance
with one aspect of the invention;
[0037] FIG. 6 is a perspective view of another diaper kit in
accordance with one aspect of the invention;
[0038] FIG. 6A is a perspective view of a diaper wipe configuration
usable with the kit of FIG. 6 in one example in accordance with one
aspect of the invention;
[0039] FIG. 7 is a perspective view of an infant care kit in
accordance with one aspect of the invention;
[0040] FIG. 8 is a perspective view of a master container in
accordance with one aspect of the invention;
[0041] FIG. 9A is a top view of another diaper kit in accordance
with one aspect of the invention;
[0042] FIG. 9B is a side view of the diaper kit of FIG. 9A;
[0043] FIG. 9C is a side view of another example diaper kit in
accordance with one aspect of the invention;
[0044] FIG. 10A is a schematic view of one step of a process of
packaging a diaper in accordance with one aspect of the
invention;
[0045] FIG. 10B is a schematic view of another step of the process
of FIG. 10A;
[0046] FIG. 10C is a schematic view of another step of the process
of FIG. 10A;
[0047] FIG. 10D is a schematic view of another step of the process
of FIG. 10A;
[0048] FIG. 10E is a schematic view of another step of the process
of FIG. 10A;
[0049] FIG. 11A is a perspective view of a diaper held by a
restraint in accordance with one aspect of the invention; and
[0050] FIG. 11B is a perspective view of a diaper held by another
restraint in accordance with one aspect of the invention;
[0051] FIG. 12 is a view of a bulky diaper in the hands of a
person;
[0052] FIG. 13 is a sketch of a diaper within a jig made for
holding and folding said diaper, with a person tucking the rough
edges inwardly;
[0053] FIG. 14 is a view of a diaper with one end being folded
inward;
[0054] FIG. 15 is a view of a diaper with the other end being
folded inward over the first fold;
[0055] FIG. 16 shows a hand clamp gripping a folded diaper;
[0056] FIG. 17 is a perspective view of a folding jig facilitating
the hand clamp for inserting a diaper into a plastic bag;
[0057] FIG. 18 shows a hand clamp held by a person compressing a
folded diaper being inserted into a plastic bag;
[0058] FIG. 19 shows a folded and compressed diaper within a small
plastic bag;
[0059] FIG. 20 shows a folded, compressed, and vacuum-packed diaper
within the plastic bag of FIG. 19 after vacuum-sealing;
[0060] FIG. 21A is a schematic view of one step of a method of
packaging a diaper;
[0061] FIG. 21B is a schematic view of another step of the method
of FIG. 10A;
[0062] FIG. 21C is a schematic view of another step of the method
of FIG. 10A;
[0063] FIG. 21D is a schematic view of another step of the method
of FIG. 10A;
[0064] FIG. 21E is a schematic view of another step of the method
of FIG. 10A;
[0065] FIG. 22 is an illustration of a preferred method for
pressing a vacuum-packed diaper;
[0066] FIG. 23 is an illustration of another preferred method for
pressing a vacuum-packed diaper;
[0067] FIG. 24 is an illustration of another preferred method for
pressing a vacuum-packed diaper;
[0068] FIG. 25 is an illustration of another preferred method for
pressing a vacuum-packed diaper;
[0069] FIG. 26 is an illustration of another preferred method for
pressing a vacuum-packed diaper;
[0070] FIG. 27 is a view of a fully extended diaper having indicia
thereon;
[0071] FIG. 28 is a view of the diaper of FIG. 27 with tucked end
margins;
[0072] FIG. 29A and FIG. 29B are views of the diaper of FIG. 28
with tucked side margins;
[0073] FIG. 30 is a view of the diaper of FIGS. 29A and 29B with a
crosswise fold;
[0074] FIG. 31A and FIG. 31B are views of the diaper of FIG. 30
after vacuum-packing;
[0075] FIG. 32 is a view of another fully extended diaper having
indicia thereon;
[0076] FIG. 33A and FIG. 33B are views of the diaper of FIG. 32
after tucking/folding and vacuum-packing;
[0077] FIG. 34 is a view of another fully extended diaper having
indicia thereon;
[0078] FIG. 35A and FIG. 35B are views of the diaper of FIG. 34
after tucking/folding and vacuum-packing; and
[0079] FIG. 36A, FIG. 36B, and FIG. 36C are views of a kit having a
vacuum-packed diaper and diaper accessories, wherein indicia of the
diaper is visible through the encasement in which the diaper is
vacuum-sealed.
DETAILED DESCRIPTION
[0080] Reference will now be made to the exemplary embodiments
illustrated in the drawings, and specific language will be used
herein to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended. Alterations and further modifications of the inventive
features illustrated herein, and additional applications of the
principles of the inventions as illustrated herein, which would
occur to one skilled in the relevant art and having possession of
this disclosure, are to be considered within the scope of the
invention.
[0081] As illustrated in FIGS. 1A through 2B, an exemplary
packaged, disposable, diaper 10 is sized and shaped to consume a
considerably smaller volume and be more conveniently shaped than
conventional disposable diapers. As illustrated, the packaged
diaper 10 begins as a diaper 12 nominally sized and shaped in
accordance with conventional diapers. The diaper can be one of a
variety of types known to those in the art, and can be formed of a
variety of materials. The diaper can be disposable or
non-disposable (i.e., resusable).
[0082] As shown in FIG. 1A, the diaper begins with a first, nominal
volumetric configuration characterized by a nominal length L and
nominal width W of the diaper. As used herein, the term "nominal"
is understood to mean to be the normal, post manufacturing state in
which it is ready to be unfolded and worn, in reference to the
various dimensions of the diaper. Thus, the diaper 12 can have a
first size having a height, width and length of nominal size, such
as conventionally provided to consumers. While not so required, the
diaper 12 can include upper 12a and lower 12b portions, which can
correspond to a front and back of the diaper. Many conventional
diapers are provided with a front and back portion of different
configuration.
[0083] As shown in FIGS. 2A and 2B, an example of a packaged diaper
10, after being prepared in accordance with the description to
follow below, includes a diaper 12 having a second, reduced
volumetric configuration characterized by a reduced length L.sub.2
and width W.sub.2 of the diaper 12. The reduced volumetric
configuration can differ from the nominal volumetric configuration
in width, height, thickness, volume and overall size. As will be
appreciated from the figures, not only is the volume of the
packaged diaper reduced overall, but in the example embodiment at
least two of the: 1) length; 2) width; and, 3) height, can also be
reduced. Thus, the diaper can be reduced in volumetric
configuration to consume much less space than the diaper consumes
when in the nominal configuration.
[0084] As mentioned, the diaper 12 can be disposed in an encasement
14, which can be formed of a substantially air impermeable
material. By disposing the diaper in the encasement in the second,
reduced volumetric configuration, a packaged diaper is provided
that consumes much less space than the when in its nominal
configuration. By "substantially air impermeable," what is meant is
that the permeability is low enough that the product has a
reasonable shelf life without significant expansion.
[0085] As an example, it has been found that by drawing a vacuum
down to about 5 Mbar at room temperature and pressure at a location
about 5,000 feet elevation above mean sea level, the volume of the
diaper can be reduced to as little as 1/3 or 1/4 that of the
nominal volume. Similar results are to be expected at locations of
different elevation. However, as is known, at lower elevations a
greater vacuum can be drawn to allow for subsequent transportation
of the packaged product to higher elevations. For example, vacuum
packaging using a vacuum down to 1 or 2 Mbar is common at lower
elevations. Thus, in the space required to store one conventional
diaper, three, four, or more, diapers packaged in accordance with
the invention can be stored. The reduced volume packaged diapers
are not only advantageous in reducing storage space, the space
required for packaging, shipping, etc., is also reduced, leading to
considerable cost savings in associated processes.
[0086] While the reduced volume configuration can be created and
maintained in a number of ways, in the embodiment shown in FIGS. 2A
and 2B, the packaged diaper 10 includes encasement 14, which can
encompass the reduced volume diaper. Once the diaper 12 is disposed
within the encasement, the encasement can be at least partially
evacuated of air so as to contain the diaper in at least a partial
vacuum state. The evacuation of air from within the diaper and
encasement can be done in a number of ways, such as by conventional
vacuum-packing methods.
[0087] For example, according to at least one conventional
vacuum-packing method known to those skilled in the relevant art,
an article to be vacuum-packed is inserted into an unsealed
encasement formed of a substantially air impermeable flexible
material. The unsealed encasement with the article therein is then
placed onto the deck of a vacuum-sealing machine. The lid of the
machine is then lowered establishing a seal with the deck and to
define a chamber between the deck and the lid with the unsealed
encased article within the chamber. A pumping system then evacuates
ambient air from the chamber creating at least a partial vacuum
state within the chamber and within the interior space of the
unsealed encasement with the article therein. Sealing bars then
seal the encasement to maintain at least a partial vacuum state
therein. Ambient air pressure is then restored to the chamber
effecting a pressure differential across the sealed encasement.
Insofar as the article within the sealed flexible encasement is
compressible, the pressure differential acts upon the encasement to
compress the article and maintains the article in a reduced volume
that is less than the volume of the article at the time the
encasement was sealed (before ambient air pressure was restored to
the chamber). The lid of the machine is then raised and the
vacuum-packed article is available for removal from the
machine.
[0088] Upon evacuation of air from the encasement, the encasement
can be sealed, for example at an edge portion 16 to maintain the
vacuum within the encasement and diaper 12. In this manner a
differential pressure can be created within and without the
encasement to maintain the second, reduced volumetric configuration
of the diaper. While the encasement is shown in FIG. 2B as sealed
at an edge portion 16, it will be understood that the encasement
can be sealed conventionally in a variety of ways in a variety of
locations.
[0089] As the encasement 14 configured to confine the diaper 12 is
unsealed, the diaper is able to return to its nominal volumetric
configuration. That is, user can cut, tear, remove a portion of the
encasement, or otherwise break the airtight seal of the encasement;
after which, the diaper 12 will no longer be subject to confining
force due to the encasement and/or a pressure differential.
Unopposed rebound forces in the materials from which the diaper is
made will tend to return it to its nominal configuration. The
encasement can include a means to facilitate opening, such as a
notch or another intentionally formed discontinuity (not shown)
provided in the encasement to aid in opening the encasement. In one
embodiment a tear-away band, or the like, provided with a grasping
tab (not shown) can be provided to facilitate opening by rupturing
the encasement as it is pulled away therefrom. One of many other
well known ways to provide a more easily broken-open encasement can
be used to facilitate opening the packaging.
[0090] As described in further detail below, the reduced volumetric
configuration can be achieved in a number of ways, and in the
embodiment shown in FIGS. 2A and 2B, the volumetrically reduced
configuration is created by foldingly reducing a length and width
of the diaper 12; increasing its thickness. The folded diaper is
then vacuum-packed to reduce its thickness (as well as its width
and length to a lesser extent). As used herein, the term "foldedly
reduced" is meant to indicate the case wherein a diaper is folded
or rolled over or under itself to thereby reduce a dimension of the
diaper.
[0091] While the final size of the reduced volume diaper can vary,
in one aspect of the invention, the reduced length and width can
each be less than about 1/2 of the nominal length and width,
respectively, of the diaper. In another aspect of the invention,
the foldedly reduced length of the diaper can be less than about
1/3 and/or 1/4 of the nominal length of the diaper. In this manner,
as shown by comparing FIGS. 1A and 1B with FIGS. 2A and 2B, the
overall width and length of the diaper can be substantially
reduced. While a height dimension, corresponding to thickness, may
be increased, it is not increased to exceed the width or the length
of the diaper. This results in a more convenient and compact size
overall.
[0092] The inventor has found that a conventional size 6 diaper can
be reduced in size and volume from a nominal size of approximately
9" long by 4.5" wide by 1/4" to 1" in height/thickness (depending
on expansion after removal from conventional packaging) to a
reduced size of approximately 3.5" long by 2.25" wide by 1" in
height. In the embodiment shown in FIGS. 2A and 2B, the packaged
diaper 10 can include a reduced volumetric shape configuration
which comprises a substantially rectangular shape, although other
shapes are contemplated as well, as discussed in further detail
below. In this manner, the packaged diaper can be easily carried,
handled and stored within a purse, pocket, bag or other place or
containment for carriage.
[0093] The packaged diaper in a densified state can thus be made
pocket sized, or pocketable. As used herein that means that it is
conveniently sized for carriage, for example about the size of a
conventional cigarette package or smaller. One way to characterize
this is that two of the three dimensions of height width and
length, when added together, are less than 10 cm, and the greatest
of the three does not exceed 10 centimeters. That said, all pocket
sized items may not strictly fit this definition, but it is a
definite guide in understanding what is meant by the term as used
herein.
[0094] It will be appreciated that in this example the present
invention provides a compact, efficiently sized packaged diaper
that requires substantially less space than conventionally packaged
diapers. The present invention can be advantageously utilized by a
variety of persons, including incontinent minors and adults, and
caretakers of individuals requiring diapers.
[0095] For example, parents of young children will benefit from the
invention in that one or more diapers 10 can be easily stored in a
pocket, or within a purse, briefcase, backpack or other storage bag
and consume relatively little space. Similar benefits can be
obtained with regard to incontinent adults, as adult diapers are
generally even more bulky and difficult to store and carry than are
smaller, children's diapers. Also, incontinent adults who may be
otherwise embarrassed by having to carry spare clean diapers will
likely find the packaged diapers in accordance with the invention
to be much more discreetly transportable, and therefore the
carriage of such spare diapers much less noticeable by others.
[0096] In addition, in one aspect of the invention a packaged,
pocketable diaper is provided and can include an encasement
configured to encase and confine a diaper disposed therein. A
diaper can be disposed within the encasement to be confined by the
encasement in a size that is volumetrically reduced relative to a
nominal size of the diaper. The volumetrically reduced size of the
diaper is characterized in that the diaper is pocketable upon a
person of an individual. As used herein, the term "pocketable" is
to be understood to indicate a configuration of the diaper in which
the diaper can be easily placed within and removed from a pocket of
an item of clothing or accessories worn or carried by individuals.
For example, the pocketable diaper can be held within a shirt,
jacket or pants pocket or stored or carried in a handbag, purse or
briefcase, etc., and can be substantially undetectable by other
individuals. In this manner, an incontinent adult can carry the
pocketable diaper without worrying that others will be aware that
the diaper is being carried. Also, an adult caretaker of an infant
can carry a diaper for the infant in a manner that does not detract
from a physical appearance of the adult and does not require
additional baggage.
[0097] In several embodiments of the invention, a reduced diaper is
provided. The reduced diaper is densified by volumetric reduction
from a first greater volume and lesser nominal density to a second
reduced volume and increased density. An encasement can also be
included and the diaper can be disposed in the encasement in the
second reduced volume. The encasement can thereby confine the
reduced diaper so that the diaper is retained in the reduced volume
by the encasement. The volumetric reduction can entail dimensional
reductions in width, thickness, length, and diameter. In this
manner, a volumetrically reduced, space-efficient densified diaper
is provided that can be easily stored and carried by an individual
in a discreet manner. Upon release of the reduced diaper from the
encasement, the diaper can be volumetrically expanded and used in
the same manner as conventionally packaged diapers.
[0098] As used herein, the term "encasement" is to be understood to
encompass a broad range of materials and configurations for
containing or restraining or enclosing a volumetrically reduced
diaper. For example, the encasement may completely encompass a
diaper and hold the diaper under a vacuum seal or other pressure
differential. In addition, the encasement may only partially
encompass the diaper to maintain the compressed state of the
diaper. Moreover, it is intended to be understood herein to be
synonymous with restraint (as discussed below) or enclosure, or
containment, in this context. The salient point being that it
constrains, by some means, the densified diaper from expanding.
Other encasements besides the examples shown can also be utilized,
as would occur to one skilled in the art.
[0099] Shown in series in FIGS. 3A through 3E is one aspect of the
invention in which a diaper is reduced from its nominal volume or
size to a reduced volume or size. Diaper 12 begins with a nominal
volumetric configuration, sized and shaped as may be conventionally
provided by a manufacturer of the diaper. In this embodiment, the
diaper is reduced in volume by fold 17 along a lengthwise aspect of
the diaper, shown at line 18. In FIG. 3C, the diaper 12 is folded
at 19 along a crosswise aspect of the diaper, shown at line 20.
Progressing to FIG. 3D, once the diaper has been folded a desired
number of times; the folded diaper is disposed within encasement
14, which is formed of a substantially air impermeable material.
Encasement 14 can then be evacuated to form a relative vacuum
within the encasement, after which the encasement can be sealed to
maintain the vacuum in the diaper and the encasement.
[0100] It will be understood by those skilled in the art that the
process of forming a vacuum within the diaper and the encasement
will extract at least a portion of air contained within the diaper.
By removing a majority of excess air from the diaper, the diaper
can be compressed upon itself by atmospheric pressure and consume a
reduced amount of space corresponding to the amount and volume of
air removed from the diaper.
[0101] In addition to the process illustrated in FIGS. 3A through
3E, in another aspect of the invention, a method of packaging a
diaper is provided and includes the steps of volumetrically
reducing a size of the diaper to a size convenient for carriage and
storage of the diaper. The volumetrically reduced diaper can then
be disposed within an encasement. The volumetrically reduced,
convenient size of the diaper can be maintained by a pressure
differential acting upon the encasement. As used herein, the term
"convenient size" is understood to refer to a size and
configuration of a diaper that can be easily and conveniently
stored in a pocket, handbag, purse, etc., and consume very little
space within the pocket, handbag, etc. Such a size will be
appreciated to be essentially a "pelletized" or "capsulated" or
"pocket sized" or "pocketable" (as defined above) version of the
diaper, having bulk due to air spaces removed, and will be
generally cylindrical, rectangular, etc, and can have rounded or
square corners. Generally, the largest dimension will be about four
inches or less. However, for certain specialized applications such
as kits contained in a feeding bottle, a longer, more "sticklike"
shape may be used in one embodiment. But likewise a cylindrical or
square configuration having height, width, and length dimensions of
roughly equal magnitude can also be advantageous in such a kit in
another embodiment. The salient point is that the size is
convenient to carry and conceal.
[0102] The size of the diaper can be volumetrically reduced in a
number of manners, including pressing the diaper into a mold or
other cavity. In this example, the encasement in which the diaper
is disposed can be sized and shaped to correspond closely to the
volumetrically reduced size of the diaper. Once disposed within the
encasement, the force applied to compress the diaper into the mold
can be released, after which the diaper will tend to return to its
nominal size and shape, but will be restrained by the encasement.
The pressure differential acting upon the easement will thus be the
result of the diaper tending to expand into its nominal
configuration. An equilibrium will be reached between a) the
restoring force tending to expand the diaper; and b) a combination
of the hoop strength (resistance to expansion of the encasement via
deformation of the encasement) and the pressure differential
tending to compress the diaper. Depending on the material from
which the encasement is made, this can be made to be predominantly
hoop strength or predominantly air pressure differential.
[0103] While the example packaged diaper shown in many of the
figures of this disclosure includes a generally rectangular shape,
it is contemplated that the volumetrically reduced diaper can be of
a variety of sizes and shapes. For instance, as shown in FIG. 4,
volumetrically reduced diaper 12a can have a substantially
cylindrical shape. This embodiment may be beneficial, for example,
in applications in which the diaper is to be stored in rounded or
cylindrical receptacles, such as cans or tubes. As will be
appreciated, by forming encasement 14a from a flexible,
substantially air impermeable material, a vacuum formed within the
encasement will force the encasement to conform to the general
shape of the reduced volume diaper. In this manner, the diaper can
be formed in a variety of reduced volume shapes for a variety of
applications.
[0104] In another example embodiment the encasement shape can
control the shape of the packaged diaper. For example, a diaper can
be compressed into an encasement within a mold cavity which
encasement has a shape which essentially follows the shape of the
mold. Thereafter the encasement maintains that shape, though the
diaper may expand slightly against the hoop strength, air pressure
differential, or combination thereof.
[0105] As illustrated in FIG. 5, in another aspect of the present
invention a diaper kit 40 is provided. The kit can include a
packaged diaper 10 in accordance with the embodiments discussed
above and at least one diaper accessory 42. A container 44 is also
provided, in which each of the packaged diaper and the diaper
accessory are disposed. The diaper accessory can be a variety of
items, including, but not limited to, a diaper rash ointment or
other medicament, talcum powder/baby powder, a lotion, moist or dry
wipes, cotton swabs, dirty diaper disposal bag, etc., as may be
needed in caring for an infant or incontinent person, as will be
known to one skilled in the art of providing products for care of
such persons. In the example embodiment shown, a packet of ointment
42A is included in the kit, as are moist wipes 42B.
[0106] Thus, in one example, substantially all of the materials
necessary for changing a soiled diaper are provided in a small,
space optimized kit that can be easily carried or stored by a
caretaker of an individual requiring diapers. The kit can be
advantageously used as a daily staple of caretakers, or may be used
in specialized circumstances such as outdoor activities, travel, or
business or recreational events away from home, or other situations
in which space and convenience of carriage may be of a premium. In
such circumstances the caretaker may wish to minimize the number of
articles needing carriage, and can advantageously carry one or two
kits, as may be needed, and dispense with the conventional diaper
bag that would otherwise have to be carried during the event or
activity. Also, the reduced size of the present diaper kit can
allow one or more kits to be stored in an out-of-the-way location,
such as a glove box of a car, and retrieved in "emergency"
situations in which spare diapers were forgotten or consumed.
[0107] In another embodiment, the kit can be configured for use by
an incontinent adolescent or adult. The kit can further include
supplies to touchup stains on clothing. It can contain a small
container of perfume or cologne, a small container of odor reducing
spray, or other items which an incontinent adult may find needful
and reassuring to carry, in addition to supplies which customarily
may be needed to change a diaper, including a clean diaper, wipes,
and lotion, ointment or other medicament, to name some
examples.
[0108] As shown in FIG. 5, the diaper kit 40 can include a
container 44 that is substantially rectangular in shape. Such kits
can be easily stacked and stored and will fit neatly into a pocket,
purse or other baggage. In another embodiment, as shown in FIG. 6,
the container 46 can be substantially cylindrical in shape. In this
embodiment, the diaper 12b can be formed in a cylindrical shape, or
other shape to facilitate maximum use of available space within the
cylindrical container. Also included in the illustrated example
shown in FIG. 6 are moist wipes 42C which can be arranged in a
disk-like or toroidal configuration for disposal within the
cylindrical container. With reference to FIG. 6A, the individual
wipes 43 are accordion folded, then rolled about an axis 45
transverse to the folds. A surprisingly large number of wipes thus
configured can be fit into a surprisingly small space. In this
manner, 6 or 7 wipes or another selected number of wipes can be
stored within the container 46 to ensure ample supply.
[0109] In another aspect of the invention, illustrated by example
in FIG. 7, an infant care kit 49 can be provided which includes a
diaper 50, one or more diaper accessories 52 and a portion of
infant food 54. An infant feeding bottle assembly is also provided
having a hollow body 56 and a nipple food delivery portion 58 of
the device couplable thereto. A cover 59a or 59b can be provided,
which keeps the feeder portion sanitary. This can be a throwaway
tear-off film cover (e.g. 59b) or a more conventional replaceable
cap (e.g. 59a). The feeding apparatus can be single use (i.e.,
disposable) or reusable. As shown, the diaper, diaper accessory,
and portion of infant food can be disposed within the infant
feeding assembly for convenient carriage. The infant feeding
assembly can thus be configured to: i) contain each of the diaper,
diaper accessory and portion of infant food; and ii) upon removal
of the diaper and diaper accessory, receive the portion of infant
food (and water, if applicable) within the hollow body and thereby
enable delivery of the infant food to an infant via a food delivery
device erstwhile acting as a container for the kit. In one
embodiment the nipple portion can be configured for delivery of
baby formula, and in another embodiment it can be configured for
delivery of a flowable baby food such as a formula/cereal mixture,
creamed vegetables or fruit, or the like. In one embodiment the
baby food can be in powder form, reconstituted by addition of
water. A chemical warming pack (similar to or the same as a
conventional hand warming pack) can be provided for use in warming
the baby formula or other baby food.
[0110] In this example implementation, substantially all of the
materials necessary to feed and change a diaper of an infant are
provided in a compact, easily carried kit. A caretaker of the
infant can use the kit to store the provided items, and when
desiring to feed the infant, can prepare the portion of infant food
and feed the infant with the infant feeding assembly, shown in this
embodiment as similar to a conventional baby bottle, but provided
with a detachable bottom.
[0111] As shown in the illustrated example, the hollow body 56 of
the feeding assembly 49 can be substantially cylindrical in shape,
although other shapes are also contemplated, such as squared,
triangular, and other polyhedral cross-sectional shapes. The
portion of infant food can include a variety of foods suitable for
consumption by infants, including powdered baby formula and
condensed baby formula, freeze dried, powdered, concentrated
creamed vegetables and fruits and other baby foods, as well as
cereal mixes, etc. A caretaker can easily remove all items from the
feeding assembly, configure it for feeding, and returning the
portion of infant food (with water, as mentioned, if necessary, or
other fluid which can be added to the infant food) and the food can
be fed to the infant via a food delivery device 58, a conventional
baby bottle nipple in the illustrated embodiment.
[0112] In one embodiment, the feeding apparatus can include a
double wall configuration to provide increased insulation so as to
keep formula or other baby food at a desired temperature for a
longer period of time. To facilitate this, or, to provide initial
warming when hot potable water is unavailable, a heat source 55, as
mentioned, can also be disposed within the feeding assembly. The
heat source can be configured to provide heat for warming the
portion of infant food, as well as any fluid having been added to
the infant food. In situations where it may be necessary to add
cold fluid such as milk or water to the infant food, the fluid and
food can be warmed to a temperature well tolerated and more
acceptable to an infant. As mentioned, the heat source can be a
conventional chemical heating apparatus, such as those producing an
exothermic reaction when two or more separate materials are mixed,
or are exposed to air. These can be packets of reactants in
granular form, chemically activated gel heating sources, etc. The
feeding apparatus can be configured to cooperate with the heat
source to heat the baby formula or other food. In one embodiment,
the kit can include an outer container (not shown) which is the
outer wall of the double wall configuration mentioned. This can be
a continuous wall, or can comprise vents (e.g. to expose air to
air-reactant heating pads). A mesh or other textile can be used as
the material forming the outer containment in which the infant
feeding assembly is disposed. The outer container can be configured
to receive and protect the feeding assembly and can also encompass
the heating source to maintain close contact between the heating
source and the hollow body 56.
[0113] In another embodiment, the heat source can be some other
means of providing heat, for example provision of a metal outer
sleeve, annular space for water, and inner container for formula or
food enabling use of a cigarette lighter, a solar reflector or
magnifier, or some other higher temperature heat source to heat the
outer sleeve and still enable more gentle warming of the contents
of the inner sleeve. Such an arrangement would also facilitate
rapid cooling of the outer sleeve after removing the high
temperature heat source so that it can be safely handled, enabling
removal of the inner sleeve for feeding for example.
[0114] In another example embodiment of the invention, shown in
FIG. 8, a plurality of single use packaged diapers (not shown), or
diaper kits 40, 40A can be provided packaged together, each stacked
vertically in a master container 60. The master container 60 can
include a removable access panel (previously removed in FIG. 8)
through which one 40 of the plurality of containers can be
accessed. Providing for the removable access panel can be in one of
a variety of ways known to those in the art, including a perforated
removable panel or hinged panel. A bottom 62 of the access panel
can be disposed in the master container 60 in a location vertically
displaced from a bottom 64 of the master container by a distance
substantially equal to a height "h" of the container. It has been
found that having the last container to be used positioned below
the access panel helps keep the shape of the master container and
improves appearance over the dispensing life of the product.
[0115] In this manner, as a kit is removed from the master
container, the kit immediately above the removed kit will fall into
place to be easily removable from the master container. Notches 66
can be provided adjacent the removable panel to enable easy
withdrawal of kits through the panel. The master container 60 can
be used to package and ship a number of kits 40, and advantageously
also used to dispense the kits at a retail center or other point of
sale. While the master container shown in FIG. 7 is configured to
store and dispense 6 diaper kits, master containers configured to
store and dispense fewer or more kits can also be provided, and
include two or more access panels disposed and oriented in a
variety of locations on the master container.
[0116] Illustrated in FIGS. 9A and 9B is a diaper kit 68 in
accordance with another example implementation of the invention. In
this embodiment, a diaper 70 and various diaper accessories 72 are
contained within an encasement 74. The accessories can include baby
ointment, baby wipes, powder, etc. as discussed above. In this
example the accessories include baby ointment 72A and wipes 72B.
Other accessories can be substituted or additionally included.
Shown at 76 are seams formed in the encasement defining adjacent
compartments that can each hold a different product. The seams can
separate products to enable differing treatment of the products in
relation to the encasement. For instance, diaper 70 can be disposed
in the encasement in a reduced volumetric configuration, as
discussed above, and the encasement can be evacuated and
vacuum-sealed about the diaper. However, the baby ointment 72A can
be vacuum sealed (if already packaged in an impermeable containment
without excess air) but need not be vacuum sealed (indeed it may be
difficult to do so if not already packaged) in its corresponding
compartment. Likewise the wipes 72b are not vacuum packed, but
could be if previously enclosed in an impermeable containment
without excess air.
[0117] While it may be desirable to vacuum-pack the diaper 70, and
it is possible to do so with some accessories, it may be the case
that certain accessories are not well suited to such an
arrangement. For instance, with regard to the previously mentioned
examples of ointment 72a and wipes 72 not pre-packaged, baby wipes
are often saturated or at least moisture-laden with a liquid
cleaning compound similar in appearance to soapy water, to aid in
the cleaning process associated with changing diapers. When
subjected to a vacuum, the moisture may be withdrawn from the
wipes, leading to poor performance of the wipes. In addition, if
undue moisture is removed during the vacuum process, the moisture
may interfere with sealing the encasement once vacuum has been
drawn, leading to premature breach of the encasement. The same
applies to the ointment, it would be likewise problematic to vacuum
pack it, even more so. Thus, for some products a vacuum seal may
not be desirable or necessary, and those products can be sealed in
the encasement without being placed under vacuum.
[0118] To address these issues, the present invention in one
embodiment advantageously provides a diaper kit that can include
differently and variably treated compartments. In the example
shown, the compartment containing the diaper 70 can be treated with
a vacuum to aid in maintaining the volumetrically reduced
configuration of the diaper. The compartment holding the ointment
72A may or may not be vacuum treated, as the situation dictates.
The compartment holding the wipes 72B can be simply sealed to
retain the moisture in the wipes without drawing any moisture out
with a vacuum process. Other compartments (not shown) can be
treated according to the product stored in each one.
[0119] In addition to the compartmentalized encasement shown in
FIGS. 9A and 9B, it is contemplated that in another example
embodiment of the invention, shown in FIG. 9C, one can provide a
diaper kit 68' in which all of the components of the kit are
contained in an encasement 74' and sealed under vacuum. For
example, the diaper wipes 69 and/or other accessories can be
pre-packaged in one or more casings 74" with liquid and wipe
material therein. In this way, both a diaper and one or more
accessories, together forming a single use kit, can be integrally
packaged in one encasement 71', and can all be accessed once the
encasement has been breached.
[0120] With reference to FIGS. 10A through 10E, in one embodiment
of the invention the encasement in which the volumetrically reduced
diaper is disposed can contain the diaper without any substantial
pressure differential acting upon the encasement. One illustrative
process in which this can be achieved is illustrated in FIGS. 10A
through 10E. In this embodiment, a "loose" diaper 80 is placed
within a chamber 84B with a pair of encasement shells 82 disposed
adjacent ends of the diaper. Rams 86 and 88 can be activated to
compress the diaper into a volumetrically reduced configuration, as
illustrated in FIG. 10B. Once optimal reduced volume is achieved,
the diaper/shell assembly can be moved adjacent a channel 85
defined between the chambers 84A and 84B, as illustrated in FIG.
10C.
[0121] Channel 85 can provide access to the diaper/shell assembly
to enable attachment of a clamping strap 90 to the shells 82. The
strap can aid in maintaining relative position of the shells 82
after the pressure applied to reduce the volume of the diaper is
released. Thus, as shown in FIG. 10E, the rams 86, 88 and chambers
84 can be removed from contact with the diaper, and the encasement
maintains the diaper/shell assembly in the volumetrically reduced
configuration. In this manner, it is not necessary to apply a
vacuum to the encasement to create and maintain the volumetrically
reduced size of the diaper. In another embodiment, the encasement
can be made air tight by application of the clamping strap, and
thus a combination of differential pressure and hoop strength of
the encasement can contain the diaper after the encasement expands
to an equilibrium state.
[0122] As shown in FIGS. 11A and 11B, in one aspect of the
invention, a restraint 92 can be provided in which the diaper 12
can be disposed a second, reduced size, relative to a first,
nominal size. The restraint 92 can confine the diaper so that the
diaper is retained in its reduced size by the restraint and so that
the diaper is returned to its nominal size upon opening of the
restraint. The restraint can be a strap or a series of independent
or interconnected straps, or, as shown in FIG. 11B, the restraint
94 can include a webbed material. The restraint can be formed of a
material having sufficient strength to retain the diaper 12 in the
reduced size, but can be removed by a consumer to release the
diaper into the first, nominal size, for example by exploiting an
engineered weakness, as is conventionally provided in "tear-away"
packaging closures.
[0123] An embodiment of a method for packaging a diaper very
compactly by folding and vacuum-sealing is shown in FIGS. 12-19.
First, a bulky diaper 6012 as shown in FIG. 12 is inserted into a
U-shaped elongated open-ended forming jig 6014 as shown in FIG. 13
with the outside 6016 of diaper facing down into the jig and the
inside 6018 of the diaper facing up and out of the jig. The ragged
elastic banded edges of the diaper are tucked inward so as to
obtain a smooth clean line exterior.
[0124] Thereafter, as shown in FIG. 14, a first end, such as end
6022, then is folded inwardly covering a middle portion of the
diaper, and then the other end 6026 is folded in over the first end
6022 and middle portion to form a rectangular shape of the diaper
as shown in FIG. 15.
[0125] A spring-tensioned hand-clamp 6030 then is opened to receive
the completely folded diaper between an upper flat rectangular jaw
6034 and a lower jaw 6036, as shown in FIG. 16. Furthermore, the
clamp 6030 and a hand 6038 each compress the diaper 6028 as shown
in FIG. 16.
[0126] The compressed, folded diaper 6028 then is inserted into an
open end of a pliable, resilient bag 6042. The diaper is inserted
into the bag using the hand clamp 6030 and jig 6014 to facilitate
the insertion as shown in FIG. 17, or, alternatively, as shown in
FIG. 18, the compressed, folded diaper 6028 is directly inserted
into the open-ended bag 6042 without the jig.
[0127] The folded diaper 6028, fully inserted into the bag 6042
(FIG. 19), is then placed onto the deck of a conventional
vacuum-sealing machine, such as a vacuum sealing-machine sold under
the trademark SUPERVAC. The lid of the machine is fastened down and
the vacuum-sealing machine vacuum-seals and cuts the bag to form a
finished product as shown in FIG. 20.
[0128] The finished product is very firm and dense, looks like a
taffy candy bar, and is comparable in size to a candy bar. In one
embodiment, the finished product, i.e., a vacuum-sealed diaper
package, measures approximately 1 inch by 2 inches by 11/2 inches,
and fits into a box for convenient carrying within a purse.
[0129] Additionally, printing on the outside of the diaper is
visible through the bag 6042 as shown, for example, in FIG. 20.
Alternatively, the printing on the outside of the diaper may be
disposed within the folded diaper by first folding end 6026
inwardly covering a middle portion of the diaper and then folding
the end 6022 in over the end 6026 and middle portion to form the
rectangular shape of the diaper.
[0130] One or more embodiments of the invention relate to a method
of packaging a diaper using a conventional vacuum-sealing machine.
As shown in FIG. 21A, a compressible absorbent diaper 104 is
disposed within a flexible substantially air impermeable encasement
102 and the unsealed encasement 102 with the diaper 104 therein is
then placed onto the deck 106 of the vacuum-sealing machine. The
lid 108 of the machine is then lowered as shown in FIG. 21B
establishing a seal with the deck to define a chamber 110 with the
unsealed encased diaper within the chamber. A pumping system 112
then evacuates ambient air from the chamber 110 creating a vacuum
state within the chamber and within the interior space 103 defined
by the encasement with the diaper 104 therein. Sealing bars 114
then seal the encasement as shown in FIG. 21C such that the
interior space of the substantially air impermeable encasement 102
is completely sealed and such that the compressible absorbent
diaper 104 is completely enclosed within the sealed interior space
103. As shown in FIG. 21D, ambient air pressure is then restored to
the chamber effecting a pressure differential across the sealed
encasement that acts upon the encasement to compress the
compressible absorbent diaper 104 and maintains the diaper in a
reduced volume (FIG. 21D) that is less than the volume of the
diaper at the time the encasement was sealed (FIG. 21C, before
ambient air pressure was restored to the chamber). As shown in FIG.
21E, the lid 108 is then raised and the vacuum-packed diaper 116 is
available for removal from the machine.
[0131] In addition to all of the foregoing, various preferred
methods of vacuum-packing a diaper also may include pressing at
least a portion of a vacuum-packed diaper and/or its encasement
with a smooth surface in order to achieve a smooth planar for
aesthetic appeal. Indeed, as will now be appreciated by the
Ordinary Artisan in view of the foregoing disclosure, a
compressible article such as a diaper that is vacuum-packed will
exhibit wrinkling and bunching. Furthermore, an air impermeable
encasement enclosing such an article will conform to any such
bunching and wrinkling of the contained diaper as well as will be
prone to forming its own undesirable wrinkles, puckers, and other
undesirable flaws during vacuum-packing. In accordance with the
invention, one or more preferred embodiments address this aesthetic
concern by pressing at least a portion of the diaper and/or
encasement in order to flattening a face of the diaper and/or
encasement. The pressing may occur before vacuum-packing, after
vacuum-packing, during vacuum-packing, or any combination
thereof.
[0132] For example, in FIGS. 13-15, portions of the outside of the
diaper are pressed by the floor of the U-shaped jig as the diaper
is foldedly reduced in the jig. For further example, as shown in
FIG. 16, prior to being disposed within an encasement, the diaper
is pressed within the clamp 6030 between the flat jaws thereof that
comprise essentially planar surfaces. As further shown in FIG. 18,
the clamp can be used to press at least a portion of the diaper
while the diaper is being inserted into and/or is otherwise
disposed within an encasement.
[0133] In another example, as shown in FIG. 22, a vacuum-packed
diaper 122 is pressed between the essentially planar surface 126 of
a conveyor belt 128 and the essentially planar surface 130 of a
press 132. A vacuum-packed diaper 120 prior to pressing appears
wrinkled with creases in the transparent material of the encasement
that tend to distort or block view of the diaper within, as shown
in FIG. 22. In contrast thereto, a vacuum-packed diaper 124 after
pressing exhibits an aesthetically pleasing appearance with indicia
134 printed on the diaper being visible through a substantially
smooth planar face of the transparent material of the encasement.
Note that in this example, the encasement of the vacuum-packed
diaper is pressed by the conveyor belt and the press providing a
generally smooth planar face in the top as well as the bottom of
the encasement. Note furthermore that the encasement is formed of a
material that is at least somewhat flexible, whereby the diaper
within the encasement is pressed by the conveyor belt and press,
too, resulting in generally smooth planar faces in the top and
bottom of the diaper.
[0134] Another example of pressing is shown in FIG. 23, wherein a
vacuum-packed diaper 138 is pressed between the essentially planar
surfaces of a pair of presses 142. A vacuum-packed diaper 136 prior
to pressing appears with wrinkles and creases whereas a
vacuum-packed diaper 140 after pressing assumes a generally smooth
planar appearance believed to be aesthetically pleasing. As in the
previous example, the vacuum-packed diaper 140 is substantially
flattened and the encasement includes generally smooth oppositely
facing planar faces 144,146.
[0135] In yet other examples of pressing shown in FIGS. 24-26,
vacuum-packed diapers are pressed with the generally smooth
circular surfaces of rollers. In particular, in FIG. 24, an upper
surface 152 of vacuum-packed diaper 150 is pressed by a roller 154
as the diaper progresses along a conveyor belt 156. In FIG. 25,
respective upper and lower surfaces 158a and 158b of a
vacuum-packed diaper 162 are pressed by respective opposing rollers
164a and 164b. In FIG. 26, a first pair of opposing rollers
166a,166b is sequentially arranged with a second pair of opposing
rollers 168a,168b such that vacuum-packed diapers 170 are
progressively smoothed in passing sequentially through the roller
pairs. Moreover, the rotational speed of opposing rollers 168a,168b
may be greater than the rotational speed of opposing rollers
166a,166b such that the encasement and/or diaper therein are
subjected to slight horizontal forces in the direction 172 of
travel of the conveyor belt, thereby further removing or pulling
out wrinkles in the encasement and/or diaper.
[0136] Also in addition to all of the foregoing, various preferred
embodiments of the present invention may include a compressible
absorbent diaper that is configured and disposed within an
encasement, a portion of which is transparent such that indicia on
the diaper may be viewable there through.
[0137] The indicia on the diaper may be printed and, as shown in
FIGS. 27-36C, the indicia may include animal characters for
amusement of a child. The indicia also may be associated with a
particular manufacturer or distributor of diapers and, thus,
constitute a trademark. In other exemplary instances, the indicia
may include brand identifiers, sizing information, or any other
information that characterizes or identifies the diaper to a
consumer. Indeed, the indicia may provide recognition of the
article that is vacuum-sealed within the encasement, which can be
especially helpful in determining the size of the diaper, since the
actual size of the diaper will be difficult to judge based on the
size of the vacuum-packed diaper itself.
[0138] In yet other examples, especially with regard to adult
diapers, indicia of the diaper may comprise or contribute to a
disguise of the diaper, thereby reducing the ability of another
party to readily identify the diaper upon a glancing view or casual
viewing.
[0139] In accordance with various preferred embodiments of the
invention, configuring a diaper for viewing of indicia disposed
thereon may entail tucking and/or folding of the diaper for
disposition within an encasement. As used herein, "tucking" refers
to the tucking in of top, bottom, and/or side margins of a diaper,
which margins typically constitute an elastic band, tabs, and the
like. Tucking of the fully extended diaper shown in FIG. 27, for
example, can result in an unfolded rectangular configuration of the
diaper as shown in FIGS. 29A and 29B.
[0140] A preferred method of tucking and folding a diaper will now
be described with reference to FIGS. 27-30.
[0141] Turning to FIG. 27, a fully extended diaper 200 includes
indicia 202 printed on the front portion of an outer surface 206 of
the diaper. Thus, when the diaper of FIG. 27 is worn, the indicia
202 is situated proximal the groin area and navel of the
wearer.
[0142] In accordance with the described preferred embodiment, end
margins 208 of the diaper 200 that are visible in FIG. 27 are
tucked along crosswise aspects of the diaper, whereby the end
margins are disposed underneath the diaper as shown in FIG. 28.
Side margins 210 that are visible in FIG. 28 also are tucked along
a lengthwise aspects of the diaper, whereby the side margins are
disposed underneath the diaper as shown in FIGS. 29A-29B. By
tucking the side and end margins, an unfolded, generally
rectangular configuration of the diaper is obtained as shown in
FIG. 29A-29B.
[0143] It should be noted that the tucking of end margins and/or
side margins is optional in obtaining a generally rectangular
configuration but is preferred due to the benefit of aesthetic
presentation of the indicia. Furthermore, it should be appreciated
by the Ordinary Artisan that, as shown, the tucking of end margins
and side margins to obtain the unfolded rectangular configuration
shown in FIGS. 29A-29B does not include folding of the absorbent
area or core 211 of the diaper, which comprises the portion of the
diaper that is intended to perform the absorbing function.
[0144] From the rectangular configuration shown in FIGS. 29A-29B,
the diaper is folded along a centered, crosswise aspect to obtain a
folded rectangular configuration in which the indicia 202 printed
on the diaper is more prominently displayed, such as shown in FIG.
30. Furthermore, it will be appreciated that, in folding the diaper
to arrive at the configuration shown in FIG. 30, a fold line
necessarily will extend through the absorbent core 211 of the
diaper.
[0145] The diaper next is disposed within an air and moisture
impermeable encasement and vacuum-sealed in accordance with one or
more methods of the foregoing disclosure for vacuum-packing
diapers. The resulting vacuum-packed diaper is illustrated in FIGS.
31A-31B, wherein the diaper of FIG. 30 has been sealed within
encasement 212 having at least a portion 214 thereof that is
transparent. The diaper, tucked and folded as here described, is
viewable through the transparent portion 214 of the encasement and,
particularly, the indicia 202 printed on the outer surface of the
diaper is readily viewable through the transparent portion of the
encasement. Additionally, notches 218 are formed along outer edges
of the encasement 212 to aid in opening the encasement.
[0146] Another exemplary preferred embodiment is illustrated in
FIGS. 32-33. In this case, a fully extended diaper 220 is shown in
FIG. 32 with indicia 222 printed on the front outer surface 226 of
the diaper. After obtaining an unfolded rectangular configuration
similar to that of FIGS. 29A-29B by tucking end and side margins,
the diaper 220 is twice folded along crosswise aspects (as
illustrated in FIGS. 14-15) to obtain a folded rectangular
configuration, and then the folded diaper is disposed and
vacuum-sealed within a transparent encasement 228 resulting in the
vacuum-packed diaper of FIGS. 33A-33B.
[0147] As shown in FIG. 33B, the crosswise folds 230 define a first
end portion 232 of the diaper folded within the configuration, a
second end portion 234 folded over the first end portion 232, and a
medial portion 236 joining the first and second end portions. The
first end portion 232 folded within the configuration is disposed
between the second end portion 234 and the medial portion 236. The
diaper, tucked and folded as here described and shown in FIGS.
33A-33B, is viewable through the encasement and, particularly, the
indicia 222 printed on the outer surface of the diaper along the
second end portion 234 is readily viewable through the transparent
encasement and enjoys a prominent area of the viewable top surface
of the diaper.
[0148] Another exemplary preferred embodiment is illustrated with
reference to FIGS. 34-35. In FIG. 34, a fully extended diaper 240
is shown with indicia 242 printed on the outer surface 246 of the
diaper. In this example, after obtaining an unfolded rectangular
configuration similar to that of FIGS. 29A-29B through tucking end
and side margins, the diaper 240 is twice folded along crosswise
aspects to obtain a folded rectangular configuration, and then the
diaper is disposed and vacuum-sealed within a transparent
encasement 248 resulting in the vacuum-packed diaper of FIGS.
35A-35B.
[0149] As shown in FIG. 35B, the crosswise folds 250 define a first
end portion 252 of the diaper, a second end portion 254 folded over
the first end portion 252, and a medial portion 256 joining the
first and second end portions. The diaper, tucked and folded as
here described and shown in FIGS. 35A-35B, is viewable through the
encasement 248 and, particularly, the indicia 242 printed on the
outer surface of the diaper along the medial portion 256 is
viewable through the transparent vacuum-sealed encasement 248.
[0150] Unlike the exemplary preferred embodiment of a vacuum-packed
diaper illustrated in FIGS. 33A-33B, the indicia of the
vacuum-packed diaper illustrated in FIGS. 35A-35B is intended
primarily for viewing in the vacuum-packed configuration as opposed
to viewing when the diaper is worn, as the indicia when worn
generally will face the feet of the wearer. The indicia of the
vacuum-packed diaper illustrated in FIGS. 35A-35B is readily
visible in the vacuum-packed configuration as well as when the
diaper is worn.
[0151] In yet another example, a diaper 260 and diaper-changing
accessories such as wipes 270 are disposed within a transparent
encasement 268. The wipes 270 preferably are, themselves,
prepackaged within a moisture impermeable encasement to avoid
moisture from the wipes 270 from being absorbed by the diaper
260.
[0152] In this example, wherein the diaper 260 is tucked and folded
in similar manner to that of the diaper of FIG. 33B, the wipes 270
are disposed below the medial portion 266 of the diaper within the
encasement. The diaper 260, tucked, folded and disposed within the
encasement 268 with the wipes 270 as shown in FIGS. 36A-36C, is at
least partially viewable through the encasement and, particularly,
the indicia 262 printed on the outer surface of the diaper along
the end portion 264 is viewable through the encasement 268. The
wipes 270 are arranged within the encasement so as not to obstruct
the view through the encasement of the indicia printed on the
diaper.
[0153] In addition to the arrangement of the diaper 260 and wipes
270 within the encasement 268, it should also be noted that notches
272 also are formed along outer edges of the encasement 268 as
shown in FIG. 36A-36C to aid in opening the encasement.
Furthermore, a weakened line 274 in the encasement 268 is formed in
the material of the encasement as an engineered weakness to further
aid in opening the encasement by providing a "tear-away" portion
276 of the encasement.
[0154] It is to be understood that the above referenced
arrangements are illustrative of the application for the principles
of the present invention. It will be apparent to those of ordinary
skill in the art that numerous modifications can be made without
departing from the principles and concepts of the invention as set
forth in the claims.
* * * * *