Disposable Diapers And Supporting Garment Therefor

Abstract

A baby diaper retaining garment and disposable flushable pads for use therewith, the pad having exposed at least the central portion of one face of the layer of absorbent material to render it readily flushable upon exposure to a liquid, and the garment having spaced pockets for retaining ends of such a pad therein and elasticized edge portions forming a waterproof pouch or channel for holding the pad adjacent the perineal region of a wearer.

Parent Case Text

RELATED APPLICATIONS

This application is a streamlined continuation application of Ser. No. 548,513, filed May 9, 1966, and now abandoned.

Description

This invention relates generally to diapers and, more particularly, to a new and improved disposable absorbent diaper pad and a diaper garment construction providing a moistureproof pouch into which such a pad may be interchangeably inserted and supported in the proper position on a wearer.

In the past, much effort has been spent in attempting to simplify the procedure of changing soiled diapers of infants and installing fresh, clean diapers. In accordance with this effort, there have evolved a large variety of so-called "disposable" diapers, the majority of which have been designed as an integral construction embodying absorbent material and waterproof material bonded or otherwise secured to each other. This inherently means that the structure must be torn apart to separate nondisposable portions from the disposable portions, necessitating undesirable handling of the soiled diaper. Previous attempts to provide a completely disposable diaper pad, and especially one that is "flushable," have been largely unsuccessful.

The term "flushable" as used herein, is intended to describe the ability of a diaper pad structure to physically deteriorate and structurally break down into small clumps of loose fibers by the normal action of the stream of water in an ordinary toilet bowl. All portions of this product should be capable of safely and harmlessly passing through a normal household sewage system without danger of clogging the system.

Many people have found that creped cellulosic wadding or tissue or bats of fluffed wood pulp disintegrate quickly in the presence of body excretions. They, therefore, employed various means to strengthen the pad structure so that it would not fall apart during use of during removal after use. This was done largely by wrapping the absorbent materials in sheet materials such as fibrous webs strengthened by different chemical binders, resins, plastics or fibers. This not only increased the cost of such a product, but also resulted in several disadvantages. The chief disadvantage which has held back widespread use of such pads has been that they not only would not disintegrate so readily but also generally lost their disposability in that they were no longer flushable unless painstakingly disassembled manually by the user. Thus, by covering the crepe wadding or absorbent material to support it during use, the advantages to be derived from a disposable diaper pad were largely lost.

In view of the disadvantages and shortcomings of previous diaper constructions, it is an advantage of the present invention to provide a new and improved disposable, flushable, diaper pad which includes layers of soft fibrous materials, one of which is openly exposed on at least part of one face thereof for direct contact with fluids and to facilitate ready disintegration. In addition, the present invention provides a novel diaper retaining garment which, when used in combination with the disposable pad of the invention, serves to confortably retain such a pad within a waterproof pouch or channel adjacent the perineal region of a wearer, so that the readily disposable pad retains its functional configuration during use.

Thus, one object of the invention is to provide a disposable, flushable, absorbent diaper pad which physically disintegrates and generally breaks down very rapidly into small clumps of fibers when dropped into the vortex of a flushed toilet.

Another object of the invention is to provide a garment for retaining a disposable diaper pad within a moisture proof pouch, which garment can be easily cleaned and reused and which provides a snug fit around the hips of a wearer.

Another object of the invention is to provide a novel type of combination disposable diaper pad and diaper supporting and retaining garment construction which provides a moistureproof pouch for containing the flushable disposable diaper pad.

It is a still further object of the invention to provide a disposable absorbent pad for use as a diaper insert in the moistureproof pouch of a diaper retaining garment, which pad is easily and readily flushable.

These and additional objects and advantages of the invention will be apparent from the following detailed description thereof, when read with reference to the accompanying drawings, which illustrate by way of example a presently preferred form of the invention and certain modifications thereof and in which:

FIG. 1 is an inner plan view of a supporting garment of the invention,

FIG. 2 is an enlarged sectional view of an elasticized portion of the fabric portion shown in FIG. 1, taken along line 2--2,

FIG. 3 is a perspective view of an assembled pad and supporting garment combination of the invention,

FIG. 4 is a longitudinal sectional view of the pad and garment combination taken along lines 4--4 of FIG. 3,

FIG. 5 is a partial sectional view taken along lines 5--5 of FIG. 4,

FIG. 6 is a perspective view of a disposable pad of the invention, showing sectional views of portions thereof, and

FIG. 7 is a perspective view of a modified disposable pad of the invention, showing sectional views of portions thereof.

Referring to the drawings and particularly to FIG. 1, there is shown a stretched-out diapering garment having an elongate body 10 of a waterproofed sheet material having its longitudinal side 11, 11 recessed centrally of their ends leaving ears or apron portions 12, 13, 14, and 15 extending laterally outward from each side of each end. Each end 16 and 17 of the elongate body portion 10 has an inwardly opening pocket 38 and 39 formed therein by a portion of the material forming the elongate body 10 being folded back over the body portion at each end and sewn only along each side. Thus, the inwardly facing edge of the pocket flap remains free forming the opening into the pocket. In a somewhat similar manner, each of the ears or apron portions 12, 13, 14, and 15 are constructed of multiple thicknesses of sheet material formed by several flaps cut into the original blank of sheet material which flaps are folded over in superimposing relationship and stitched together along lines 18, 19, 20, and 21, respectively. This multiple thickness serves to strengthen this portion of the garment where the greatest stress is applied during use. Each of the ears or apron portions, 12, 13, 14, and 15 have a plurality of fastener elements 22 secured thereto, the apron portions 12 and 13 at end 16 of the elongate body 10 having a male type of fastener element 22 while the apron portions 14 and 15 at end 17 of the elongate body 10 have a cooperating female portion of fastener element 22. Several fastener elements 22 are provided at each apron portion at each end 16 and 17 to allow adjustment and positioning of the garment onto infants of varying size. Any type of fastener element may be employed such as buttons, hooks, or snaps, but snaps are preferred and illustrated in FIG. 1.

The inwardly recessed portions of the elongate sides 11, 11 are elasticized for at least a portion of their length. As shown in FIG. 1, an elastic band 24 is stitched at point 25 and point 26 between apron portion 12 and apron portion 14. It should be noted that the sheet material forming the elongate body 10 is gathered prior to stitching the elastic strip 24 along the inwardly recessed portion of each side 11. The elastic strip 24 is similarly covered by an enclosing cloth strip 27 in a manner illustrated in detail in FIG. 2. It can be seen while both longitudinal edges of the cloth strip are stitched to opposite sides of the sheet forming elongate body 10, only one elongate edge of the elastic strip 27 is stitched to the gathered edge of elongate body 10. The inwardly recessed portion of the opposite longitudinal side 11 of the body 10 is similarly gathered and elasticized between point 28 of apron portion 13 and point 29 of apron portion 15. The above elasticized portions serve to hold the body portion 10 into contact with the through extending limbs of a wearer and yet allow the flexibility required to prevent movement during use of the garment.

In a somewhat similar manner, each of the ends 16 and 17 of the elongate body portion 10 are gathered and elasticized between the respective apron portions. A strip 32 of elastic material, which may be rubber or may be a composite material formed of strands of rubber woven into a cloth mesh, is sewn between point 30 adjacent apron portion 12 and point 31 adjacent apron portion 13 to the gathered and elasticized end edge 16 of the sheet forming elongate body 10. These gathered and elasticized end portions 16 and 17 provide for flexibility of the garment around the waist of a wearer and allow for some variation in size while providing a snug fit.

Referring now to the spaced end pockets 38 and 39 formed by the overturned end portions or flaps of body 10, the flap 42 adjacent strip 32 of elastic material at end 16 is of greater width than the flap 43 at the opposite end 17 of the garment. That is, it extends inwardly toward the center of the garment for a greater distance and the inwardly opening edge of the flap 42 forming the open pocket 38 is not elasticized but is merely terminated by overturning a small end margin of the fabric and stitching it onto itself. The pocket 39 formed by the overturned flap 43 at the opposite end 17 of the elongate body 10 adjacent strip 33 of flexible material has a lesser depth. That is, it does not extend inwardly toward the center of the garment as far as the flap 42 and its inner edge forming the open end of the pocket 39 is elasticized in a manner similar to that illustrated in FIG. 2 and used on the inwardly recessed side portions 11, 11.

This has been found desirable since after a disposable diaper pad is inserted into the garment for retention by the end pockets 38 and 39, during wearing the pad tends to slide forwardly into open pocket 38 at the front end of the garment and therefore does not require an elasticized edge adjacent the opening to the pocket 38 to aid in retaining it therein. However, at the opposite end of the garment, the tendency is for the pad to slide out of the pocket 39 during wearing and, therefore, the free edge of this pocket 39 is elasticized to aid in applying pressure to the end of the diaper pad. However, the depth of the pocket 39 formed by flap 41 is less than that of the front pocket 38. This area of the diaper tends to become more soiled during use due to the position on the wearer and more pad must be exposed at this end.

A preferred embodiment of the garment has a body 10 comprised of a waterproof sheet material formed from a layer of woven nylon fabric coated on its inner surface with vinyl. The manner in which the garment is constructed ensures that the portions of the garment contacting the wearer are primarily uncoated with vinyl. Thus, the tops or flaps 42 and 43 of the spaced end pockets 38 and 39, respectively, are uncoated and the vinyl coated inner surface of body 10 is covered by a disposable diaper pad during use. This prevents irritation of the skin due to moisture retention on the skin by the vinyl and sticking of the vinyl to a wearer.

FIG. 3 is a perspective view of a combination disposable diaper pad and supporting garment and illustrates the garment shown in FIGS. 1 and 2 in the assembled condition for use on a wearer and, in addition, shows one embodiment of a disposable diaper pad for use with the diapering garment. FIG. 4 is a sectional view taken along 4--4 of FIG. 3 and illustrates more clearly the manner of construction of the diaper garment of FIG. 1 with regard to the elasticized portions of the pocket edges and the ends 16 and 17 of the elongate body 10.

The pad illustrated in FIGS. 3, 4, and 5 comprises a plurality of superimposed, overlying layers 45 of crepe wadding partially wrapped by a facing ply 46 of a porous nonwoven fabric having elongate side margins extending around the elongate sides of layers 45 and overturned upon and bonded to the top side margins of the top inner layer 45 of crepe wadding as shown in FIG. 5. As can be seen, this leaves the central portion 47 of the top inner layer 45 of crepe wadding open and exposed. This layer 45 is preferably placed against the body portion 10 so that only the ply 46 contacts the wearer as shown in FIG. 3. The number of layers 45 of crepe wadding employed is preferably about 30 although good results have been obtained with varying numbers of layers ranging from 15 to 40 depending upon the size of the particular wearer and the absorbency characteristics of the crepe wadding used.

The nonwoven facing fabric 46 is preferably treated with a bacteriostat, i.e., a substance which will inhibit the growth of bacteria without destroying them. Although many types of bacteriostats are known and may be successfully employed in the invention, the preferred type is G-11 Hexachlorophene USP dissolved in Deltyl. The amount of such bacteriostat employed was approximately 25 percent of the fiber weight and was incorporated in the nonwoven bonding agent.

Many different methods can be used to bond the overlying extended side margins of the facing nonwoven sheet 46 to the top layer 45 of the crepe wadding, such as by embossing techniques, stitching, or fasteners. However, it is preferably done by employing a hot melt adhesive in a very thin longitudinal strip 48 adjacent each of the side margins. One adhesive which produces good results was UPACO, H-3525-X-1, blue, supplied by Union Paste Company of Massachusetts.

FIGS. 6 and 7 illustrate additional embodiments of disposable, flushable pads which may be employed with even better results in accordance with the invention. Referring to FIG. 6, three mats or composite layers 50 are superimposed on each other and enclosed by a facing sheet 51 of nonwoven fabric which, again, has extended side margins overturned and bonded to the top surface adjacent the side margins thereof. Each mat or layer 50 includes a layer 52 of fluff material enclosed between two layers 53 of two-ply crepe wadding. In addition, each mat 50 is embossed longitudinally so as to create deep channels or pressed portions 54 spaced apart so as to maintain the fluff material 52 in position during use of the pad. The ends 55 and side margins of each mat are secured together by crimping or deep embossing so as to retain the fluff material 52 within.

Referring to FIG. 7, the structure of the pad shown is generally similar to the pad shown in FIG. 6. However, in this instance, the spaced-apart pressed portions 54, shown in FIG. 6, are in the form of small circular areas 54, shown in FIG. 7, having a diameter of from about one-fourth inch to about 1 inch. These depressions also hold the fluff material 52 in position in the pad and provide for even greater flexibility in the pad which is desirable.

The fluff material comprises an inexpensive flocky material of high absorptive rate and capacity, and of which there are many types. Varieties of fluffed wood pulp are preferred because of their low cost and relatively high absorptive capacity. It also provides the desired bulk while additionally providing a soft structure free from stiffness and readily conformable to the body contours. Since tissue is often employed in disposable pads, as described above, the use of wood pulp which is the raw material from which paper tissue is made provides obvious economic savings.

Good results have been achieved with a mixture of about 35 percent pine and about 65 percent gum paper pulp. A fluff of 100 percent pine paper pulp has also been successfully employed. It will be readily apparent that many different types and forms of fluffed paper pulp, or other fluff material, may be employed with equal success without departing from the scope of the invention.

The size of each of the above described pads and garments is not critical, it being only required that they be large enough to perform their intended function for the individual person involved. For infants, the length of the pads has varied from about 10 to 14 inches, and the width from about 4 to 5 inches. The thickness of the pads has ranged from about one-fourth to one-half inch. However, it will be recognized that this is dependent on the absorption capacity desired as well as the length of time between pad changes.

One feature of the garment of the invention is the relatively reduced length of the front body portion extending from the perineal region of a wearer to the front end of the garment. This ensures that the garment will be retained on a wearer at a point below the stomach which generally protrudes. In the past, garments having longer front body portions have slipped and sagged during wearing due to this protrusion. The garment of the invention is designed for application to a wearer in a form and position which it will maintain during use.

The above described combination supporting garment and disposable pad of the invention provides several advantages over the previously known types. The nature of the garment is such that by employing a moistureproof pouch to enclose the perineal region of a wearer, such a pouch having end pockets 28 and 39 and upturned sides 11, 11 to form a channel, a pad can be employed which has greatly improved disposability characteristics. That is, use of the truly flushable pad of the invention is made practicable without the difficulties previously encountered.

The pads of the invention are constructed so as to place a surface of soft crepe wadding directly into a position of exposure to fluids upon removal from the garment without requiring manual disassembly of the pad. Thus, the pad is only supported by a partially encircling backing sheet of nonwoven material which itself is non-bulky, flexible, and therefore disposable. This construction permits the crepe wadding to contact moisture instantly and to immediately fall apart structurally when held within the vortex of a flushed toilet or other stream of water.

However, the relatively unsupported pads of the invention are firmly supported during use when employed in combination with the garment of the invention and particularly in a moistureproof pouch as described above. This ensures that the pads will be comfortably yet firmly retained in place adjacent to and substantially in contact with the perineal region of a wearer.

From the above description of the invention, it will be apparent that various modifications of the principle involved and the manner in which it is carried out can be practiced without departing from its spirit and scope, as defined by the following claims.

Claims

What is claimed is:

1. A combined disposable diaper and retaining garment comprising an elongate body of sheet material having its longitudinal edges recessed centrally of their ends, the portions of the body between its ends and the recesses forming apron portions arranged to encircle the waist of a wearer, the portion of the body between said apron portions forming a crotch and arranged to surround the perineal part of the wearer, means disposed on each of said apron portions for detachably connecting the respective apron portions along each longitudinal side edge of the body together with each other, at least a portion of each of the end edges and longitudinal side edges of said body between respective apron portions being gathered and elasticized so as to form an elongate flexible channel in said crotch, said channel having spaced inwardly opening end pockets and being open between them in the area adjacent substantially the entire perineal region of a wearer, at least a portion of the edge of the open side of one of said end pockets being gathered and elasticized for flexibly retaining one end of a disposable diaper pad, a disposable flushable absorbent pad, said pad having at least one elongate body of fluff, at least one layer of crepe wadding surrounding said body of fluff, and a facing layer of at least one ply of porous nonwoven fabric, said facing layer having elongate side margins extending around the sides and overturned upon and bonded to the bottom side margins of the bottom layer of said crepe wadding so as to leave the central portion of said bottom layer open and exposed, said channel being adapted to removably receive said pad and retain it adjacent to, and substantially in contact with, said perineal region.

2. A combined disposable diaper and retaining garment comprising an elongate body of sheet material having its longitudinal edges recessed centrally of their ends, the portions of the body between its ends and the recesses forming apron portions arranged to encircle the waist of a wearer, the portion of the body between said apron portions forming a crotch and arranged to surround the perineal part of the wearer, means disposed on each of said apron portions for detachably connecting the respective apron portions along each longitudinal side edge of the body together with each other, at least a portion of each of the end edges and longitudinal side edges of said body between respective apron portions being gathered and elasticized so as to form an elongate flexible channel in said crotch, said channel having spaced inwardly opening end pockets and being open between them in the area adjacent substantially the entire perineal region of a wearer, a disposable flushable absorbent pad, said pad comprising at least one elongate composite absorbent layer superimposed upon at least one facing ply of a porous nonwoven fabric, said facing ply having elongate side margins extending around the elongate sides of said layer and overturned upon and bonded to the bottom elongate side margins of the bottom composite absorbent layer, said composite absorbent layer comprising a layer of flocky absorbent material covered with a facing sheet and a backing sheet, each of said sheets comprising at least one layer of crepe wadding, said absorbent material being retained in position between said sheets of crepe wadding by a plurality of spaced embossed areas pressed into said composite layer from at least one side, the side margins and ends of said sheets being physically bonded together, and at least the central portion of said bottom layer being exposed.

3. A disposable, flushable, absorbent pad for use as an insert in a diaper retaining garment, comprising at least one elongate composite absorbent layer superimposed upon at least one facing ply of a porous nonwoven fabric, said facing ply having elongate side margins extending around the elongate sides of said layer and overturned upon and bonded to the bottom elongate side margins of the bottom composite absorbent layer, said composite absorbent layer comprising a layer of flocky absorbent material covered with a facing sheet and a backing sheet, each of said sheets comprising at least one layer of crepe wadding, said absorbent material being retained in position between said sheets of crepe wadding by a plurality of spaced embossed areas pressed into said composite layer from at least one side, the side margins and ends of said sheets being physically bonded together, and at least the central portion of said bottom layer being exposed.

4. A disposable, flushable, absorbent pad according to claim 3, wherein said flocky absorbent material comprises fluffed wood pulp.

5. A disposable, flushable, absorbent pad according to claim 3, wherein said porous nonwoven fabric contains a bacteriostat.

6. A disposable, flushable, absorbent pad according to claim 3, wherein said plurality of spaced embossed areas are in the form of longitudinal channels recessed into at least one surface of each said composite layer to a substantially equal depth.

7. A disposable, flushable, absorbent pad according to claim 3, wherein said longitudinal channels are recessed into each surface of each said composite layer to a depth less than 50 percent of the thickness of each composite layer.

8. A disposable, flushable, absorbent pad according to claim 3, wherein each end margin of each composite layer is embossed to ensure containment of said flocky absorbent material within said layer.

9. A disposable, flushable, absorbent pad for use as an insert in a diaper retaining garment, comprising at least one elongate composite absorbent layer superimposed upon at least one facing ply of a porous nonwoven fabric, said facing ply having elongate side margins extending around the elongate sides of said layer and overturned upon and bonded to the bottom elongate side margins of the bottom composite absorbent layer, said composite absorbent layer comprising a layer of flocky absorbent material covered with a facing sheet and a backing sheet, each of said sheets comprising at least one layer of cellulosic wadding, said absorbent material being retained in position between said sheets of cellulosic wadding by a plurality of spaced embossed areas pressed into said composite layer from at least one side, the ends of said sheets being physically bonded together, and at least the central portion of the bottom sheet of cellulosic wadding of said bottom layer being exposed.

10. A disposable, flushable, absorbent pad according to claim 9, wherein said flocky absorbent material comprises fluffed wood pulp.

11. A disposable, flushable, absorbent pad according to claim 9, wherein said porous nonwoven fabric contains a bacteriostat.

12. A disposable, flushable, absorbent pad according to claim 9, wherein said plurality of spaced embossed areas are in the form of longitudinal channels recessed into at least one surface of each said composite layer to a substantially equal depth.

13. A disposable, flushable, absorbent pad according to claim 9, wherein said longitudinal channels are recessed into each surface of each said composite layer to a depth less than 50 percent of the thickness of each composite layer.

14. A disposable, flushable, absorbent pad according to claim 9, wherein each end margin of each composite layer is embossed to ensure containment of said flocky absorbent material within said layer.

15. The disposable, flushable, absorbent pad according to claim 9, wherein a plurality of elongate composite layers are superimposed upon said at least one facing ply of said porous nonwoven fabric.

16. A disposable, flushable, absorbent pad according to claim 9, wherein each of said facing and backing sheets are comprised of a plurality of layers of cellulosic wadding.

17. The disposable, flushable, absorbent pad according to claim 16, wherein said layers of cellulosic wadding are all substantially the same width.