U.S. patent number 3,816,227 [Application Number 05/128,267] was granted by the patent office on 1974-06-11 for expandable article.
This patent grant is currently assigned to Colgate-Palmolive Company. Invention is credited to Charles H. Schaar.
United States Patent |
3,816,227 |
Schaar |
June 11, 1974 |
EXPANDABLE ARTICLE
Abstract
Expandable articles comprising flat interleaved sheets of
bendable material some portions of which overlap, and fastening
means securing the sheets together in the overlapping portions
without obstructing relative movement of the remaining portions of
the sheets to bend the unfastened positions of the sheets
independently of each other and bulk the article. The bulked
article can function as a diaper, wipe or other absorbent, or as a
pillow or other kind of spacer.
Inventors: |
Schaar; Charles H. (Lake
Zurich, IL) |
Assignee: |
Colgate-Palmolive Company (New
York, NY)
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Family
ID: |
26718075 |
Appl.
No.: |
05/128,267 |
Filed: |
March 26, 1971 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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41377 |
May 28, 1970 |
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Current U.S.
Class: |
428/101; 156/196;
428/179; 428/192; 604/369; 156/197; 428/189; 428/223 |
Current CPC
Class: |
A61F
13/49004 (20130101); A61F 13/00029 (20130101); A61F
13/53418 (20130101); A61F 13/49426 (20130101); A61F
13/539 (20130101); A61F 5/05825 (20130101); A61F
13/535 (20130101); Y10T 428/24752 (20150115); A61F
2013/53445 (20130101); A61F 2013/00744 (20130101); Y10T
156/1002 (20150115); Y10T 428/24669 (20150115); Y10T
428/24777 (20150115); Y10T 428/249923 (20150401); A61F
2013/15048 (20130101); A61F 2013/53908 (20130101); A61F
2013/5395 (20130101); A61F 2013/53966 (20130101); A61F
2013/4512 (20130101); Y10T 428/24025 (20150115); A61F
13/534 (20130101); Y10T 156/1003 (20150115); A61F
2013/1539 (20130101) |
Current International
Class: |
A61F
13/15 (20060101); A61F 13/00 (20060101); A61F
5/04 (20060101); A61F 5/058 (20060101); B32b
003/06 () |
Field of
Search: |
;161/145,148,17,18,19,156,49 ;156/196,197 ;128/285,287 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lesmes; George F.
Assistant Examiner: Bell; James J.
Attorney, Agent or Firm: Trevors; Ellen P.
Parent Case Text
This application is a continuation-in-part of copending application
Ser. No. 41,377, filed May 28, 1970 and now abandoned.
Claims
What is claimed is:
1. A bulkable product comprising bendable sheet material superposed
together in flat planar relation and presenting more layers of said
sheet material in a central region of said product than in other
regions thereof, the layers in the other regions having outer
substantially aligned edges forming the major portion of the edges
of the product, means retaining portions of said layers in said
central region in said superposed planar relation and remaining
portions of said sheet material being movable independently of each
other in a predetermined direction into irregularly bent nonplanar
layers patulously bulking said product and retaining said product
in bulked configuration.
2. A product in accordance with claim 1 wherein at least some of
said layers are formed of an absorbent sheet material.
3. The bulkable product of claim 1 comprising separate pieces of
bendable sheet material superposed together in flat planar relation
and presenting more layers of said sheet material in a central
region of said product than in other regions thereof, the layers in
the other regions having outer substantially aligned edges forming
the major portion of the edges of the product, means retaining
portions of said layers in said central region in said superposed
planar relation and remaining portions of said sheet material
having fold-free edges movable independently of each other in a
predetermined direction into irregularly bent non-planar layers
patulously bulking said product and retaining said product in
bulked configuration.
4. A bulkable product comprising bendable sheet material superposed
together in flat planar relation and presenting more layers of said
sheet material in a central region of said product than in other
regions thereof, the layers in the other regions having outer
substantially aligned edges forming the major portion of the edges
of the product, with the product edges on one side of the product
being constituted of edges of different layers than the product
edges on an opposite side of the product, means retaining portions
of said layers in said central region in said superposed planar
relation and remaining portions of said sheet material being
movable independently of each other in a predetermined direction
into irregularly bent non-planar layers patulously bulking said
product and retaining said product in bulked configuration.
Description
This invention relates to articles which are expandable to provide
bulk, which articles in their bulked form are useful for a variety
of purposes, for example, as fillers, absorbents, insulators,
spacers and the like. In many such uses the articles are of the
disposable type.
More specifically, this invention relates to an expandable article
which comprises a plurality of sheets of bendable material
superposed together in flat planar relation and presenting more
layers in a central region than in other regions, and at least one
fastening means retaining said interleaved sheets in superposed
planar relation in the central region while permitting remaining
portions of the sheets to be moved into irregularly bent layers
which patulously bulk the product as by the formation of cusps or
conical areas. The article is retained in its expanded form by the
cusps or conical areas, or other opposed non-planar irregularities
in the moved layers.
Illustrative of the articles included in the scope of this
invention are disposable diapers for infants and geriatric
patients; pillows, such as for ambulances, airplanes, etc.;
temporary splints for first-aid kits; handkerchiefs; absorbent
wipes; dusting and polishing materials; body swabs; surgical
sponges; insulating panels; sanitary pads; disposable adsorbent
bonnets for use after washing and/or treating hair; etc.
The structure of said articles will be better understood by
reference to the following description of the invention and the
accompanying drawings in which:
FIG. 1 is a perspective view of one form of the article of this
invention prior to expansion;
FIG. 2 is a perspective view of the article of FIG. 1 after
expansion;
FIG. 3 is a perspective view of a modified form of article with the
sheets spaced from one another for clarity;
FIG. 4 is a perspective view of the article of FIG. 3 after
expansion;
FIG. 5 is a perspective view of another embodiment of the invention
prior to expansion;
FIG. 6 is a similar perspective view of another embodiment of this
invention prior to expansion;
FIG. 7 is a similar perspective view of another embodiment of this
invention prior to expansion;
FIG. 8 is a perspective view of a tubular form of the invention
useful as a splint;
FIG. 9 is a view of the splint of FIG. 8 in its expanded form
applied to a human limb;
FIG. 10 is a perspective view of a disposable diaper of this
invention prior to expansion;
FIG. 11 is a cross-sectional view taken along the longitudinal
center line 11--11 of FIG. 10 prior to folding the diaper;
FIG. 12 is a cross-sectional view taken along the line 12--12 of
FIG. 10;
FIG. 13 is a plan view of the diaper of FIG. 10 after expansion,
with a portion broken away to show the bulked interior;
FIG. 14 is a cross-sectional view taken along the line 14--14 of
FIG. 13;
FIG. 15 is a cross-sectional view taken along the line 15--15 of
FIG. 13;
FIG. 16 is a perspective view illustrating another form of a
disposable diaper with a portion of one end cut away and unfolded
to show the internal construction;
FIG. 17 is a fragmentary plan view of an alternate embodiment of a
disposable diaper;
FIG. 18 is a cross-sectional view taken along line 18--18 of FIG.
17;
FIG. 19 is a fragmentary plan view illustrating another embodiment
of a disposable diaper;
FIG. 20 is a perspective view after expansion of a disposable
diaper employing the structure of the article shown in FIG. 8;
and
FIG. 21 is an end view of an alternate embodiment of a disposable
diaper.
Referring to FIG. 1, there is shown an expandable article 10
comprising interleaved sheets 11, 12, 13, 14 of absorbent tissue
paper. The inner edges of these sheets are overlapped and the
sheets secured together at central area 16 by any suitable
fastening means such as crimping, adhesive, double-face
pressure-sensitive adhesive tabs, stapling, combinations thereof,
etc. Furthermore, area 16 is shown for purposes of illustration
only; fastening can be achieved at many other locations on the
article.
In order to expand the article illustrated in FIG. 1, one merely
holds the ends of the article remote from the overlaps and pulls in
a direction which is perpendicular to the overlapped edges (arrows
20) along a line offset from a line passing through the fastened
portion running in the direction of pull, thereby obtaining the
bulked article illustrated in FIG. 2. The bulk is retained due to
crumpled distortion of the layers which prevents them from
returning to their original flat configuration.
Sheets 11, 12, 13, 14 can be any bendable material, selection being
dependent upon the end use of the article. Thus, where disposable
diapers, pillows, handkerchiefs, etc. are intended, soft absorbent
materials such as paper; creped wadding; sponge sheeting, e.g.
urethane sponge; etc. are used; while fiberglass or asbestos
sheeting can be employed in the construction of insulating
panels.
Although the article depicted in FIG. 1 comprises four sheets, the
invention encompasses articles having two, three and preferably
four or more interleaved sheets, the number being dependent on the
intended end use and the friction or stiffness of the material of
which the sheets are comprised.
While the overlapping edges appear in alignment in FIG. 1, random
amounts of overlapping are contemplated. Furthermore, the
individual sheets may be staggered in a relationship other than
one-to-one, i.e., two-to-two, three-to-one or more. The extent of
overlap will determine the final size of the article upon
expansion.
In FIG. 3, interleaved sheets 31, 32, 33, 34 are fastened at the
side edges 36 and 37. In this case, when the ends are pulled the
article is pinched in and the layers move independently to form
cusps. This cusping effect results in the edge of one layer
catching on the face of an adjacent layer to "tent" the layers.
Thus, the process of expanding the article of this invention adds a
dimension to an initially regularly compact, planar article by
bending the layers into cusps or other non-planar
configurations.
As illustrated in FIG. 4, the article is necked down in the
intermediate portion thereof upon expansion.
FIG. 5 depicts an article similar to that of FIG. 3 with the
exception that interleaving and overlapping is achieved by folding
individual sheets. Thus, sheets 51 and 52 are folded as shown and
secured together at points 56 and 57. Using this basic type of
construction, it will be apparent that an article can be
constructed from a single sheet of bendable material by making
multiple folds both at the sides of the article and in the central
portion thereof.
FIG. 6 illustrates an article having sheets 61, 62, 63, 64 in which
corners of alternate sheets are torn away to provide means for
grasping the remaining sheets. The sheets are secured together at
point 60. This construction permits the article to be expanded by
pulling the alternate sheets, in opposite directions, as indicated
by the arrows in the drawing.
In FIG. 7, two stacks of sheets of bendable material, 70 and 71,
are arranged in an overlapping relationship wherein the stacks are
cut inwardly along parallel lines and the intervening material is
then folded inwardly towards the center. Thus, lines 76, 77, 78, 79
represent the cut lines. In this embodiment of the invention, the
folded portions of the sheets function as retaining means. The
individual sheets comprising stacks 70 and 71 can be individually
cut, folded and assembled in a random or alternating overlapping
relationship, or the overlapped stacks can be cut and folded
together. Expansion by pulling as indicated in the drawing provides
an article having greatly increased fluff in the intermediate
portion. In a variation of this construction, the folded portions
of one or more of the individual sheets comprising stacks 70 and 71
can be opened to lie flush with the article.
In FIG. 8, a tubular article having sides 80, 81, 82 is
illustrated, each side comprising a set of at least two sheets.
Sheets 83 and 84 of side 80 are shown to depict the manner in which
the sheets are interleaved. Preferably, these are sheets of
aluminum foil or thin pliable metal. Fastening is achieved at any
point or points along the lines joining the sides together by any
of the aforementioned suitable means. This particular construction
is preferred in the construction of splints wherein a limb is
inserted into the article which is subsequently expanded by pulling
in the direction shown in the drawing until the article becomes
rigid enough to protect and immobilize the limb, as shown in FIG.
9.
In FIG. 10, a disposable diaper incorporating a construction
similar to that shown in FIG. 3 is shown, except that the fastening
means is provided by enclosure of the structure within diaper
covers, instead of, or in addition to the adhesive fastening means
of FIG. 3.
As shown in FIGS. 10, 11 and 12, the diaper is of the box pleat
type and includes a water-repellant back cover 91 having side flaps
92 overturned on and secured to an absorbent front cover 93. They
contain therebetween a filler generally indicated at 94.
In contrast to the usual box pleated disposable diaper, the
composite construction shown in FIG. 10 includes a lateral box
pleat 95 in the back sheet 91 and a similar box pleat 96 in the
absorbent top cover sheet 93.
The longitudinal box pleats and/or the lateral box pleats can, if
desired, be maintained by application of adhesive at any convenient
points so long as the lateral pleats can be opened by pulling the
ends of the diaper.
The filler 94 has its overlapping layers between the top and bottom
sheets with the sheets extending in staggered relation towards the
two waist areas of the diaper. Thus when the waist ends of the
diaper are taken hold of, each hand grasps only some of the filler
layers permitting the entire diaper to be expanded in accordance
with the invention, bulking the diaper due to the filler 94
assuming much the configuration shown in FIG. 4, including the
necking of the entire diaper.
FIG. 12 shows the application of adhesives at 97 to maintain a
longitudinal box pleat configuration.
The configuration of the diaper after the expansion is generally
shown in FIGS. 13, 14 and 15. Thus the adhesive supports 97, 97
remain to maintain the box pleat in the crotch area with the waist
sections of the diaper flaring out in the usual manner and the
filler 94 having been constricted in the crotch area and having its
several layers cusped to bulk the entire article as indicated by
the non-planar configuration of the filler layers in FIGS. 14 and
15.
Lengthwise, the diaper also assumes an arcuate configuration which
is helpful in diapering.
In FIG. 16, a modification of the diaper of FIGS. 10, 11 and 12
having edge pleats 110 and 112 in cover sheet 114 is shown. Thus,
the type of pleat in both the top and back sheets is not critical,
as long as the diaper expands in the desired manner when pulled.
The filler 94 in FIG. 16 is enclosed between back sheet 91 and
cover sheet 114 by heat sealing.
Another variation which can be obtained is shown in FIGS. 17 and
18. This embodiment is similar to that shown in FIGS. 10-15, except
that additional layers 120 and 130 have been added to the absorbent
pad under cover sheet 93. Layers 120 and 130 are characterized by a
slit 140 formed along the longitudinal center line in the crotch
region of the diaper, which line parallels the direction of
expansion of the diaper. Such a slit 140 provides greater ease in
expanding the diaper, increased rate of absorbency especially in
the slit region, and a greater amount of fluffing when expansion
takes place.
Although only the two top sheets of the absorbent pad are slit in
FIGS. 17 and 18, it will be apparent that the slitting operation
can be applied to one sheet, or to as many sheets as desired.
Preferably the slit sheets are contiguous and are located directly
under the cover sheet; it is also desirable not to slit some of the
sheets which are nearer to the back sheet. Furthermore, the slit
could extend the entire length of the diaper, but for ease of
expansion it is preferable to terminate the slit short of the
diaper ends.
While a single slit along the longitudinal center line has been
shown for purposes of illustration, multiple slits can be applied
to each sheet, or a single slit offset from the longitudinal center
line can be cut in one or more sheets.
Alternately, as shown in FIG. 19, increased rate of absorbency can
be achieved by slitting sheet 130 in a general I configuration and
folding the portions bounded by the slits away from the center
slit, thereby forming flaps 130a and 130b and revealing sheet 120.
Similarly, such slitting and folding can be applied to one or more
sheets of the absorbent pad.
As illustrated in FIG. 20, an absorbent pad having the structure
illustrated in FIG. 8 can be used in a disposable diaper by placing
a cover sheet 93 over sides 80 and 82 and a fluid impervious back
sheet 91 over side 81. Sides 80 and 82 are folded longitudinally,
as illustrated by the fold lines shown in the drawing.
Although FIG. 20 illustrates an expandable diaper formed from three
sets of two sheets each, a larger number of sets could be used to
produce a greater bulkiness when the diaper is expanded, if so
desired.
FIG. 21 illustrates another variation of a disposable diaper
wherein the filler sheets are creased in a direction parallel to or
coincidental with the line of pull. Such creases, which can be
applied to one or more of the filler sheets, function to direct the
bulking primarily in one direction. For example, a crease away from
the cover sheet as shown in FIG. 21 will provide a desirable trough
in the expanded article.
While the pleats in the back and cover sheets in FIGS. 10-20 are
shown to be parallel to overlapping edges of the absorbent pad,
they need only be approximately parallel to function as intended.
Thus, they can even be diagonal to the overlapping edges and yet
expand when pulled in a direction perpendicular to the overlapping
edges. Furthermore, one or more pleats may be provided. For
example, where the back sheet has several pleats, the diaper can be
expanded to fit various sizes of babies by pulling out one or more
of the pleats. In lieu of pleats, overlapping cover and/or back
sheets can be used.
Back sheet 91 is any flexible, fluid impervious material, such as
polyethylene film, polypropylene film, ethylene-acrylate copolymer
film, ethylene-propylene copolymer film, vinyl chloride polymer and
copolymer film, etc.
The sheets of filler 94 are comprised of any soft absorbent
material such as paper; creped wadding; tissue; etc. Preferably,
the sheets, which may be single or multi-ply, have a total weight
of 20-40 pounds per ream.
Cover sheet 93 can be a wet strength tissue paper, polyurethane
foam, or preferably a soft nonwoven material such as cotton, rayon,
polypropylene, nylon, etc. The paper cover sheet has a basis weight
of at least about 14, and preferably 18 to 20 pounds per ream,
while nonwovens having a weight of 15 to 20 grams per square yard
are generally employed.
Alternately, a single sheet of stretchable material such as
polyurethane foam, or perforated material, can be employed as the
cover sheet.
Various modifications are possible in securing together the back
sheet, filler and cover sheet. For example, the edges of the back
sheet, which have larger dimensions than the filler or cover sheet,
can be folded around the filler. The cover sheet is then secured to
the folded around edges of the back sheet. Alternately, the cover
sheet may be larger than the filler and back sheet, and the edges
of the cover sheet folded around the corresponding edges of the
filler. In this embodiment, the edges of the back sheet are secured
to the folded around edges of the cover sheet. The diaper may also
be constructed with both cover and back sheets having larger
dimensions than the filler, and secured together in any of the
aforementioned manners.
There are many advantages to the diaper constructions illustrated
herein. Thus, expansion provides a diaper having three significant
features. First, the diaper is fluffy and highly absorbent in the
critical areas. Secondly, the operation to expand the diaper
results in a narrowing down of the crotch area and thirdly, a
contouring or girdling effect in the waist area. Accordingly, the
expanded diaper assumes a shape having a better contact with the
body, and the structure of the expanded diaper in the area into
which the exudates flow is such that the diaper retains moisture
and fecal matter without leakage. Also, it will be apparent the
diapers are easily packaged and stored prior to use because of
their compactness before expansion.
Another feature of the diaper construction disclosed herein is its
applicability to sexually oriented diapers. Thus, the absorbent
filler can be constructed so as to provide bulk offcenter from the
transverse center line of the diaper. The diaper is applied
according to the sex of the infant, the part having the region of
increased bulk being placed against the bottom of a female and the
front of a male. Thus, a diaper providing increased absorbency for
both sexes when applied as previously described can be readily
constructed.
If desired, free sheets of various materials can be interspersed in
the articles of this invention. For example, waxed paper to assist
in sliding the sheets can be added. Also, "fluff", which is a mass
of loosely associated fibers such as cotton fibers or comminuted
wood pulp, and/or talcum powder can be inserted in the disposable
diapers.
While diapers of various dimensions can be constructed, the
expandable feature eliminates the necessity of providing a series
of different sizes for babies of different age and size. For
example, a diaper approximately 13 inches wide by 14 inches long,
and having a thickness in the crotch area of about 1/4 inch,
expandable to 17 or 18 inches long and 3 to 4 inches thick in the
crotch area, would function both as a regular and large size
diaper, since it could be used for smaller babies in a partially
expanded form and then fully expanded to fit larger babies.
Although the various diaper constructions described herein have
been directed to disposable types, it will be apparent that
improved reusable diapers can be constructed according to this
invention. Thus, expandable gauze diapers, which can be collapsed
or reformed to approximately their original dimensions after use,
are contemplated. After laundering, these diapers are again readily
expandable. Furthermore, if no longitudinal box pleat is formed
because the adhesive 97 is omitted, the disposable diaper can be
collapsed and reformed after use, by pulling outwardly on the side
flaps 92. Such a use is contemplated in the event the disposable
diaper has not been soiled, and is to be stored prior to reuse.
While this invention has been described above in detail with
respect to certain preferred embodiments of the invention as
illustrated in the drawings, other modifications and design changes
are also contemplated which are within the spirit and scope of the
appended claims.
* * * * *