Note: Descriptions are shown in the official language in which they were submitted.
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DIAPER WITH ELASTIC AND HOOK AND PILE FASTENERS
INTRODUCTION
This invention relates to a baby diaper and, more
particularly, to a baby diaper which utilises fastening
systems allowing increased comfort to the baby and greater
integrity in the diaper connections.
BACKGROUND OF l'HE INVENTION
There are many diapers available for use on
infants, such diapers being of the permanent or disposable
type. Many of the diapers so available contain certain
features which are intended to increase the comfort or
utility of the diaper.
One such diaper is disclosed in U.S. Patent
4,568,342 to Davis. Davis teaches a diaper which is
intended to have greater utility during washing. Davis uses
VELCRO (Trademark) as a fastening means, with two VELCRO
tabs being mounted on opposite sides of the rearward portion
of the diaper and a complementary single long piece mounted
on the forward portion of the diaper. When the diaper is
positioned on an infant, the rear tabs hook hold to the
forward long piece on opposite sides of the front portion
and keep the diaper positioned on the infant.
While the attachment technique used in Davis
allows for easy positioning of the diaper on the baby, there
is no expansion or elasticity in tha forward portion of the
diaper after the diaper has been attached on the infant.
Since the stomach of the infant is accordingly restrained,
it can be potentially uncomfortable.
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SUMMARY OF THE INVENTION
According to one aspect of the invention, there is
provided a diaper for an infant comprising a forward
portion, a rearward portion connected to said forward
portion, attachment means positioned on opposite sides of
said forward and rearward portions and expansion means
positioned between said attachment means on said forward
portion.
According to a further aspect of the invention,
there is provided a diaper for an infant comprising a
forward portion, a rearward portion and expansion means
mounted in the central portion of said forward and rearward
portions, said expansion means being under a predetermined
tension such that said diaper forms a cup shape in its non-
fitted position.
According to yet a further aspect of the invention,
there is provided a fastener cover for a diaper comprising
a first hook portion mounted to the fabric of said diaper
about the periphery of said hook portion, a second loop
portion mounted separately from and adjacent to said hook
portion, said loop portion being connected to said fabric
along a connection axis on one side of said loop portion
nearestmost to said hook portion, said second loop portion
being operable to rotate about said connection axis to cover
and connect with said hook portion.
According to yet a further aspect of the invention,
there is provided a diaper comprising at least two layers
of fabric material and a plurality of elastic portions to
conform the shape of said diaper more closely to the shape
of the user of said diaper, at least one of said elastic
portions being connected to said diaper and contacting only
the outside surface of said two layers of fabric.
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According to yet a further aspect of the invention,
thare is provided a diaper comprising a forward portion, a
rearward portion connected to said forward portion,
attachment means positioned on opposite sides of said
forward and rearward portions, said attachment means
comprising a loop portion on the forward portion of said
diaper and a hook portion on the rearward portion of said
diaper, said hook portion being made from an extruded
plastic material and being operable to contact and fasten to
said loop portion.
According to yet a furlher aspect of the invention,
there is provided an absorbency pad for a diaper comprising
a first layer of needled fabric material having a first side
in which the needle has entered said material and a second
side in which the needle has penetrated from said first
side, said pad further having a second layer of needled
fabric material having a first side in which said needle
has entered said material and a second side in which said
needle has penetrated from said first side,said first side
of said first layer being connected to said first side of
said second layer.
According to yet a further aspect of the invention,
there is provided a method of constructing an absorbent pad
comprising the steps of positioning a first piece of fabric
material having first and second sides in contact with a
second piece of fabric material having first and second
sides, said first sides being in contact, said first side of
each of said pieces of material being the side entered
initially by the needles in a sewing process.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
An embodiment of the invention will now be
described, by way of example only, with the use of drawings
in which:
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Figure 1 is an isometric view of a diaper
according to the invention in a fastened position;
Figure ~ is a side view of the diaper of Figure 1
in an unfastened and unrestrained position ready for fitting
to an infant;
Figure 3 is a plan view of the diaper of Figure 2
according to the invention;
Figure 4 is a view of the forward portion of the
baby diaper according to the invention;
Figure 5 is a view of a typical tab used to fasten
the diaper;
Figure 6 is a partial view of the inside back
portion of the diaper according to the invention in a
further embodiment;
Figure 7 is a diagrammatic partial side view of the
diaper of Figure 6,
Figure 8 is a view of the outside of the diaper
according to the invention in a further ambodiment;
Figure 9 is an enlarged side view of the extruded
portion of the fastener in a further embodiment of the
invention;
Figure 10 is a diagrammatic view of the method of
manufacturing the rayon wear pad of the diaper in a further
embodiment according to the invention; and
Figure 11 illustrates the needling or sewing
process on the material prior to the material becoming part
of the rayon fabric used for the wear strip of the diaper.
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DESCRIPTION OF SPECIFIC EMBODIMENT
Referring now to the drawings, a baby diaper is
generally illustrated at 10 in Figure 1. It includes a
forward portion 11, a rearward portion 12, two wing portions
13, 14 which extend outwardly from the rearward portion 12.
The diaper 10 is made from two layers of cotton material
which are sewed together with elastic and a rayon absorbent
pad mounted therebetween as described in greater detail
hereafter.
The forward portion 11 of the diaper 10 includes
two VELCRO tabs 20, 21 affixed to the diaper 10 in the
normal manner by stitching. A piece of elastic 22 is
stitched into the fabric of the diaper 10 between the layers
and directly between the VELCRO tabs 20, 21 and not
overlapping with the tabs 20, 21.
As best seen in Figure 4, the elastic 22 is centred
between the tabs 20, 21 so that the elastic 22 pulls the
tabs 20, 21 together directly in the centre of the tabs 20,
21 thus creating a minimal moment on the connection which
exists between the tabs 20, 21, 23, 24 when the diaper 10 is
fastened on an infant and thus allowing greater connection
strength and integrity than would otherwise be the case if
the elastic 22 was offset mounted such that a moment was
created between the tabs 20, 21. The tabs 20, 21 are also
of a size that, when connected to the complementary VELCRO
tabs 23, 24 on the rearward portion 12 of the diaper 10, the
tabs will not buckle while in use. That is, the tabs 20,
21, 23, 24 will remain flat and will not fold. The tabs 23,
24, are hook tabs and they are located outwardly of the
rearward portion. The protect tabs 31, 32 are loop pads and
they are positioned inwardly of the hook tabs 23, 24.
A distance of approximately 3/4 inch as shown is
left between the top of the tabs 20, 21 and the upper side
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25 of the forward portion 11 o~ the diaper 10. This
distance is designed to allow forward movement of the infant
without discomfort to the stomach when the infant reaches
forward or sits down. The cotton fabric of the diaper 10 is
designed to fold over the tabs 20, 21 in this instance thus
protecting the stomach of the infant against abrasion.
Two VELMATE (Trademark) protect tabs 31, 32 extend
sidewise from the tabs 23, 24 and are connected thereto.
The protect tabs 31, 32 are adapted to be folded over the
tabs 23, 24, respectively, when the diaper 10 is being
washed without the necessity of also folding over the flaps
50, 51. This prevents the tabs 23, 24 ~rom catching with
other clothes in a washing machine.
In order to cover the protect tabs 31, 32, when the
diaper 10 is in use, two flaps or wing pieces 27, 30 are
connected to and extend sidewise from the forward portion 11
of the diaper 10 as best seen in Figure 4. At the widest
fitting of the diaper 10, it is possible that the tabs 31,
32 could be positioned against the skin of the infant
without being covered. Thus, the flaps 27, 30 which extend
outwardly from the end of the tabs 20, 21 act to protect the
infant in this eventuality as they will cover the protect
tabs 31, 32 in all cases.
Reference is again made to Figure 3. A second
elastic portion 33 is sewed between the two layers of fabric
of the diaper 10 and is positioned between the protect tabs
31, 32. The VELCR0 tabs 24, 23 and the protect tabs 31, 32
suitably have a dimension "h" as shown of approximately 1".
This width allows the elastic portion 33 is be mounted in
the centre of the height "h" which, as described above,
allows a minimal moment to be exerted when the tabs 23, 24
are connected to the front tabs 20, 21. A rayon absorbent
strip 34 having a thickness of approximately 1/2" to 5/8" is
sewed between the two layers of the diaper 10. A dimension
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"dl" of 2 1/4" between the end of the rayon wear strip 34
and the top of the diaper 10 has been found suitable to
allow connections of the tabs 20, 21, 23, 24 without
interfering with the rayon strip 34. A dimension "d2" of 2
3/4" between the end of the rayon absorbent strip 34 and the
upper side 40 of the rearward portion 12 of the diaper 10
has been found satisfactory to allow unobstructed
flexibility for the elastic portion 33 and provides a fit
where the rayon wear pad 34 does not stick out if it were
located closer to the top 40 of the rearward portion 12 of
the diaper 10. It further allows a comfortable taper fit of
the diaper 10 to the infant.
Elastic portions 41, 42 are also mounted to the
diaper 10 on opposite sides of the longitudinal axis 43 in
the central area. These elastic portions 41, 42 are mounted
a distance "d3" of approximately 5". Such a dimension and
the elastic portions 41, 42 allow a snug and comfortable fit
of the diaper 10 to the infant and assist to reduce the
drooping of the diaper 10 between the legs of the infant.
The elastic portions 22, 23 are separated a
distance "d3" of approximately 5" in the centre area. Such
a dimension allows a snug and comfortable fit between the
legs of the infant.
A distance "d4" of approximately 5~" is the
distance from the upperside 25 of the forward portion 11 of
the diaper 10 to the beginning of the elastic portions 41,
42. Such a distance will allow non-interference of the
diaper 10 with the top of the VELCR0 tabs 20, 21. Further,
the distance "d4" allows the tabs 20, 21 to be connected to
the tabs 23, 24 without the elastic portion 41, 42 acting to
separate the connecting pieces and, thereby, will similarly
allow a greater connection integrity to the diaper 10 when
it is fastened on the infant.
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As viewed best in Figure 2, the diaper 10 has a
cupping action when it is in a rest position prior to
positioning the diaper 10 on an infant. This action allows
for easy placement of the diaper 10 relative to the infant
on which the diaper 10 is to be fastened and reduces the
necessity for excessively moving either the infant or the
diaper to obtain the proper and comfortable fit. In
addition, since the rearward portion 12 and the for~ard
portion 11 of the diaper 10 are closer together, it takes
less time to remove and install the diaper 10 on the infant.
The cupping action illustrated best in Figure 2 is
achieved by the dimensions of the elastic material (3/8"
wide) the distance oE "d6" (1 1/8") of the elastic 41, 42
from the outside of the diaper 10 and the distans:e from both
upper sides 25, 40. The distance of the elastic 41, 42 from
the upper side 40 of the rearward portion 12 is
approximately 4". The elastic portions 41, 42 are put under
a predetermined tension when they are embedded between the
cotton layers of the diaper 10. This pretension of the
elastic is obtained by lying the diaper flat and by then
installing an elastic portion of known length over a known
length on the fabric of the diaper 10. A distance of the
elastic of 5" and a distance of the fabric of 9 1/2" has
been found to allow the formation of the appropriate cuppiny
action of the diaper 10.
Each of the VELCRO attachment tabs 20, 21, 23, 24,
31, 32 have rounded corners as best seen in Figure 5 where a
typical tab is generally illustrated at 44. This tab 44
with its rounded corners allows for the absence of the
otherwise sharp corners which are inherent in attachment
tabs of the VELCRO type. ~he rounded corners reduce the
risk of sharp edges coming into contact with the infant.
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OPERATION
In operation, an infant will be positioned on the
diaper 10, the diaper 10 being in the positions best
illustrated in Figures 2 and 3; that is, the diaper 10 will
have the cupping rest position illustrated in Figure 2 due
to the position of the elastic portions 41, 42 on the diaper
10 .
The front portion 11 of the diaper 10 will be
snugly placed against the stomach of the infant and the
flaps 50, 51 of the rearward portion 12 will be raised with
the attached tabs 23, 24. The flaps 50, 51 will be brought
into contact with the forward portion 11 of the d.iaper 10
until the tabs 23, 24 contact and attach to tabs 20, 21 on
the formed portion 11 in a snug and comfortable fit on the
infant. It will be noted that in such an attached position
as viewed in Figure 1, the flaps 27, 30 of the forward
portion 11 of the diaper 10 will overlap with the protect
tabs 31, 32 so as to prevent contact of these tabs with the
infantO In positioning the diaper 10 on the infant, the
elastic portion 33 in the rearward portion 12 of the diaper
10 will expand as necessary allowing the tabs 23, 24 to
reach the correct attachment position relative to the tabs
20, 21 on the forward portion 11 of the diaper 10.
When the stomach of the infant moves, the movement
will be accommodated by the elastic 22 in the forward
portion of the diaper 10. This movement, assuming an
outwardly movement of the stomach of the infant, will result
in a force being exerted on the connection between the tabs
20, 21 and the tabs 23, 24. This force, however, will be a
shear force only and will contain a relatively nominal
moment force which will, therefore, result in enhanced
connection integrity.
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Wh~n the baby bends as if, for example, to pick up
an item, the forward portion 11 of the diaper 10 abovs the
elastic 22 and represented by the dimension "d3" will bend
over the tabs 20, 21 which may still be exposed if the
5 infant is large and the diaper 10 is intended for a small
infant. Thus, the fabric will cover the tabs 20, 21 and
prevent contact of these tabs either the stomach of the
infant.
When the diaper 10 is removed from the infant, the
process is simply reversed. Th~e diaper 10 may then be
washed by simply folding the VELMATE protect tabs 31, 32
over the attachment tabs 23, 24. Thus, no catching action
of the tabs with other fabrics or clothing will occur in the
washing machine.
A further embodiment according to the invention is
illustrated in Fig~res 6 and 7. In this embodiment, the
fastener and cover combination is illustrated generally at
100 and comprises a hook portion 101 and a loop portion
102. The hook portion 101 is sewed to the fabric 103 of the
baby diaper 10 about its periphery so that it remains flat
and may be attached to the VELCRO tab or loop portion 21
(Figure 4) on the front of the diaper ln.
The loop portion 102 of the further embodiment,
however, is separately connected to the fabric 103 also by
sewing but is stitched down on only one side, namely that
side nearestmost to the hook portion 101. As indicated in
Figure 6, there are two hook portions 101 and two
complementary loop portions 102, one set being connected to
each of the flaps 50, 51, respectively.
In operation, the loop portions 102 are used as
fastener covers for the hook portions 101 when, for example,
the diaper 10 is washed and it is intended to prevent
contaminants from attaching themselves to the hook portions
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101. The loop portions 102, being sewed to the fabric 103
only at one side, are biased upwardly and are rotatable
about the connection axis defined by the row of stitching
104. When washing the diaper 10, the loop portion 102 is
folded over about axis 104 and pressed against the hook
portion lOl which will prevent the attachment of foreign
material to the hook portion lO1. When the washing
operation is terminated, the hook portion 101, being biased
away from the fabric 103 is esslentially self opening and a
minimum amount of removal force is required to separate the
loop portion 102 from the hoo~ ]portion 101.
Yet a further embodiment of the invention is
illustrated in Figure 8. Whereas in Figures 1-3, the
elastic portions 22, 33, 41, 42 are mounted to the inside of
the diaper 10 or, at least, between the two layers of
fabric, the embodiment of ~igure 8 contemplates that the
elastic portions 110, 111, 112, 113 will be mounted on the
outside of the diaper 10. Mounting the elastic portions to
the outside of the diaper lO is advantageous since the
mounting speeds up the manufacturing process because there
is no need to curve the elastic manually prior to attachin~
it to the fabric material. Rather, the fabric is simply
laid flat and the elastic portions 101, 102, 103, 104 are
stretched to the desired length and sewed directly to the
fabric 103. A further advantage is attaching the elastic
portions directly to the fabric 103 on the outside of the
diaper 10 is that the infant is separated from the elastic
by two layers of fabric 103 rather than one as is the case
with the embodiment of Figures 1-3.
In a further embodiment of the invention, there is
provided a fastening device using an extruded plastic
polymeric material such as nylon or polypropylene, rather
than the aforementioned VELCR0 material. While VELCR0 type
woven fabric material is useful for the hook portion of the
fastener in many applications, there is a tendency for the
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fabric of the hook portion to retain foreign material in its
interstices, such foreign material being readily available
to the hook portion from washing. The retention o~ the
foreign material reduces and eventually may eliminate the
fastening ability of the hook.
Yet a further disadvantage of the VELCR0 material
is that, because of chemicals used in washing diapers, there
is a tendency over time for the woven fabric hook portion to
harden and break off which reduces the fastening ability of
the hooks and results,again eventually, in a hook portion
which will not fasten.
In contradistinction, an extruded plastic hook may
be used which will replace the aforementioned woven fabric
hook portion. The extruded plastic hook portion is much
stronger and is substantially uniform over the entire
fastening area. Thus, increased fastening integrity can be
obtained. Since the hook is extruded, it is cleaner with
the result that the aforementioned problems are
substantially reduced or eliminated. Finally, such a hook
portion is substantially thinner with the result that the
bulk of the diaper is reduced.
An extruded plastic material which may be used in
replacement of the previous VELCRO hook portion is sold
under the trademark U~TRA-MATE and reference is made to
Figure 9 where the extruded hook is generally illustrated at
64.
Yet a further embodiment relates to the composition
and method of manufacture of the rayon absorbent pad or wear
strip 34 illustrated in Figure 3. Although the pad 34 was
useful in many instances and particularly so for diapers
with relatively short lives, it was found that the pad 34
which had a weight of 12 oz. and was made from 100~ natural
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regenerated rayon, was unacceptably soft with the result
that the pad 34 would eventually ball or mat during washing.
In preparing rayon material for the rayon wear pad,
a needling or sewing process is used on the material to form
the fabric as seen in Figure 11. The needles 52 would pass
down through the material 53 from the top surface 54 to the
bottom surface 60. The needles 52 then return to the top
position originating position. Thus, a rayon pad 34 would
result which would have a width of approximately 84 inches.
The top surface 54 would be somewhat firmer that the bottom
surface as this is inherent in the sewing process which
compresses the top surface 54 to a somewhat greater extent
than the bottom surface 60.
To overcome the aforementioned problems with the
absorbent pad 32, two layers of fabric 61, 62 (Figure 10)
were used, each obtained as is usual from the process shown
in Figure 10. However, these two layers of fabric 61, 62
were combined to form a new pad as will be described.
Reference is made to Figure 10 where the two layers
61, 62 are fed into the needling apparatus generally
illustrated at 63. The soft sides, that is, the bottom
sides 60 in the first sewing process just described, were
fed in contact with and facing each other. The combination
was then sewed together once again with the result that the
top surface of the combination was slightly harder than the
bottom surface. An advantage of this process is that the
pad 34 will have a soft central portion which allows better
fluid distribution. When the combined pad is positioned and
sewn into th~ diaper, the soft side, that is, the bottom
side, faces the user and the top side faces outwardly from
the user. This allows better wear and increased softness to
the user.
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Many dimensions have been disclosed which have
been formed to be appropriate for an infant of normal size.
Clearly, however, such dimensions may be amended or modified
depending on the particular size of the infant on which it
is intended to position the diaper.
While a specific embodiment of the invention has
been described, such an embodiment is illustrative of the
invention only and should not be taken as limiting its
scope. Many further modifications will readily occur to
those skilled in the art to which the invention relates and,
accordingly, the invention should be construed in accordance
with the accompanying claims.
