Abstract:
A chlorine free disposable diaper has a main body having an open top area through which a body of an individual wearing the diaper is positioned and a pair of side openings. An individual side opening is formed on opposing side surfaces of the main body for positioning a leg of the individual wearing the diaper. The main body has a multi-layered diaper assembly. The multi-layered diaper assembly has an exterior layer comprising a non-woven material having a planar, soft, cloth-like surface layer. A core layer is provided and is made of non-chlorine bleached material for holding waste materials within the disposable diaper. A containment layer is coupled to a first side and a second side of the core layer. The containment layer is used for containing the waste material in the core layer and away from skin of a wearer. A distribution layer is coupled to the containment layer. The distribution layer is used for evenly distributing waste material to the core layer. An interior layer is coupled to the distribution layer. The interior layer is made of a non-woven liquid permeable material.

Description:
RELATED APPLICATIONS  
       [0001]     The present application is a Continuation-In-Part of U.S. patent application entitled, “DISPOSABLE DIAPER AND METHOD THEREFOR”, HAVING Ser. No. 10/768,376, and a filing date of Jan. 30, 2004 which is related to U.S. patent application entitled, “DISPOSABLE DIAPER AND METHOD THEREFOR”, having Ser. No. 10/109,091, and a filing date of Mar. 27, 2002 and U.S. Pat. No. 5,743,895 entitled “DISPOSABLE DIAPER AND METHOD THEREFOR”, issued on Apr. 28, 1998 in the name of the same inventors and incorporated by reference into the present application. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to a disposable diaper and, more specifically, to a disposable diaper and method that is chlorine free.  
         [0004]     2. Description of the Prior Art  
         [0005]     Disposable diapers are well known and widely used. Over the years, disposable diapers have become the dominant diaper, largely replacing the old form of reusable diaper. Typical disposable diapers generally use an absorbent interior area for absorbing a wearer&#39;s urine, bounded by a thin plastic exterior layer. The interior portion of the typical disposable diaper presently on the market is generally comprised of a bottom layer of non-woven material that is in direct contact with the area of the child&#39;s skin covered by the diaper, a backing layer of tissue paper that contacts the bottom portion of the layer of non-woven material, a wadding batt layer of wood pulp that is located between the thin plastic exterior layer and the layer of tissue paper, and, in order to increase the diaper&#39;s fluid absorbency, diaper manufacturers add a superabsorbent polymer or other chemical additive to the wadding batt layer. Without the superabsorbent polymer, wood pulp generally absorbs in the range of  12  to  15  times its weight. With the superabsorbent polymer, the wadding batt layer is able to absorb in the range of 30 to 55 times its weight.  
         [0006]     One problem with current disposable diapers is that the wood pulp used is bleached with chlorine. This bleaching process produces low levels of dioxins or furons as by-products. While the government may allow certain low levels of dioxins, dioxins are toxic and carcinogenic. Some companies use ECF elemental chlorine free bleached wood pulp. ECF elemental chlorine free bleached wood pulp still has small trace amounts of chlorine.  
         [0007]     As stated above, most disposable diapers use a backing layer of tissue paper that contacts the bottom portion of the layer of non-woven material. This tissue paper is generally a bleached tissue layer. The tissue paper is bleached using a chlorine bleach process. As stated above, the chlorine bleaching processes produces low levels of dioxins or furons as by-products. Furthermore, the bleached tissue paper may also contain small trace amounts of chlorine.  
         [0008]     Therefore, a need existed to provide an improved disposable diaper and method that overcome the problems associated with prior art disposable diapers. The improved disposable diaper and method must be totally chlorine free. The improved disposable diaper and method must use materials that do not use a chlorine bleach during the manufacturing process.  
       SUMMARY OF THE INVENTION  
       [0009]     In accordance with one embodiment of the present invention, it is an object of the present invention to provide an improved disposable diaper and method.  
         [0010]     It is another object of the present invention to provide an improved disposable diaper and method that overcomes the above problems associated with prior art disposable diapers.  
         [0011]     It is still another object of the present invention to provide an improved disposable diaper and method that is totally chlorine free.  
         [0012]     It is still another object of the present invention to provide an improved disposable diaper and method that uses materials that are not chlorine bleached during the manufacturing process.  
       BRIEF DESCRIPTION OF THE EMBODIMENTS  
       [0013]     In accordance with one embodiment of the present invention a chlorine free disposable diaper is disclosed. The chlorine free disposable diaper has a main body having an open top area through which a body of an individual wearing the diaper is positioned and a pair of side openings. An individual side opening is formed on opposing side surfaces of the main body for positioning a leg of the individual wearing the diaper. The main body has a multi-layered diaper assembly. The multi-layered diaper assembly has an exterior layer comprising a non-woven material having a planar, soft, cloth-like surface layer. A core layer is provided and is made of non-chlorine bleached material for holding waste materials within the disposable diaper. A containment layer is coupled to a first side and a second side of the core layer. The containment layer is used for containing the waste material in the core layer and away from skin of a wearer. A distribution layer is coupled to the containment layer. The distribution layer is used for evenly distributing waste material to the core layer. An interior layer is coupled to the distribution layer. The interior layer is made of a non-woven liquid permeable material.  
         [0014]     In accordance with another embodiment of the present invention, a method for providing a chlorine free disposable diaper having a multi-layered diaper assembly is disclosed. The method comprises: forming an exterior layer comprising a non-woven material having a planar, soft, cloth-like surface layer; coupling a leakage protection layer to the exterior layer for preventing waste material from leaking out of the disposable diaper; forming a core layer made of non-chlorine bleached wood pulp for holding the waste materials within the disposable diaper; coupling a containment layer to a first side and a second side of the core layer for containing the waste material in the core layer and away from skin of a wearer; coupling a distribution layer to the containment layer for evenly distributing waste material to the core layer; coupling an interior layer to the distribution layer comprising a non-woven liquid permeable material; and forming the multi-layered diaper assembly into a pull-up diaper having an open top area through which a body of an individual wearing the diaper is positioned and a pair of side openings, an individual side opening formed on opposing side surfaces of the main body for positioning a leg of the individual wearing the diaper.  
         [0015]     The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiments of the invention, as illustrated in the accompanying drawing. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]     The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, as well as a preferred mode of use, and advantages thereof, will best be understood by reference to the following detailed description of illustrated embodiments when read in conjunction with the accompanying drawings.  
         [0017]      FIG. 1  is an elevated front side view of one embodiment of the disposable diaper of the present invention.  
         [0018]      FIG. 2  is an elevated rear side or backside view of one embodiment the disposable diaper of the present invention.  
         [0019]      FIG. 3  is a cross-sectional view of the disposable diaper of  FIG. 1  taken along line  3 - 3  of  FIG. 1 .  
         [0020]      FIG. 4  is a perspective view of another embodiment of the disposable diaper of the present invention.  
         [0021]      FIG. 5  is a front view of another embodiment of the disposable diaper of the present invention.  
         [0022]      FIG. 6  is a side view of the embodiment depicted in  FIG. 5 .  
         [0023]      FIG. 7  is a cross-sectional view of a bottom section of the disposable diaper of  FIGS. 4-6  taken along line A-A. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     Referring to the embodiment of  FIGS. 1-3 , reference number  10  refers generally to the disposable diaper of this invention. It should be noted that the following description is one embodiment of the present invention.  
         [0025]     Referring to  FIG. 1 , a front or interior view of the disposable diaper  10  is shown, in the open position. The disposable diaper  10 , like other disposable diapers, comprises front flaps  12  and back flaps  14 . Reference numbers  12   a  and  14   a  refer to the side portions of the front flaps  12  and the back flaps  14 , respectively, that are visible in the front view of the disposable diaper  10  depicted in  FIG. 1 . Adhered to the back flaps  14   a , and oriented substantially parallel to an upper edge  16  of the diaper  10 , are preferably two tape assemblies  18 . Each tape assembly  18  comprises a base portion that is attached directly to the surface of the diaper  10 , and a partially separable adhesive portion that may be peeled from the base portion for adhesion attachment to the reverse side of front flaps  12  (see both  FIGS. 1 and 2 ) when the diaper  10  is being placed on a baby or child. Other types of adhesion devices may be used for the tape assemblies  18  without departing from the spirit and scope of the present invention. For example, hook and look material may be used for the tape assemblies  18 . On both sides of the diaper  10 , oriented in a substantially perpendicular direction to the upper edge  16  and the lower edge  20 , are two elastic portions  22 . The elastic portions  22  snugly grip the legs of the child during the wearing of the diaper  10  to, among other things, minimize the leaking of fluid out of the diaper  10 .  
         [0026]     Referring to  FIG. 2 , a rear or backside exterior view of the disposable diaper  10  is shown, in the open position. Reference numbers  12   b  and  14   b  refer to the sides of the front flaps  12  and the back flaps  14 , respectively, that are visible in the rear or backside view of the disposable diaper  10 . Adhered to the back flaps  14   b , and oriented substantially parallel to the upper edge  16  of the diaper  10 , are portions of the two tape assemblies  18 . These are continuations of the portions of the tape assemblies  18  which are located on the back flaps  14 a, as shown in  FIG. 1 . Located between tabs  12   b  is a preferably rectangular plastic strip  22 A, which strip  22 A receives the adhesive portion of the tape assemblies  18  when the diaper is being placed on a baby or child. Referring to  FIG. 3 , a cross-sectional view of the disposable diaper  10  is shown, showing the layers of material comprising the diaper  10 . The disposable diaper  10  general has a plurality of different layers. The first layer  24  has an outer surface  24   a  and an inner surface  24   b . The outer surface  24   a  is generally exposed. Since the outer surface  24   a  is exposed, the first layer  24  is used primarily for aesthetics. In accordance with one embodiment of the present invention, the first layer  24  is made of a spunbond hydrophobic non-woven polypropylene material having a soft, cloth-like appearance.  
         [0027]     A second layer  26  is provided and also has an inner and outer surface. The outer surface of the second layer  26  is coupled to the inner surface  24   b  of the first layer  24 . The second layer  24  is used to contain any fluids or solids within the disposable diaper  10 . Thus, the second layer  24  helps to prevent leakage. The second layer  24  is generally made from a polyethylene material.  
         [0028]     A third layer  28  is coupled to the inner surface of the second layer  24 . The third layer has an outer surface which is directly coupled to the inner surface of the second layer  24 . The third layer  28  is also used to contain any fluids and material within the disposable diaper  10 . The third layer  28  further provides an area to keep fluids and other material inside the disposable diaper  10  away from the skin of the wearer of the disposable diaper  10 . The third layer  28  is generally made of a spunbond hydrophilic non-woven material. All disposable diapers currently use a bleached tissue. However, the disposable diaper  10  will use a non bleached spunbond hydrophilic non-woven material as the third layer  28 .  
         [0029]     Coupled to an inner surface of the third layer  28  is a fourth layer  30 . The fourth layer  30  is a wadding batt layer consisting of a wood pulp mixture  30   a . All present disposable diapers bleach their wood pulp with chlorine. This bleaching process low levels of dioxins. Many people would prefer to have a disposable diaper  10  made from non-chlorine bleached materials. Thus, in accordance with one embodiment of the present invention, a non-chlorine bleached/unbleached wood pulp  30   a  is used. An unbleached untreated softwood fluff pulp which is biodegradable and totally chlorine free may also be used. In order to whiten the wood pulp  30   a , the wood pulp  30   a  may be bleached using other processes other than chlorine. In accordance with one embodiment of the present invention, the wood pulp  30   a  is bleached with a hydrogen peroxide and oxygen process. The use of hydrogen peroxide should not be seen as to limit the scope of the present invention. Other whitening processes may be used without departing from the spirit and scope of the present invention.  
         [0030]     The fourth layer  30  may further comprise a superabsorbent mixture  30   b . The superabsorbent mixture  30   b  will allow the wadding batt layer to absorb in the range of 30 to 55 times its weight. The superabsorbent mixture  30   b  may be a natural (i.e., starch) or an artificial superabsorbent mixture  30   b . A superabsorbent polymer such as polyacrylates may be used as the superabsorbent mixture  30   b.    
         [0031]     A fifth layer  32  is coupled to the fourth layer  30 . The fifth layer  32  is similar to that of the third layer  28 . The fifth layer  32  and the third layer  28  are used in combination to contain any fluids and material within the fourth layer  30 . The fifth layer  32  further provides an area to keep fluids and other material inside the disposable diaper  10  away from the skin of the wearer of the disposable diaper  10 . The fifth layer  32  is generally made of a spunbond hydrophilic non-woven material. All disposable diapers currently use a bleached tissue. However, the disposable diaper  10  will use a non bleached spunbond hydrophilic non-woven material as the fifth layer  32 .  
         [0032]     A sixth layer  34  is coupled to one side of the fifth layer  32 . The sixth layer  34  is an acquisition distribution layer. The sixth layer  34  is used to distribute any fluids evenly through the fourth layer  30  and to keep the surface of the sixth layer  34  dry. In accordance with one embodiment of the present invention, the sixth layer  34  will use a non bleached non-woven material.  
         [0033]     A seventh layer  36  is coupled to the sixth layer  34 . The seventh layer  36  is a top sheet which is the closest layer to the skin of the wearer. The seventh layer  36  is generally made of a spunbond polypropylene hydrophilic non-woven material. The seventh layer  36  is used to carry the fourth layer  30  through machine and provides a soft layer against the user&#39;s skin. The seventh layer  36  will further be a non-woven liquid permeable material.  
         [0034]     By using spunbond hydrophilic non-woven material and a TCF chlorine free wood pulp, a disposable diaper  10  is produced which is 100% chlorine free.  
         [0035]     Referring to  FIG. 4 , another embodiment of the disposable diaper  10  is shown. In the embodiment shown in  FIG. 4 , the diaper  10  is a pull-up diaper  10 A. Thus the front flaps  12  and back flaps  14  of the diaper  10  of  FIG. 1  are coupled together to form a body  40  of the pull-up diaper  10 A. The body  40  will generally have side seams  42  where the front flaps  12  and back flaps  14  are coupled together to form a one piece body  40 .  
         [0036]     The body  40  will have an open top area  44  through which a body of the individual wearing the pull-up diaper  10 A is positioned. A pair of openings  46  is formed such that one of the pair of openings  46  is positioned on each side surface of the body  40 . The openings  46  are used to position a leg of the individual wearing the pull-up diaper  10 A.  
         [0037]     The body  40  may have a stretchable material  48  placed around an outer circumference of the open top area  44  of the body  40 . The stretchable material  48  is generally placed around the upper edge  16  and the lower edge  20  of the pull-up diaper  10 A. The stretchable material  48  will allow the open top area  44  to fit snugly around the body of the wearer. In general, a material such as elastic or the like is used.  
         [0038]     Located in a bottom section of each opening  46  are elastic portions  22 . The elastic portions  22  snugly grip the legs of the child during the wearing of the pull-up diaper  10 A to, among other things, minimize the leaking of fluid out of the pull-up diaper  10 A.  
         [0039]     Referring to  FIGS. 5 and 6 , another embodiment of the disposable diaper  10  is shown. In this embodiment, the pull-up diaper  10 B is similar to that shown in  FIG. 4 . The pull-up diaper  10 B is of one piece construction.  
         [0040]     The body  40 A will have an open top area  44  through which a body of the individual wearing the pull-up diaper  10 B is positioned. A pair of openings  46  is formed such that one of the pair of openings  46  is positioned on each side surface of the body  40 A. The openings  46  are used to position a leg of the individual wearing the pull-up diaper  10 B.  
         [0041]     The body  40 A will generally have a stretchable material  48  placed around an outer circumference of the open top area  44  of the body  40 A. The stretchable material  48  will allow the open top area  44  to fit snugly around the body of the wearer. In general, a material such as elastic or the like is used.  
         [0042]     Located in a bottom section of each opening  46  are elastic portions  22 . The elastic portions  22  snugly grip the legs of the child during the wearing of the pull-up diaper  10 B to, among other things, minimize the leaking of fluid out of the pull-up diaper  10 B.  
         [0043]     Referring to  FIG. 7 , a cross-sectional view of the pull-up diapers  10 A and  10 B is shown. The composition of the pull-up diapers  10 A and  10 B is similar to that shown for diaper  10  in  FIG. 3 . The pull-up diapers  10 A and  10 B general have a plurality of different layers. The first layer  24  has an outer surface  24   a  and an inner surface  24   b . The outer surface  24   a  is generally exposed. Since the outer surface  24   a  is exposed, the first layer  24  is used primarily for aesthetics. In accordance with one embodiment of the present invention, the first layer  24  is made of a spunbond hydrophobic non-woven polypropylene material having a soft, cloth-like appearance.  
         [0044]     A second layer  26  is provided and also has an inner and outer surface. The outer surface of the second layer  26  is coupled to the inner surface  24   b  of the first layer  24 . The second layer  24  is used to contain any fluids or solids within the pull-up diaper  10 A and  10 B. Thus, the second layer  24  helps to prevent leakage. The second layer  24  is generally made from a polyethylene material.  
         [0045]     A third layer  28  is coupled to the inner surface of the second layer  24 . The third layer has an outer surface which is directly coupled to the inner surface of the second layer  24 . The third layer  28  is also used to contain any fluids and material within the pull-up diaper  10 A and  10 B. The third layer  28  further provides an area to keep fluids and other material inside the disposable diaper  10  away from the skin of the wearer of the disposable diaper  10 . The third layer  28  is generally made of a spunbond hydrophilic non-woven material. All disposable diapers currently use a bleached tissue. However, the pull-up diaper  11 A and  10 B will use a non bleached spunbond hydrophilic non-woven material as the third layer  28 .  
         [0046]     Coupled to an inner surface of the third layer  28  is a fourth layer  30 . The fourth layer  30  is a wadding batt layer consisting of a wood pulp mixture  30   a . All present disposable diapers bleach their wood pulp with chlorine. This bleaching process low levels of dioxins. Many people would prefer to have a pull-up diaper  10 A and  10 B made from non-chlorine bleached materials. Thus, in accordance with one embodiment of the present invention, a non-chlorine bleached wood pulp  30   a  is used. An unbleached treated softwood fluff pulp which is biodegradable and totally chlorine free may also be used. To whiten the wood pulp  30   a , the wood pulp  30   a  may be bleached using other processes other than chlorine. In accordance with one embodiment of the present invention, the wood pulp  30   a  is bleached with a hydrogen peroxide and oxygen process or other type of whitening process. The use of hydrogen peroxide should not be seen as to limit the scope of the present invention. Other whitening processes may be used without departing from the spirit and scope of the present invention.  
         [0047]     The fourth layer  30  may further comprise a superabsorbent mixture  30   b . The superabsorbent mixture  30   b  will allow the wadding batt layer to absorb in the range of 30 to 55 times its weight. The superabsorbent mixture  30   b  may be a superabsorbent polymer or a natural absorbent (i.e., starch). A superabsorbent polymer may include, but is not limited to, polyacrylates and the like.  
         [0048]     A fifth layer  32  is coupled to the fourth layer  30 . The fifth layer  32  is similar to that of the third layer  28 . The fifth layer  32  and the third layer  28  are used in combination to contain any fluids and material within the fourth layer  30 . The fifth layer  32  further provides an area to keep fluids and other material inside the pull-up diaper  10 A and  10 B away from the skin of the wearer of the pull-up diaper  10 A and  10 B. The fifth layer  32  is generally made of a spunbond hydrophilic non-woven material. All disposable diapers currently use a bleached tissue. However, the pull-up diaper  10 A and  10 B will use a non bleached spunbond hydrophilic non-woven material as the fifth layer  32 .  
         [0049]     A sixth layer  34  is coupled to one side of the fifth layer  32 . The sixth layer  34  is an acquisition distribution layer. The sixth layer  34  is used to distribute any fluids evenly through the fourth layer  30  and to keep the surface of the sixth layer  34  dry. In accordance with one embodiment of the present invention, the sixth layer  34  will use a non bleached non-woven material.  
         [0050]     A seventh layer  36  is coupled to the sixth layer  34 . The seventh layer  36  is a top sheet which is the closest layer to the skin of the wearer. The seventh layer  36  is generally made of a spunbond polypropylene hydrophilic non-woven material. The seventh layer  36  is used to carry the fourth layer  30  through machine and provides a soft layer against the user&#39;s skin. The seventh layer  36  will further be a non-woven liquid permeable material.  
         [0051]     By using spunbond hydrophilic non-woven material and a TCF chlorine free woodpulp, a pull-up diaper  10 A and  10 B is produced which is 100% chlorine free.  
         [0052]     While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.