Diaper construction and method

A diaper configured with an inner panty enclosed within an outer panty, the inner panty having an absorbent pad inserted in an opening in the inner panty. The inner panty holds the absorbent pad snugly between the legs of the wearer but in spaced relationship to the outer panty. The outer panty is secured around its periphery to the inner panty and encloses both the absorbent pad and inner panty in spaced relationship. The spaced relationship forms an overflow reservoir beneath the absorbent pad.

BACKGROUND 
1. Field of the Invention 
This invention relates to diapers and, more particularly, to a novel, 
diaper and method whereby a pad of absorbent material is supported as an 
insert in a water-resistant inner shell, the inner shell being enclosed in 
a water-resistant, outer shell, the outer shell including a hook and loop 
fastener system along with elasticized leg openings. 
2. The Prior Art 
Diapers of one form or another have been known for many generations and are 
generally defined as a basic garment for human waste containment for 
infants and incontinent adults. A conventional diaper consists of a folded 
cloth or other absorbent material drawn u between the legs and fastened 
about the waist of the wearer. Historically, diapers were available in the 
form of a layer of cloth about one meter square. To produce a suitable 
diaper, the cloth was folded in any one of plurality of patterns to 
achieve the appropriate diaper size and then pinned with at least one 
safety pin to retain the diaper about the waist of the wearer. This entire 
process is fraught with problems not only in folding the diaper to the 
wrong size but also in injuries resulting from accidental punctures from 
the safety pin. Since the primary function of the diaper is to absorb 
urine and act as a catchment for feces, considerable effort has been made 
to reduce, or even eliminate, the natural revulsion one feels when 
required to change a diaper, particularly one containing feces. Cloth 
diapers also require the use of a separate, water-repellant cover to 
resist leakage of urine or even watery feces through the cloth fabric. The 
result of the foregoing is that within the past few decades there has been 
an explosive increase in the use of disposable diapers in both the 
pediatric and the adult settings. The primary driving force behind the 
wide acceptance of disposable diapers has been user convenience along with 
the aesthetics of easy disposability. 
While convenient, disposable diapers represent not only a significant 
increase in cost but, more importantly, represent a major concern 
environmentally in that they constitute a significant portion of the solid 
waste stream. This, in turn, means that a significant portion of the 
landfill space is occupied by disposable diapers. Further, since a 
significant number of the disposable diapers contain feces, they also 
represent a threat to the environment through fecal contamination 
particularly due to the pathogens carried in most feces. One of the 
principal advantages to the use of cloth or reusable diapers is the fact 
that the human wastes are directed into the sewer system. However, a 
disposable diaper that uses less material in its construction without any 
corresponding decrease in its functionality will also prove to constitute 
a significant advancement in the art. 
Numerous undergarments are known in the art and include, for example, a 
disposable combination panty and sanitary napkin as shown by Titone et al 
(U.S. Pat. No. 2,748,772). The panty portion includes a pocket-like crotch 
portion into which a sanitary napkin is enclosed during manufacture of the 
panty. 
Blaufus (U.S. Pat. No. 2,754,824) discloses a diaper garment constructed 
from a sheet of moisture repellant material and having a pair of 
longitudinal pockets along each side and spaced an incremental distance 
apart. An absorbent pad is held in the pockets and receives waste 
deposited thereon. 
Parravicini (U.S. Pat. No. 3,424,162) discloses an hygienic panty designed 
to be thrown away after use. Advantageously, a conventional cellulose 
material is used for the body portion of the panty while an insert of 
cotton gauze is used in the crotch portion of the panty. 
Rickard (U.S. Pat. No. 3,599,638) discloses a disposable panty having a 
crotch construction adapted to receive a sanitary napkin, the sanitary 
napkin being replaceable without disposing of the panty so that the same 
panty can be used with several sanitary napkins. 
De Woskin (U.S. Pat. No. 3,613,686) discloses a panty having a special 
crotch section adapted to hold a sanitary napkin snugly in place without 
fasteners or other attachments. 
Tong (U.S. Pat. No. 352,356) discloses a urinary incontinence garment 
constructed with a panty-like configuration. A pouch inside the panty is 
adapted to receive an absorbent pad. 
Davis (U.S. Pat. No. 4,568,342) discloses a variable-size, reusable diaper 
that utilizes a hook and loop fastener system to readily adapt the diaper 
to different wearer sizes. 
Steer (U.S. Pat. No. 4,695,279) discloses a pair of incontinence briefs 
having a pocket located in the crotch region. An absorbent pad is 
removably inserted into the pocket. 
Proxmire et al U.S. Pat. No. 4,770,656 discloses a disposable diaper having 
leg and waist gathers for form-fitting, self-adjusting disposable diapers. 
Khan (U.S. Pat. No. 4,834,737) discloses a disposable diaper having a 
liquid impervious back sheet to which the absorbent padding is attached. 
Cottenden (U.S. Pat. No. 4,898,594) discloses an incontinence garment 
having an absorbent pad sewn into the garment. The absorbent pad is 
enclosed in a liquid-impervious material and secured thereto by stitching 
that is carefully designed to preclude the capillary flow of urine along 
the stitching. 
Van Gompel et al (U.S. Pat. No. 4,938,757 and 4,940,464) discloses a 
disposable pant-like garment having a liquid pervious liner, a liquid 
impervious outer cover and an absorbent medium between the liner and the 
cover. 
Mc Cloud (U.S. Pat. No. 4,961,736) discloses a reusable cloth diaper having 
a highly absorbent inner liner permanently attached at one edge to an 
absorbent panel. 
Clearly, each prior art diaper and/or sanitary garment has its advantages 
and disadvantages. Accordingly, it would be a significant advancement in 
the art to provide a diaper and method that incorporates selected 
advantages from each system. It would also be an advancement in the art to 
provide a diaper that includes an absorbent pad suspended in an inner 
shell and enclosed within a water-resistant outer shell. Another 
advancement would be to provide a diaper having a removable liner to 
facilitate transfer of feces from the diaper to the toilet or other waste 
disposal facility. Such a novel diaper and method is disclosed and claimed 
herein. 
BRIEF SUMMARY AND OBJECTS OF THE INVENTION 
This invention relates to a diaper configured with an absorbent, 
cloth-covered pad incorporated as an integral unit in an inner shell, the 
inner shell being enclosed in an outer, water-resistant shell. The inner 
shell suspends the absorbent pad snugly between the legs of the wearer and 
in spaced relationship to the outer shell. The inner shell in the region 
of the absorbent pad is in fluid communication with the spacial separation 
between the inner shell and the outer shell to allow surplus liquid to 
pass into this space. The inner shell also supports the absorbent pad in 
the extended configuration to resist its bunching during periods of wear. 
An optional liner is available to facilitate removal of any feces 
deposited in the diaper. The liner can be either reusable or disposable. A 
hook and hoop fastener system fastens the diaper about the waist of the 
wearer. Elasticized sections at each side of the diaper provide a snug fit 
around the legs of the wearer. 
It is, therefore, a primary object of this invention to provide 
improvements in diapers. 
Another object of this invention is to provide a diaper characterized by 
the absence of absorbent material on the external profile of the legs of 
the wearer. 
Another object of this invention is to provide improvements in the method 
of providing a diaper. 
Another object of this invention is to provide a diaper having an absorbent 
pad incorporated into an inner shell with the inner shell enclosed in a 
water-resistant, outer shell. 
Another object of this invention is to provide a diaper having a removable 
liner to facilitate removal and disposal of feces collected in the diaper. 
Another object of this invention is to provide a diaper having an absorbent 
pad supported snugly between the legs of a wearer, the absorbent pad being 
held against twisting or bunching while being held snugly between the legs 
of the wearer. 
Another object of this invention is to provide a diaper having a hook and 
loop fastener system for adjustably fastening the diaper about the waist 
of the wearer. 
These and other objects and features of this invention will become more 
readily apparent from the following description, the accompanying drawing 
and the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
The invention is best understood from the following description with 
reference to the accompanying drawing wherein like parts are designated by 
like numerals throughout. 
GENERAL DISCUSSION 
Diapers are important not only for the pediatric population but also for 
certain segments of the adult population. The term "diaper" is used herein 
in a generic sense for any absorbent-type undergarment worn for the 
catchment and containment of urine and/or feces. The need for diapers 
among the pediatric population is accepted knowledge and is due to the 
fact that in practically all cases of pediatric diaper usage, the diaper 
is a temporary (up to three or four years) measure until the wearer's 
physiological maturity progresses sufficiently to the point where the 
normal excretory functions can be controlled voluntarily. The term 
"pediatric population" is usually understood to mean those persons up to 
about three or four years of chronological age and a weight up to about 40 
pounds (18 kilograms). The term "adult population" is used herein to 
describe all other persons who may require the use of a diaper either in 
an acute sense or a chronic sense. 
Usage of diapers by the adult population is generally the result of 
enuresis, injury, mental and/or physical deterioration, disease, 
confinement, incontinence, and the like, regardless of the origin of the 
particular problem. For instance, many women suffer from certain forms of 
urinary incontinence due to injuries inflicted on the bladder sphincter 
during childbirth. Physical incapacity as well as mental dementia, 
particularly among the geriatric portion of the adult population, appears 
to be the major factor necessitating the use of diapers among this 
population. In either circumstance, it is important for the wearer that 
the diaper should be easily donned either by the wearer or another person 
and changeable with equal facility. 
Advantageously, the novel diaper of this invention is configured with an 
absorbent pad that is held snugly in place between the legs and is 
particularly characterized by the absence of padding on the outside of the 
profile of the legs. This means that, unlike many prior art diapers, there 
is no extraneous bulk around the waist or legs of the wearer to reveal to 
the casual observer that the wearer is wearing a diaper. Not only does 
this feature enable the ambulatory wearer to wear the diaper of this 
invention under normal clothing but it also significantly enhances the 
self esteem of the wearer by the knowledge that the presence of a diaper 
on the wearer is effectively hidden from accidental discovery or 
observation. The novel diaper system of this invention is either reusable 
or disposable. The reduced bulk of this diaper means that it will occupy 
less space in the waste disposal system. 
DETAILED DESCRIPTION 
Referring now more particularly to FIG. 1, the novel, diaper of this 
invention is shown generally at 10 and includes an outer panty or outer 
shell 12 and an inner panty or inner shell 30 with inner shell 30 
supporting an absorbent pad 40 in spaced relationship inside outer shell 
12. Diaper 10 is configured with a panty-like external profile having leg 
openings 16 and 17 along with a waist band 14 separated into a front waist 
band 14a and a rear waist band 14b. Front waist band 14a is configured to 
be releasably joined to rear waist band 14b at each side of diaper 10 
above leg openings 16 and 17. Leg opening 16 is designed as an opening for 
the left leg of a wearer (not shown) and includes an elasticized segment 
16a to assure a snug fit about the leg (not shown) while leg opening 17 is 
correspondingly configured with an elasticized segment 17a to accommodate 
the right leg of the wearer (not shown) in a snug-fitting relationship. 
The releasable joinder of the ends of front waist band 14a to the 
respective ends of rear waist band 14b is accomplished using matching 
pairs of hook and loop fastener systems 18 and 19. Loop portions 18a and 
19a of hook and loop fastener systems 18 and 19, respectively, are 
attached at each end of front waist band 14a while hook portion 18b and 
hook portion 19b (FIG. 4) are attached at each end and on the outside face 
of rear waist band 14b. This particular orientation of the respective hook 
and loop portions of hook and loop fasteners 18 and 19 is important due to 
the inherent nature of commercially available hook and loop fastener 
systems. In particular, the loop portion is generally configured with a 
relatively soft, felt-like texture whereas the hook portion is 
specifically designed with a certain degree of stiffness to enable the 
hooks therein to suitably penetrate the loops so as to releasably engage 
the same. Such hook and loop fastener systems are widely available 
commercially from Velcro, Inc., Manchester, N.H., under their trademark 
VELCRO. In view of the relatively soft, felt-like texture of loop portions 
18a (FIGS. 2-4) and 19a, they are placed on the inner face of front waist 
band 14a where any exposed portions thereof (as shown in FIG. 1 by loop 
portion 19a) are placed in contact with the wearer (not shown). It is 
particularly important that hook portions 18b and 19b (FIG. 4) are placed 
on the outside face of rear waist band 14b so as to minimize contact by 
the wearer (not shown). 
At this point of the description of the various features included in diaper 
10, it should be pointed out that even though diaper 10 can be fully 
reusable, the same, novel features can be incorporated, advantageously, 
into a diaper 10 that is entirely disposable. As such, diaper 10 provides 
significant advantages in that the total bulk thereof as the result of the 
overall size and placement of absorbent pad 40 is substantially reduced as 
compared to a commercially available, disposable diaper (not shown). In 
particular, absorbent pad 40 as well as inner shell 30 and outer shell 14 
can be fabricated entirely from materials acceptable as solid wastes and, 
as such, provide significant advantages since the overall bulk of 
absorbent pad 40 is substantially less than the conventional, commercially 
available, disposable diaper (not shown). 
An elastic gore 15 of an elastic fabric is inserted in the center of rear 
waist band 14b. Elastic gore 15 is designed to enhance the fit of waist 
band 14 about the waist of a wearer (not shown) by providing a limited 
degree of elasticity to waist band 14. This amount of elasticity is 
sufficient to adapt waist band 14 to changes to the circumference of waist 
of the wearer (not shown) during movement, changes in posture, breathing, 
and the like. 
Referring now also to FIG. 2, inner shell 30 generally conforms to the 
external profile of outer shell 12 but is assembled from a front panel 32, 
a rear panel 33, a left panel 34, and a right panel 35. Front panel 32 is 
joined to a front end of absorbent pad 40 along a seam 36 while rear panel 
33 is joined to a rear end of absorbent pad 40 along a seam 37. Left panel 
34 extends the full length of inner shell 30 and is joined along a seam 38 
to a left edge of each of front panel 32, absorbent pad 40, and rear panel 
33. Similarly, right panel 35 extends the full length of inner shell 30 
and is joined along a seam 39 to the right side of each of front panel 32, 
absorbent pad 40, and rear panel 33. 
Inner shell 30 is designed to suspend absorbent pad 40 in spaced 
relationship between leg openings 16 and 17 (FIG. 1) and thereby suspend 
absorbent pad 40 snugly between the legs of the wearer (not shown) when 
waist band 14 is snugly engaged around the waist of the same. Further, 
inner shell 30 is also specifically configured to suspend absorbent pad 40 
in spaced relationship within the profile of outer shell 12. With 
particular reference also to FIG. 3, absorbent pad 40 is shown in this 
cross sectional view as being suspended by inner shell 30 in spaced 
relationship to outer shell 12, the spatial separation therebetween being 
shown as spatial separation 13. 
Absorbent pad 40 is configured from an upper layer 42 and a lower layer 46 
with a fiber fill 44 therebetween. Upper layer 42 and lower layer 46 are 
fabricated from a soft fabric material such as a cotton flannel while 
fiber fill 44 is selected from a nonwoven, batting-type material such as a 
polyester, or the like. In one presently preferred embodiment fiber fill 
44 is selected from a blended cotton and wool batting. In effect, 
absorbent pad 40 is constructed as a small quilt or pillow whose primary 
function is the absorption and retention of liquids. Upper layer 42 is 
specifically directed to a soft, absorbent, nonallergenic material such as 
cotton flannel, since its primary function is to reside snugly between the 
legs of a wearer and wick away any moisture deposited thereon. The 
moisture (not shown) is pulled directly into fiber fill 44 through this 
inherent wick action. 
Spatial separation 13 allows outer shell 12 to assume a loose, slightly 
bouffant profile when secured to a wearer with the additional advantage of 
forming an overflow reservoir in the event excess liquid is deposited in 
absorbent pad 40. However, given the nature of absorbent pad 40 this 
eventuality is somewhat limited. For example, in one experimental test, 
over 280 milliliters of water were poured on and absorbed by absorbent pad 
40 without any of the water passing into spatial separation 13. This 
particular experiment was conducted using a pediatric size, diaper 10. The 
advantage of absorbent pad 40 in such a circumstance is more clearly 
understood when it is pointed out that a pediatric wearer (not shown) of 
diaper 10 has normal bladder capacity of only about 85 milliliters. 
Absorbent pad 40 performs another unique function when reusable diaper 10 
is used in an adult setting. In particular, for those instances of bladder 
incontinence, the outflow of urine is more or less a constant drip 
generally at a rate that approximates the excretion of urine from the 
kidneys. In such circumstances, it is highly desirable for upper layer 42 
to wick away this liquid directly into fiber fill 44. Absorbent pad 40 
thereby quickly and efficiently retains the absorbed liquid while inner 
shell 30 suspends absorbent pad between leg openings 16 and 17. This 
feature is important since it effectively inhibits excess liquid in 
absorbent pad 40 from leaking out of either of leg openings 16 or 17. 
Outer shall 12 and inner shell 30 are each fabricated from a water 
resistant fabric such as a nylon. This feature is important not only with 
respect to outer shell 12 and the fact that it creates an overflow 
reservoir in spatial separation 13, but also because it also effectively 
inhibits the migration or wick action of liquid from absorbent pad 40 
through either of left panel 34 or right panel 35 to the respective leg 
openings, leg opening 16 or leg opening 17. 
With reference now to FIG. 4, outer shell 12 and inner shell 30 are shown 
in an exploded plan view of the various elements that are assembled to 
create diaper 10. Outer shell 12 includes a cutout 11 adapted to receive 
elastic gore 15. A matching cutout 31 is also found in rear panel 33 and, 
when superimposed over cutout 11 conforms to the profile of elastic gore 
15. 
FIG. 5 shows a liner 50 that is adapted to be placed on top of absorbent 
pad 40 for the purpose of acting as a catchment for the solids part of 
feces excreted by the wearer (not shown) of diaper 10. Liner 50 may be 
fabricated from a flannel cloth material with the intention of being 
either reusable or even disposable. As a reusable item, liner 50 
significantly reduces handling problems when feces (not shown) is 
deposited thereon since it is a simple matter for the attendant (not 
shown) to simply grasp each end of liner 50 and transport it to the 
appropriate waste receptacle (not shown). As a disposable system, liner 50 
is fabricated from a suitable fabric material commonly found in disposable 
diapers, for example, and deposited directly into a toilet for disposal. 
THE METHOD 
Diaper 10 is assembled with inner shell 30 enclosed within outer shell 12. 
Absorbent pad 40 is suspended in inner shell 30 and is specially 
configured to be held snugly between the legs of the wearer (not shown). 
Inner shell 30 is configured with a modified hour glass-like outline as is 
outer shell 12 so as to readily adapt diaper 10 to being worn between the 
legs of the wearer (not shown). Inner shell 30 is joined to outer shell 12 
along their respective external perimeters so as to effectively enclose 
absorbent pad 40 inside the confines of outer shell 12. Importantly, 
absorbent pad 40 is not merely attached to an upper surface of inner shell 
12 but is, in effect, inserted in an opening formed therein through the 
joinder of front panel 32 and rear panel 33 with each of left panel 34 and 
right panel 35. In this manner, excess liquid (not shown) received by 
absorbent pad is free to enter spatial separation 1 thereby significantly 
reducing the possibility that the excess liquid could escape from either 
of leg openings 16 and 17. Clearly, if absorbent pad 40 were placed 
directly on top of a water-resistant fabric (such as if inner shell 30 
were constructed similarly to outer shell 12) there would be a very high 
probability that the excess liquid would leak out of either of leg 
openings 16 and 17. 
Diaper 10 is readily mounted and removed from about the waist of the wearer 
(not shown). Mounting is accomplished by bringing absorbent pad 40 snugly 
between the legs and fastening waist band 14 about the waist. Hook and 
loop fasteners 18 and 19 each have sufficient length to accommodate 
adjustably securing waist band 14. Further, elastic gore 15 contributes a 
limited degree of elasticity to waist band 14 to accommodate changes in 
the circumference of waist band 14 during wear of diaper 10. 
Advantageously, since all of the bulk of absorbent pad 40 is held between 
the legs, the only visible portion of diaper 10 on the outsides of the 
legs are the respective portions of inner shell 30 and outer shell 12. 
Accordingly, excessive bulk is utterly eliminated from those portions of 
diaper 10 which would otherwise create an unsightly bulge in the outer 
clothing of the wearer. This is important particularly when diaper 10 is 
configured as an undergarment for a member of the adult population. 
Diaper 10 is easily replaced by simply separating hook and loop fasteners 
18 and 19 and removing absorbent pad 40 from between the legs of the 
wearer. Since the total bulk of diaper 10 is substantially smaller than 
that of a conventional disposable diaper as well as a conventional 
reusable diaper, diaper 10 is readily concealable (if necessary) for 
transportation to a place for washing the same. 
The present invention may be embodied in other specific forms without 
departing from its spirit or essential characteristics. The described 
embodiments are to be considered in all respects only as illustrative and 
not restrictive. The scope of the invention is, therefore, indicated by 
the appended claims rather than by the foregoing description. All changes 
which come within the meaning and range of equivalency of the claims are 
to be embraced within their scope.