Washable diaper and method of assembly

A washable diaper having an outer article with an inner liner system detachably coupled to the outer article. The outer article has front and back ends, with opposing side edges connecting the ends, and inner and outer surfaces, with at least one fastening mechanism on the inner surface proximate to at least one of the ends. The inner liner system has first and second ends and includes at least one washable article, so that when assembled with the outer article, the first and second ends of the inner liner system align with the front and back ends of the outer article to be detachably coupled. The inner liner system may also include a liner member and/or at least one absorbent pad, configured to be placed within the washable article. A method of assembly of the washable diaper having an outer article and inner lining system is also disclosed.

FIELD OF INVENTION

The invention relates generally to diapers. More particularly, the present invention relates to washable and reusable diapers.

BACKGROUND OF INVENTION

Disposable diapers and cloth diapers for the absorption and containment of urine and other bodily excrements are generally known in the art. Disposable diapers have been convenient, but are costly and present environmentally adverse consequences.

Cloth diapers with flushable components have been developed, but continue to be inconvenient, bulky, and present unsanitary conditions because of inadequate construction of the diaper. Cloth diapers are often used in conjunction with waterproof plastic pants to provide some protection against leakage. Unfortunately, adding this additional element does not generally solve the longstanding waste constraint and disposal difficulties.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a solution to these identified problems. The present invention provides a durable washable diaper with the convenience and effectiveness of a traditional disposable diaper without the adverse environmental consequences. Consumers will save money and reduce consumer waste because the washable diaper and the absorbent articles are reusable. The liquid pervious liner of the inner liner system, captures any non-liquid waste and is easily removable in its entirety and disposed through a regular toilet. The option of the immediate disposal of solid bodily waste provides increased sanitary conditions.

The present invention provides in one aspect, a washable diaper that has an outer article with a front end and a back end, and opposing side edges connecting the ends. The outer article further has an inner surface and an outer surface with at least one fastening mechanism located on the inner surface and positioned in close approximation to the front or back ends. The washable diaper also has an inner liner system that includes at least one washable article that has a first end and a second end, and is positioned adjacent to the inner surface of the outer article. When the inner liner system is assembled, the first end is aligned to detachably couple to the front end of the outer article and the second end is aligned to detachably couple to the back end of the outer article.

The present invention provides in another aspect, a diaper that has a reusable outer article with a front end and a back end, with opposing side edges extending between the front end and the back end. The reusable outer article also has an inner surface and an outer surface, and has fastening mechanisms positioned on the inner surface of each of the front end and the back end. The diaper also has an inner liner system that includes a washable article with a first end and a second end and is positioned adjacent to the inner surface of the reusable outer article. When assembled with the reusable outer article, the first end of the washable article is aligned and detachably coupled with the front end of the reusable outer article, and the second end of the washable article is aligned and detachably coupled with the back end of the reusable outer article. The inner liner system also includes a flushable liner member that is configured to surround the washable article and be positioned adjacent to the inner surface of the reusable outer article upon assembly of the diaper.

Also described herein is a method of assembling a washable diaper. The method includes the step of obtaining a reusable outer article, that has a front end and a back end, with opposing side edges connecting the front end to the back end, and that also has an inner surface and an outer surface, with a fastening mechanism on the inner surface of each of the front end and the back end. The method may also include the step of obtaining at least one washable article with a first end and a second end. The method may further include the step of obtaining a disposable liner member, with a first end and a second end and configured to cover the washable article. The method may include the step of aligning the first end of the at least one washable article with the first end of the liner member and aligning the second end of the at least one washable article with the second end of the liner member, and wrapping the liner member about the at least one washable article so that the liner member wholly surrounds the at least one washable article forming an inner liner system that has a first end and a second end. The method may further still include the step of positioning the assembled inner liner system within the reusable outer article and securing the inner liner system within the reusable outer article with the fastening mechanisms.

DETAILED DESCRIPTION FOR CARRYING OUT THE INVENTION

The following detailed description of a washable diaper illustrates by way of example and not by way of limitation. While the detailed description is made in the context of a diaper, it is apparent that the present invention would also be suitable for feminine care products, incontinence garments, training pants, and the like. Generally stated, disclosed herein is an embodiment of a washable diaper, comprising of an outer article and an inner liner system. Further described herein is a method of assembling an embodiment of the washable diaper.

One embodiment of a washable diaper10, embodying the principles and concepts of the present invention, is illustrated inFIGS. 1-9and described below.FIG. 1shows washable diaper10that has been assembled, comprising an outer article20, and an inner liner system40.

As illustrated inFIG. 5, one embodiment of washable diaper10may be assembled with at least one absorbent pad70, at least one washable article50, a liner member60and outer article20. At least one absorbent pad70is fabricated from any absorbent material, including but not limited to, cotton, flannel, and organic cotton. At least one absorbent pad70may further be shaped to better suit the needs of male wearers or female wearers. In assembling washable diaper10, at least one absorbent pad70is inserted within at least one washable article50, through an opening55configured to accept at least one absorbent pad70.

As seen inFIG. 5, at least one washable article50has a first end51and a second end52, and also includes an opening53located about first end51and an opening54located about second end52. Openings53,54are located on opposing ends of at least one washable article50. At least one washable article50further comprises opening55that is configured to receive at least one absorbent pad70. Opening55is disposed on at least one washable article50and may be configured to extend longitudinally from first end51to second end52of washable article50, and may be located in various positions, including on the front side, back side, or either lateral sides of at least one washable article50, so long as opening55can accommodate the insertion of at least one absorbent pad70. At least one washable article50is typically fabricated from any absorbent material, including, but not limited to, cotton, flannel, and organic cotton.

As exhibited inFIGS. 6A-6C, at least one washable article50, that may have at least one absorbent pad70placed within, is wrapped by or enclosed within liner member60. Liner member60, having a first end61and a second end62, has at least one opening63on first end61and at least one opening66on second end62. Liner member60is compliant, soft feeling, and non-irritant to the wearer's skin. Liner member60may be fabricated from a liquid pervious material, including but not limited to, rice paper, cellulose fibers, blend of rayon and cellulose fibers and any other liquid permeable hydrophobic fibrous materials that will allow liquid to readily penetrate through its thickness. Liner member60may also be fabricated from a material that will wick moisture away from the wearer's skin. Liner member60may further still be fabricated from a material that is biodegradable and flushable through a regular toilet system. A person having ordinary skill in the art is aware of the type of liquid pervious material that can be used to manufacture liner member60so that it would be biodegradable and flushable. When liner member60is fabricated from a liquid pervious, flushable material, it will function to contain non-liquid bodily excrements and allow for easy disposal via a regular septic/sewer system.

As shown inFIG. 6A, liner member60has a length that is approximately the same as at least one washable article50and width that is generally wider than at least one washable article50. Liner member60further has three openings63,64,65on first end61and three openings66,67,68on second end62. As shown inFIG. 6C, assembled inner liner system40has an opening43at the first end41and an opening44at the second end42. As shown inFIG. 6D, openings63,64,65on first end61of liner member60are coaxially aligned with opening53on first end51of at least one washable article50to form opening43(shown inFIG. 6C) at first end41inner liner system40.

FIG. 5shows inner liner system40being constructed of at least one absorbent pad70placed within at least one washable article50and liner member60. Inner liner system40is then configured to detachably couple to outer article20by aligning inner liner system40adjacent to the inner surface29of outer article20and, by using the at least one fastening mechanism31disposed on the inner surface of the front end21(shown inFIG. 1) and the at least one fastening mechanism32disposed on the inner surface of the back end22(shown inFIG. 7) of outer article20.

As seen inFIG. 1, first end41of inner liner system40is aligned with front end21and is positioned to be held within the front compartment23of outer article20. Front compartment23is configured to receive first end41of inner liner system40and at least one fastening mechanism31detachably couples first end41of inner liner system40to outer article20by coupling opening43. As also shown inFIG. 1, at least one fastening mechanism31is located on front end21and is disposed on the inner surface of front compartment23of outer article20and may be constructed by using hook and loop fasteners, such as the Velcro® brand hook and loop fastener system, but at least one fastening mechanism31may also be constructed by using a hook and eye, pin, button, snap button or clasp mechanisms.

As shown inFIG. 7, second end42of inner liner system40is aligned with back end22and is positioned to be held within the back compartment24of outer article20. Back compartment24is configured to receive second end42of inner liner system40and at least one fastening mechanism32detachably couples second end42of inner liner system40to outer article20. As also exhibited inFIG. 7, at least one fastening mechanism32is disposed on the inner surface of back compartment24of outer article20and may be constructed using hook and loop fasteners, such as the Velcro® brand hook and loop fastener system, but at least one fastening mechanism32may also be constructed by using a hook and eye, pin, button, snap button or clasp mechanisms.

As illustrated inFIGS. 1,5and7, outer article20is configured with front end21and back end22, and the opposing side edges25,26. Outer article20may also include the opposing side barriers27,28, situated on inner surface29of outer article20and positioned substantially parallel to opposing side edges25,26. As shown inFIGS. 1,2,5, and7, opposing side barriers27,28may be elasticized.

FIGS. 1,3,4,5and7illustrate opposing side edges25,26being configured to conform to the legs of the wearer to maximize fit and minimize potential leakage. This configuration gives outer article20an hourglass-like silhouette, with back end22being wider than front end21due to the extended portions36,37of back end22. Outer article20has back compartment24, extending perpendicular to opposing sides edges25,26, that will allow extended portions36,37to wrap around the wearer's body from the back side to the front side, as seen inFIG. 9. Outer article20also has front compartment23, extending relatively perpendicular to opposing side edges25,26, that will allow wrapping around the wearer's body on the front side, as seen inFIG. 8.

In this embodiment of washable diaper10, front compartment23and back compartment24are fashioned as a pocket or enclosure like structure, as illustrated inFIGS. 1,3,4,5, and7, but front compartment23and/or back compartment24may be designed as a flap, a pouch, reinforced patch of material or reinforced strip of material.

Outer article20, as shown inFIGS. 1,3,4,5, and7-9, may be constructed using any material that will allow inner surface29(as shown inFIGS. 3,4,5and7) of outer article20to be liquid impervious. Outer article20may be comprised of a single layer shell construct manufactured from a liquid impervious material, or liquid resistant material, including but not limited to nylon. Outer article20may also be constructed using multiple layers of material, with one layer being constructed of a liquid impervious layer. When outer article20is made of multiple layers, a liquid impervious layer may be disposed as one of the inner layers. The outer-most layer may be manufactured from any material, including but not limited to a breathable material. The outer-most layer may also be manufactured from any material that would be desirable, including for the purpose of increasing the comfort for the wearer, and enhancing the aesthetics of washable diaper10.

The fastening mechanisms33,34, disposed on extended portions36,37of back end22of outer article20, as depicted inFIGS. 1,3,4,5and7, are used to detachably couple to the front of outer article20, when washable diaper10is worn, as shown inFIG. 8. Fastening mechanisms33,34as shown inFIGS. 1,3,4,5and7, are hook and loop fasteners, such as the Velcro® brand hook and loop fastener system, but fastening mechanisms33,34may also be one of hook and eye, pin, button, snap button, buckle, or clasp mechanisms.

FIG. 2depicts a cross section of washable diaper10ofFIG. 1, showing the multiple layers that compose inner liner system40. Typically, inner liner system40is constructed with at least one washable article50, liner member60and at least one absorbent pad70. Liner member60completely surrounds at least one washable article50. Opposing side barriers27,28further secure inner liner system40in outer article20, so that inner liner system40does not shift or move when washable diaper10is worn and operate to enhance the containment and absorption of urine and other bodily excrements.

FIGS. 3 and 4show additional embodiments of outer article20of washable diaper10. As illustrated inFIGS. 1,3-5, and7-9, opposing side edges25,26of outer article20are configured to conform to the legs of the wearer of washable diaper10. Opposing side edges25,26may be elasticized, as shown inFIG. 4, or not, as illustrated inFIG. 3. The contoured configuration of opposing sides25,26of outer article20ensures the secure fit of washable diaper10and minimizes potential leakage issues. Elasticized opposing side edges25,26as seen inFIG. 4, create a tighter fit on the wearer's legs (seeFIG. 8) and provide enhanced protection against leakage.

FIGS. 6A-6Cillustrate the method of assembly of liner member60and at least one washable article50. As shown inFIG. 6A, at least one washable article50includes opening53on first end51and opening54on second end52. At least one washable article50is usually placed on top of liner member60that has first end61and second end62, with three openings63,64,65on first end61and three openings66,67,68on second end62. First end51of at least one washable article50is aligned with first end61of liner member60, and second end52of at least one washable article50is aligned with second end62of liner member60, so that middle opening63,66of liner member60are aligned with openings53,54of at least one washable article50.

As shown inFIGS. 6B and 6C, the width of liner member60is wrapped about at least one washable article50, so as to wholly surround at least one washable article50. When liner member60is wrapped about at least one washable article50, openings64,65are aligned with opening63on first end of liner member61and openings67,68are aligned with opening66on second end of liner member62, as seen inFIG. 6C. Openings53,63,64,65are coaxially aligned to represent the composite opening43on first end41of inner liner system40and openings54,66,67,68are aligned to represent the composite opening44on second end42of inner liner system40.

FIG. 6Ddepicts an enlarged view of the area identified by the circle noted inFIG. 6Cand shows the detailed view of opening43on first end41of assembled inner liner system40, that is created by aligning opening53on first end51of at least one washable article50and openings63,64,65on first end61of liner member60(shown inFIG. 6C). Composite opening43facilitates the ease of detachably coupling inner liner system40to outer article20using at least one fastening mechanism31,32.

FIGS. 8 and 9show washable diaper10being worn by an infant. As seen inFIG. 8, front end21of outer article20is configured to fit on the front of the infant, with back end22of outer article20covering the infant's bottom (seeFIG. 9). Fastening mechanism35is located on outer surface30of front end21of outer article20. Extended portions36,37of back end22of outer article20are wrapped around the infant to detachably couple to front end21of outer article20. Fastening mechanism35as shown inFIG. 8depicts a strip of one part of the hook and loop fastener. Additionally, fastening mechanism35may be made of several latching mechanisms including hook and eye, pin, button, snap button or clasp constructs.

Although the preferred embodiments have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, and substitutions may be made without departing from the spirit of the invention, and therefore, those are to be considered to be within the scope of the following claims.