Reusable diaper

The present invention provides a nondisposable diaper comprising at least three layers. In one embodiment, continuous perimeter closure is provided between at least two of the layers and discontinuous perimeter closure is provided between at least two of the layers. In other embodiments, continuous or discontinuous perimeter closure is provided between all the layers.

FIELD OF INVENTION 
The present invention relates to an improved nondisposable diaper. 
BACKGROUND OF THE INVENTION 
With the ever present waste management problem, the baby care industry has 
felt a long and increasing need for new and improved nondisposable 
diapers. For example, some publications have estimated that approximately 
18 billion plastic diapers are buried in landfills each year, and that 
disposable diapers constitute approximately 30% of the total 
nonbiodegradable materials buried in landfills in the United States. 
Part of the problem is that the baby care industry has made few 
improvements to enhance the ease of use and durability of the conventional 
nondisposable diapers. The present invention provides such improvements 
and accordingly should provide additional encouragement to parents to 
switch from using disposable diapers, which have created an environmental 
problem, to a nondisposable diaper. 
For example, the present invention provides a nondisposable diaper in which 
critical stitching is enclosed and thus protected against wear and tear 
from outside contact. Also, by not exposing such seams to the baby's 
bottom, the nondisposable diaper in the present invention is more 
comfortable for the baby. Also, the present invention provides an improved 
design which permits the nondisposable diaper to dry faster and more 
efficiently. Decreased drying time translates into energy savings. Also, 
the nondisposable diaper according to the present invention requires less 
material which means that more diapers may be washed in one drying load. 
A related problem often encountered with conventional nondisposable diapers 
is that because they do not dry during a typical drying cycle, they remain 
somewhat damp while stored. A damp diaper is more susceptible to molding 
and rotting, and thus typically will not last as long. The present 
invention helps to eliminate these and other problems associated with 
conventional nondisposable diapers. 
SUMMARY OF THE INVENTION 
The nondisposable diaper of the present invention includes at least three 
layers having perimeter ends. Between at least two of the layers, 
continuous perimeter closure is provided along their respective perimeter 
ends. Also, between at least two of the layers, discontinuous perimeter 
closure is provided. The discontinuous perimeter closure defines at least 
one opening between the layers and thereby permits the diaper to dry 
faster. 
In another embodiment, continuous perimeter closure is provided between all 
the layers. 
In another embodiment, discontinuous perimeter closure is provided between 
all the layers.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring now to the drawings, FIGS. 1-5 disclose a nondisposable diaper 
constructed according to the preferred embodiment of the present 
invention. FIG. 6 discloses an alternative preferred embodiment of the 
nondisposable diaper shown in FIGS. 1-5. It should be noted that like 
reference numerals designate corresponding elements throughout the 
drawings. 
Referring to FIGS. 1, 2 and 5, the nondisposable diaper 10 according to the 
present invention includes a top section 12 and a bottom section 14. In 
the preferred embodiment, the top and bottom sections 12, 14 are 
symmetrical, each having corresponding perimeter ends 16 and inside 
surfaces 18 and outside surfaces 20. The respective inside surfaces of the 
top and bottom sections face one another. 
The nondisposable diaper further includes attachment means 22 for attaching 
the top section 12 to the bottom section 14 along their respective 
perimeter ends 16 in a discontinuous manner. The attachment means may 
comprise discontinuous perimeter stitching 22 as shown in FIGS. 1 and 5. 
The discontinuous perimeter stitching defines at least one opening 24 
between the respective top and bottom sections 12, 14. The opening 24 
permits air to more freely enter and flow between the respective inside 
surfaces 18 of the top and bottom sections during, for example, a drying 
cycle. This permits the nondisposable diaper 10 to dry faster and more 
efficiently and thereby helps to eliminate the problem encountered when 
the diaper does not dry during the typical drying cycle which is used for 
other clothes. 
In the preferred embodiment, the discontinuous perimeter stitching 22 
defines first and second openings 24, 26 located at opposite ends of the 
nondisposable diaper. As shown in the drawings, the nondisposable diaper 
10 according to the preferred embodiment comprises a wedge-shaped 
nondisposable diaper, having a wider end 28 and a narrower end 30, wherein 
the first opening 24 is located at the wider end 28 and the second opening 
26 is located at the narrower end 30. It is noted that the wedged-shaped 
nondisposable diaper 10 according to the present invention is adapted to 
be used as an insert within a conventional diaper cover. It should be 
understood, however, that under the present invention, the diaper could be 
made in a variety of different shapes, including but not limited to 
wedged-shaped as shown, or hourglass shaped, rectangular shaped or other 
shapes adaptable to fit a baby's bottom. Also, the nondisposable diaper 
according to the present invention need not be an insert; it may be 
otherwise attachable with pins or other means for securing the diaper to 
the baby's bottom. 
As best shown in FIGS. 2 and 5, the top section 12 further includes a top 
outside layer 32, a top inside layer 34, and a top absorbency pad 36 
located between the top outside and inside layers 32, 34. In the preferred 
embodiment, the top section 12 further includes first top attachment means 
38 for attaching the top absorbency pad 36 to the top inside layer 34. In 
the preferred embodiment, the first top attachment means 38 is enclosed 
within the top outside layer and thus protected from wear and tear 
associated with outside contact to the nondisposable diaper. The first top 
attachment means preferably comprises stitching 38 as shown in FIGS. 2 and 
3. It should be understood that in alternative embodiments, the first 
attachment means could attach the absorbency pad to the top outside layer 
and still incorporate patentable features of the present invention. The 
top section 12 according to the preferred embodiment further includes a 
second top attachment means 40 for attaching the top outside layer 32 to 
the top inside layer 34. 
The bottom section 14 includes a bottom outside layer 42, a bottom inside 
layer 44, and a bottom absorbency pad 46 located between the bottom 
outside and inside layers. The bottom section 14 further includes a first 
bottom attachment means 48 for attaching the absorbency pad 46 to the 
bottom inside layer 44, the attachment means being enclosed within the 
bottom outside layer 42 and thus protected from wear and tear from outside 
contact. The first bottom attachment means preferably comprises stitching 
48 as shown in FIGS. 2. The bottom section 14 according to the preferred 
embodiment also includes a second bottom attachment means 50 for attaching 
the bottom outside layer 42 to the bottom inside layer 44. 
As shown in FIGS. 2, 3 and 4, the top and bottom absorbency pads are 
smaller in size than the other layers and are centrally located where 
added absorbency is needed. It should be noted that the top and bottom 
absorbency pads 36, 46 need not be located between the respective top and 
bottom outside and inside layers. For example, in an alternative 
embodiment, the top and bottom absorbency pads could be attached to the 
inside surfaces 18 (i.e., the opposite sides of the top and bottom inside 
layers 34, 44) of the top and bottom sections. 
In a preferred embodiment, the second top attachment means 40 and the 
second bottom attachment means 50 comprise continuous perimeter stitching 
as shown in FIGS. 1, 3 and 4. In an alternative preferred embodiment shown 
in FIG. 6, the second top and bottom attachment means 40, 50 and the means 
for attaching the top section 12 to the bottom section 14 comprise 
discontinuous perimeter stitching 22 which defines at least three 
openings: a first opening 24 between the top section 12 and the bottom 
section 14; a first top opening 52 between the top outside layer 32 and 
top inside layer 34; a first bottom opening 56 between the bottom outside 
layer 42 and the bottom inside layer 44. In the preferred embodiment, the 
discontinuous stitching 22 defines six openings, including the above 
listing openings: a second opening 26 between the top section 12 and 
bottom section 14; a second top opening 54 between the top outside layer 
32 and the top inside layer 34; and a second bottom opening 58 between the 
bottom outside layer 42 and the bottom inside layer 44. These openings 
allow air to more freely flow between the various layers and sections and 
thereby permit the diaper to dry faster and more efficiently. Each opening 
should extend at least half the width of the end (i.e., of the wider end 
28 or of the narrower end 30) on which the opening is located. This 
proportion for the openings provides improved dryability of the diaper 
without jeopardizing the integrity of the diaper's construction. For cost 
reasons, the manufacturer may, however, prefer to have each opening extend 
the entire width of the diaper end. It should be understood that the width 
of the opening may vary. 
Several advantages should be noted in the present invention. First, the 
nondisposable diaper constructed according to the preferred embodiment 
provides two separate absorbency pads, as opposed to one thicker 
absorbency pad. This feature facilitates drying. Also, by providing air 
vents as described above, the absorbency pads are exposed to a more direct 
air flow. 
FIGS. 3 and 4 are identified as top section 12. However, it should be 
understood that FIGS. 3 and 4 could also be used to describe bottom 
section 14 because, in the preferred embodiment, bottom section 14 mirrors 
the top section 12. For convenience, the top section will be referred to 
but it should be understood that FIGS. 3 and 4 also describe the bottom 
section 14. FIGS. 3 and 4 show that the absorbency pad 36 is enclosed 
between the top outside layer 32 and top inside layer 34. As shown, the 
stitching 38 does not penetrate the top outside layer 32 and therefor is 
protected against the wear and tear from outside contact. Thus, the 
critical seams associated with stitching 38 are not exposed for example to 
the baby's bottom. This feature also makes the nondisposable diaper more 
comfortable for the baby. Thus, the nondisposable diaper according to the 
present invention should be more durable and comfortable. 
In alternative embodiments of the present invention, the diaper may 
comprise at least three layers. It should be noted that the term "layer" 
as used herein does not necessarily mean a single discrete sheet of 
material. In other words, several (or any number of) layers may be formed 
from a single sheet of material as shown in FIGS. 7-13. It should be noted 
that significant labor saving advantages are obtained by using, for 
example, a single sheet of material to make several layers. For example, 
on the folded side, additional stitching or attachment means need not be 
provided to have perimeter closure along the folded side. 
It should be noted that in other embodiments of this invention, continuous 
perimeter closure may be provided between all the layers of diaper. 
In the preferred embodiment, between at least two of the layers, continuous 
perimeter closure means may be provided. Perimeter closure between two 
layers may be provided by some means of attachment such as stitching, 
adhesive, velcro, or the like. Perimeter closure may also be provided by a 
fold in material which provides continuity between the two layers. 
Perimeter closure may also be provided between two discrete layers by 
being enclosed within a fold of one of the layers or by being enclosed 
between two independent layers having a fold which provides continuity. In 
other words, continuous perimeter closure does not necessarily mean that 
the two layers are attached around their respective perimeter ends in a 
continuous manner. Rather, the perimeter ends may be attached or enclosed 
as discussed above. 
Between at least two of the layers, discontinuous perimeter closure may be 
provided. The phrase "perimeter closure" is defined above. The 
discontinuous perimeter closure defines at least one opening between the 
two layers, the opening permitting air to more freely enter and flow 
between the layers and thereby permit the diaper to dry faster. 
It should be noted that in other embodiments, discontinuous perimeter 
closure may be provided between all the layers of the diaper. See, for 
example, FIGS. 6 and 8. 
Referring now to the drawings, FIGS. 7, 8 and 9 show an alternative 
embodiment, diaper 70, made according to the present invention. The diaper 
70 comprises six layers 71, 73, 75, 77, 79 and 81. These six layers are 
made from two sheets of material 72 and 74 as shown in FIG. 7. In the 
preferred embodiment, sheet 72 is half the size of sheet 74. Sheet 72 is 
preferably made from a more absorbent material such as terry cloth or the 
like. In the preferred embodiment, sheet 72 is made from a woven or knit 
material or the like. 
FIG. 8 shows that sheet 74 is folded along line 7--7 to form three layers. 
It should be noted that FIG. 8 also shows another embodiment of the present 
invention. This embodiment may be made with discontinuous perimeter 
closure as shown or continuous perimeter closure. In the preferred 
embodiment, stitching or attachment means 76 and 78 are provided. 
Stitching 78 provides closure between the three layers along the line 
defined by stitching 78. It should be noted that stitching 76 is not 
needed to provide closure along the line defined by stitching 76. Rather, 
closure between the three layers shown in FIG. 8 is already provided by 
the fold along lines 7--7 in sheet 74. Stitching 76, however, helps to 
secure the layers so that, for example, during the washing of the diaper, 
the internal layers do not get crumpled or misaligned. 
FIG. 9 shows that the layers in FIG. 8 are folded to define the six layers 
of the diaper 70. Stitching or attachment means 80 and 82 are provided in 
the preferred embodiment. 
Accordingly, in the preferred embodiment, continuous perimeter closure is 
provided between layers 71 and 73; 73 and 75; 77 and 79; and 79 and 81 by 
stitching 72, stitching 82, stitching 76 (or fold along line 7--7), and 
stitching 80 (or fold along line 8--8). Discontinuous perimeter closure is 
provided between layers 75 and 77. In the preferred embodiment apertures 
83 and 84 are defined between layers 75 and 77. Apertures 83 and 84 permit 
air to flow through the center of the diaper 70. 
FIGS. 10 and 11 show another alternative embodiment of the present 
invention. This embodiment comprises six layers made from three sheets of 
material 86, 87 and 88. Preferably, sheet 86 is made from a more absorbent 
material. In the preferred embodiment, stitching or attachment means 94, 
92 and 90 are provided. Sheets 86, 87 and 88 are folded along line 10--10 
to define six layers. In the preferred embodiment, stitching 96 is 
provided. Accordingly, apertures 98 and 99 are defined between the middle 
two layers. Continuous perimeter closure is provided between the remaining 
layers in the preferred embodiment as shown. 
In other embodiments of the diaper 85, stitching or attachment means could 
be provided to define at least one opening between each of the layers. For 
example, stitching 90 and 92 could be eliminated thus defining an opening 
between each layer. 
It should be noted that a four layer diaper may be constructed in a similar 
manner as shown in FIGS. 10 and 11. For example, it could be accomplished 
by eliminating one of the sheets of material 86, 87 or 88. 
FIGS. 12 and 13 show an alternative embodiment of the present invention. 
Diaper 100 comprises three layers made from a single sheet 102. Sheet 102 
is first folded as shown in FIG. 12. In the preferred embodiment, 
stitching 104 and 105 is provided. However, stitching 104 and 105 is not 
necessary. Sheet 102 is again folded as shown in FIG. 13. In the preferred 
embodiment, stitching 106 and 108 is provided. Accordingly, apertures 110 
and 111 are defined between the top two layers. In the embodiment which 
eliminates stitching 104 and 105, apertures would be provided between each 
of the layers in diaper 100. It should be noted that sheet 102 could also 
be folded accordion style. 
It is to be understood that, even though numerous characteristics and 
advantages of the present invention have been set forth in the foregoing 
description, together with details of the structure and function of the 
invention, the disclosure is illustrative only, and changes may be made in 
the detail, especially in matters of shape, size and arrangement of parts 
within the principles of the invention to the full extent indicated by the 
broad and general meaning of the terms in which the appended claims are 
expressed.