A FORMED AND WASHABLE DIAPER

Abstract: A formed and washable diaper comprised of multiple layers of material including an inner layer of soft nonirritating absorbent washable fabric, an absorbent and moisture retentative mildew-resistant washable felt layer, and an outer moisture barrier layer of fabric, diaper being formed with an hourglass shape with an upper end (27) longer in length than the bottom end (35) such that when placed on the wearer, with the upper end (27) forms the back of the diaper and the bottom end is pulled up between the wearer's legs and disposed on the front, with top and bottom edges (23) and (25) curved slightly convex upward and downward respectively.

Description: TITLE OF THE INVENTION A Formed and Washable Diaper CROSS-REFERENCES TO RELATED APPLICATIONS The present invention is related to U.S. Patent Application S.N. 06/365,157 filed April 5, 1982, for a Reusable Fluid Absorption Pad, and assigned' to Art Unit 336, and is a continuation-in-part of U.S. Patent Application S.N. 06/588,349, filed March 12, 1984, and issued as U.S. Letters Patent No. 4,516,975 on May 14, 1985. BACKGROUND OF THE INVENTION FIELD OF THE. INVENTION The present invention relates to diapers and more particularly to a formed and washable diaper having multiple layers of different types of material for different functions which is reusable and conforms to the body of the wearer. DESCRIPTION OF THE PRIOR ART There are numerous multiple layer fabric diapers on the market such as those described in U.S. Patent Nos.: 3,646,937; 3,848,594; . 3,860,003; and 4,041,951. The problem with these diapers is that all of them are made of disposable materials which cannot be washed and reused because they cannot stand the stress of the washing procedure and the high 25 temperatures of tumble drying which occur in clothes washing and drying machinery. Disposable diapers are very expensive when compared with reusable diapers which are more expensive initially but can be washed and reused many times. A further problem results if a person wants to undo a disposable diaper to check it for deposits: it is almost always necessary to replace the diaper because disengaging the adhesive securement strips usually results in tearing the diaper so it cannot be refastened. There are other problems with disposable diapers. The chemicals utilized in the fragrances put into the diapers have proven to cause skin irritation and bronchial infection and irritation. Numerous cases of infant deaths have been reported which have been determined to have been due to inhalation of particles and pieces of disposable diapers which were apparently torn or picked off the diaper by the infants when the diapers became wet and lost their tensile strength. Additional deaths been determined to have occurred from suffocation when the diapers became wet and the securement means tore off and the diaper ended up covering the infant's face. The present invention has been designed to at least minimize but in most cases eliminate these problems. SUMMARY OF THE INVENTION The present invention is a formed and washable diaper comprised of a multiplicity of layers of material including an outer layer forming a moisture barrier cover, a moisture absorbent felt layer forming the frame of the diaper, and a soft inner facing layer made of a non-irritating absorbent washable fabric. The diaper has a particular body enclosing configuration due to its unique construction which includes an hour-glass outline with each of the hour-glass shaped sides forming a continous sculpted crescent shaped concave curve. The top and bottom edges are generally curved slightly convex upward and downward respectively. The upper end of the diaper is slightly longer in lateral length than the bottom end whereby when the diaper is placed on the wearer with the top end disposed at the back of the body and with the bottom end pulled up between the wearer's legs and disposed with the bottom end in front on the stomach of the wearer's body, the two edges of the top end of the diaper will wrap around the wearer's body from behind and overlap the two edges at the bottom end of the diaper disposed on the wearer's stomach. The lateral curved vertically disposed edges of the diaper are provided with a stretched elastic edging which is secured to the material for a portion of the length of the curved edges whereby when the elastic is released, and allowed to retract, the diaper is pulled into a U-shaped configuration. The outer edges of the inner and felt outer layers of the material are formed generally co-extensive throughout the extent of the configuration of the diaper. The outer layer extends peripherally outward beyond the edges of said co-extensive inner and felt layers to provide a moisture barrier border which extends beyond the edges of the absorbent layers of the diaper. The tabs formed by the top and bottom lateral edges or corners of the diaper are provided with adjustable strip and grip fasteners for securing the overlapping edges together to hold the diaper on the wearer's body. OBJECTS OF THE INVENTION It is therefore an important object of the present invention to provide a formed diaper which conforms to a wearer's body. It is another object of the present invention to provide a washable diaper which can withstand both the stress of washing in automatic clothes washers and the high temperatures of hot air clothes dryers. It is a further object of the present invention to provide a reusable diaper which provides a felt absorbent layer for retaining greater amounts of moisture than disposable diapers. It is yet another object of the present invention to provide a diaper which is safe, non- irritating, mildew-resistant, and does not require any pins to hold it on the wearer. It is yet a further object of the present invention to provide a diaper which is adjustable in size and can be easily arranged in a non-snagging configuration for washing. Other objects of the present invention will become apparent when the description of the preferred embodiment thereof is considered in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation of the formed and washable diaper of the present invention; FIG. 2 is a rear elevation of the diaper of the present invention; FIG. 3 is a front elevation of the diaper of the present invention; FIG. 4 is a bottom plan view of the diaper of the present invention in a stretched out configura¬ tion showing the outside thereof; FIG. 5 is a top plan view of the diaper of the present invention showing the inner side thereof in a stretched out configuration; FIG. 6 is a partial cross-section of the diaper of the present invention taken along lines 6-6 of FIG. 1; and FIG. 7 is a partial cross-section of the diaper of the present invention taken along lines 7-7 of FIG. 6. DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred embodiment of the formed and washable diaper of the present invention has a natural body-enclosing configuration which is due to its unique form of construction. It is substantially form-fitting to a wearer's body. It's primary use is for infants, but with proper sizing it can be used equally well for any incontinent person and geriatric patients. The material utilized in the construction of the diaper of the present invention permits it to be reused through an average of between 30 to 50 and up to 85 washings. The present invention includes a non-allergenic moisture barrier outer layer 11 which prevents excreted fluids retained * by the absorbent layers from passing through the diaper covering to the garments or bedclothes of the wearer. In the preferred embodiment, the outer layer is made of urethane coated 100% nylon taffeta. The absorbent layer 15 is constructed of felt made from a needle punched rayon and polyester blend. This layer is of uniform thickness but is considerably thicker than the inner and outer layers. It functions as a frame for the diaper to hold its shape and maintain its formed configuration once the construction of the diaper has been completed. It supports the other materials which are attached to both sides of it. The inner layer 17 of the diaper is a soft non- irritating absorbent washable fabric that is disposed next to the skin of the wearer to absorb the excreted fluids and permit them to wick through to the absorbent layer. In the preferred embodiment, it is comprised of 100% cotton, but it has been found that a blend of up to 50% polyester with the cotton will also work satisfactorily. The diaper has a particular body enclosing configuration due to its construction. This is created by forming the diaper in an outline described as somewhat of an hourglass but with the pinched in sides actually being formed by a continuous sculpted crescent shaped concave curve on each of the lateral edges 19. These edges are narrowed more towards the bottom end 21 of the diaper which end forms the front thereof. The top and bottom edges 23, 25, respect¬ ively, of the diaper are also generally curved slightly convex upward and downward respectively. In actual practice, the flat top and bottom edges are tapered slightly toward the center of the diaper to provide the convex configuration. The upper end 27 of the diaper is slightly longer in lateral length than the bottom end, whereby, when the diaper is placed on the wearer with the top end disposed at the back of the body, and with the bottom end 21 pulled up between the wearer's legs and disposed at the front of the wearer's body on the stomach, the two lateral edges 29 or corners of the top end of the diaper will wrap around the wearer's body from behind and overlap the two lateral edges 31 or corners formed by the bottom end of the diaper when it is disposed on the wearer's stomach. This configuration reduces the bulk of material that must be disposed between the wearer's legs. In addition to providing a configuration which allows uniformity of thickness be disposed on the wearer's body without the bunching up of material, the unique construction of the diaper also causes it to be formed into a body enclosing configuration. This is done by providing the curved lateral vertically disposed edges 19 of the diaper with a ^ stretched elastic edging 33 which is secured to the material of the diaper with an overlook stitch for that portion of the length of the curved edges which is disposed around the wearer's legs. This elastic 33 is stretched during the sewing operation whereby when the elastic is released and allowed to retract to its normal state of rest, the diaper is pulled into a U-shaped configuration. The resulting opposed portions of the U-shaped configuration are the front and rear flaps 35, 37, respectively, of the diaper. The outer edges of the inner and felt layers, 11, and 17, respectively, of the material forming the diaper are generally co-extensive throughout the extent of the configuration of the diaper. The absorbent layer 15 may not extend fully to the corners of the diaper and yet function fully-. The outer layer extends peripherally outward- beyond the edges of the co-extensive inner and absorbent felt layers to provide a moisture barrier border which extends beyond the edges of the absorbent layers of the diaper. This border has been found necessary to prevent the sewn edges of the diaper, which are particularly susceptible to wicking moisture from the absorbent felt layer to the edges of the diaper, from contacting the wearer's skin. The tabs 39, 41 that are formed by the top and bottom lateral edges or corners of the diaper, 19 and 21, respectively, are provided with strip and grip fasteners 43 for securing the overlapping edges together to hold the diaper on the wearer's body. In the preferred embodiment, Velcro brand or similar fasteners are used which when positioned as shown in the drawings provide an adjustable perfect body- fitting securement means which is on the front of the diaper so that the wearer can be laid on his or her back to fasten the diaper. The wearer's legs are lifted, the top or rear of the diaper is slid under¬ neath, the wearer's legs are allowed to drop on both sides of the diaper, the front flap is pulled up, the two tabs from the rear flap wrap over and press on those that lie on the front, and the diaper is automatically secured to the wearer with no further effort and particularly without pins that could possibly be stuck into the wearer by accident. A stick strip, that interwoven mass of fabric element of the fastener which is engaged by the hooks of the grip element, is disposed on the outward side of the front of the diaper proximate the top peripheral edge. This allows a large range of adjustment of the size of the diaper. On the corners of the other end of the diaper, aligned mating pairs of strip and grip tabs are provided with the grip tabs at the puter ends of the corners and the strip tabs adjacent thereto. These pairs of tabs allow the corners of the diaper to be folded over to engage themselves. This keeps the grip portion from snagging any other engagable surface and is particularly helpful during washing of the diapers to keep them from entangling with and snagging each other. The present invention is 10 to 15 times more expensive per unit than disposable diapers presently on the market, but since it can be reused between 30 to as many as 85 times it is in effect between 1/2 and 2/17 as expensive as a disposable diaper in overall cost. The benefits of the comfort and safety of having a non-allergenic, pinless diaper, which always retains its tensile strength so it cannot fall or be picked apart when it becomes wet, are self-evident. These advantages are not obtainable from disposable diapers. Thus, it will be seen from this description of the preferred embodiment of the present invention that the formed and washable diaper disclosed and described herein achieves the objects and advantages attributable thereto, and while the invention has been described in considerable detail, it is not to be limited to such details as set forth except as may be necessitated by the appended claims.

Claims: I CLAIM: 1. A formed and washable diaper comprised of a multiplicity of layers of material including a non-allergenic outer layer forming a moisture barrier cover, a moisture retentive mildew resistant washable felt layer, and an inner facing layer of soft non-irritating absorbent washable fabric, said diaper having a particular body enclosing configuration due to its construction which includes an hour-glass outline with each of the hour-glass shaped sides forming a continuous sculpted crescent shaped concave curve - with the top and bottom edges of the diaper being generally curved slightly convex upward and downward respectively, the upper end of said diaper being slightly longer in lateral length than the bottom end whereby when the diaper is placed on the wearer with the top end disposed at the back of the wearer's body and with the bottom end pulled up between the wearer's legs and disposed on the front of the wearer's body on the stomach, the two lateral edges of the top end of the diaper will wrap around the wearer's body from behind and overlap the two lateral edges at the bottom end of the diaper disposed on the wearer's stomach, the laterally curved vertically disposed edges of the diaper being provided with an elastic edging which is secured to said material for a portion of the length of the curved edges which surround the wearer's leg when the diaper is disposed in operative position whereby when the elastic is released after being secured to the diaper in a stretched condition along the edge of said diaper and allowed to retract, said diaper is retracted into a U-shaped configuration with the resulting opposed portions being the front and rear flaps of said diaper, the outer edges of said inner and felt layers of said material being generally co-extensive throughout the extent of the configuration of the diaper, said outer layer being disposed to extend peripherally outward beyond the edges of said co¬ extensive inner and felt layers to provide a moisture barrier border which extends beyond the edges of the absorbent layers of said diaper, and tabs formed by the top and bottom lateral edges or corners of said diaper being provided with adjus¬ table strip and grip fasteners for securing said overlapping lateral edges together to hold the diaper on the wearer's body. 2. The formed and washable diaper of claim 1 wherein said outer layer is made of urethane coated 100% nylon taffeta; said absorbent felt layer is made of needle punched rayon and polyester; and said inner layer is made of cotton or a cotton blend. 3. The formed and washable diaper of claims 1 or 2 wherein two corners at the same end of the diaper are provided with mating pairs of strip and grip tabs so that the corners of the diaper having the mating pairs of strip and grip tabs can be folded over to engage themselves and keep the grip portion of the tab from snagging any other engagable surface, the other end of said diaper being provided with an elongated strip tab disposed across the front of said diaper to adjustably engage the grip tabs.

Inventors: MITCHELL DEBRA J, MITCHELL, DEBRA, J.
Applicants: MCCOY ERNEST H, MCCOY, ERNEST, H.
Application year: 1985
Main classification: A61F13
IPC codes: A61F13