Abstract:
A reusable diaper product created to fit premature and newborn babies, toddlers, young youth, young adults, adults, the elderly, and patients with special problems such as a colostomy bag. The diaper comprises an all fabric stretchable shell which in the preferred embodiment is secured to the wearer by an encased elastic waistband with hook and loop VELCRO tabs. The legholes on the shell are encased elastic designed to fit many different leg sizes. Within the shell is disposed a soft breathable liquid impervious layer encasing multiple layers of a absorbent material. The sides of the absorbent material are permanently affixed to the shell and finished with elastic edges forming a body gusset of sorts. Several embodiments of the diaper are disclosed to fit special needs.

Description:
The present invention relates to a comfortable reusable cloth diaper and the like, capable of being fitted to premature and newborn babies, babies, toddlers, young youth, young adults, and the elderly. Embodiments for special needs are disclosed. 
     BACKGROUND OF THE INVENTION 
     Historically the diaper has been a flat piece of cloth folded to a desired fit to contain bodily waste. Few substantial changes have been made over the years. 
     When disposable diapers came into being more absorbancy was required since users wore them for longer and longer periods of time. With the advent of environmental issues the reusable cloth diaper came upon the scene with a mass absorbtion problem and fitting of the wearer without pins. 
     At present there are two main types of diapers on the market for children, one a disposable diaper and two a reusable cloth diaper. However both of these diapers have an exterior impervious layer garment for prevention of leakage. In the case of the disposable diapers the impervious outer garment is attached to the interior absorbent layers and in the case of the reusable diaper the exterior impervious layer plastic garment is separate from the interior washable absorbent material and bodily shaped members. The exterior plastic garment creates an undesirable and distinct crackling sound. This is particularly undesirable when the reusable diaper is worn by an adult having for instance an incontinance health problem. Furthermore, the exterior plastic garment is normally a poor fitting and uncomfortable garment with some leakage problem. 
     SUMMARY AND OBJECTIVE OF THE INVENTION 
     By using the diaper of the present invention it is an objective to further enhance personal comfort with proper diapering and incontinent care. For ease of care the product entails an all in one complete unit with no pieces to put together with the added dignity of knowing what you are wearing can&#39;t be heard when moving. Namely, a diaper is provided comprising an outer liquid permeable material shell specifically a cloth shell shaped to fit the body. A continuous impervious layer of material is carried by the outer shell. Layers of absorbent material are disposed within and carried by said liquid impervious layer. The lifespan of the diaper is extended by utillizing a breathable liquid impervious fabric that will not crinkle or break in the washing and drying process. The diaper of the present invention is very soft and comfortable to the touch with the capabilities of naturally breaking down during the normal course of use even before it hits the landfills, yet capable of lasting through more than one sibling, therefor keeping overall cost, waste, and price down. 
     The use of birdseye absorbent material assures that comfort and breathability are achieved. The wearer needn&#39;t worry about the absorbent fabric keeping ones outer garment dry and it prevents extrements from staining the outer garment. Finally an outer cloth shell without being covered in plastic allows the air to come in contact with a greater portion of the skin, keeping a more healthy environment for the wearer. 
     In accordance with this invention the liquid impervious layer is completely covered in the waistband and leg area to ensure further comfort. A slight variation of size in the flannel lined VELCRO® sides attached to the outer shell allow maximum adjustments and still maintain a comfortable yet taut fit. 
     It is a great advantage that all the components are united as one with no pieces to put together and have the look and feel of underwear. 
     Another objective of this invention is the meeting of special needs without departing from the three main component system for the diaper. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will be described in detail with reference to the accompanying drawings which illustrate a preferred embodiment of the invention and several other embodiments wherein: 
     FIG. 1 is a perspective view of the preferred embodiment of a reusable diaper product made in accordance with the principles of this invention. 
     FIG. 2 shows a view of the preferred embodiment closed in a position for wearing; 
     FIG. 3 illustrates the three main components of the preferred embodiment. 
     FIG. 4 illustrates the inner face of the preferred embodiment. 
     FIG. 4A shows an outside view of the preferred embodiment in a position to be worn. 
     FIG. 5 is a view of the premature or newborn baby diaper in a worn position in accordance with a second embodiment of this invention. 
     FIG. 5A shows a view of the interior surface of the premature or newborn baby diaper in accordance with the second embodiment of the invention. 
     FIG. 5B shows an outside view of the second embodiment of this invention. 
     FIG. 5C shows an interior view of the second embodiment of this invention. 
     FIG. 6 shows a view of a colostomy diaper in the closed position in accordance with a third embodiment of this invention. 
     FIG. 6A is an interior surface view of the colostomy diaper in accordance with the third embodiment of this invention. 
     FIG. 7 shows a view of a lighter incontinent diaper in the closed position in accordance with a fourth embodiment of this invention. 
     FIG. 7A is an interior surface view of the lighter incontinent diaper in accordance with the fourth embodiment of the invention. 
     FIG. 8 shows an outer surface view of the boys/men pull-up diaper of the fifth embodiment of this invention and is shown in a position to be worn. 
     FIG. 8A is an interior surface view of the boys/men pull-up diaper in accordance with the fifth embodiment of this invention, and 
     FIGS. 9 and 9A shows an outer surface view of the girls/women pull-up diaper of the fifth embodiment of this invention and is shown in a position to be worn. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1 through 4 illustrate a reusable diaper  10  made in accordance with the preferred embodiment of this invention in which various changes can be made to the diaper without departing from the spirit of the three main component system. As illustrated, the diaper  10  comprises an outer liquid permeable shell, specifically a cloth shell  12 , having a back end  13  and a front end  14 , and shaped to fit a body (not shown), a continuous liquid impervious layer  15 , sewn to and carried by the cloth shell  12 , and layers of absorbent liquid permeable material  16 , having a central portion  16 A, disposed within and sewn to and carried by the liquid impervious layer  15  with the liquid impervious layer  15  being of substantially the same general shape as the first layer  17  of absorbent material  16 . The liquid impervious layer  15  is disposed between the cloth shell  12  and the absorbent material  16 , and thus between the shell  12  and the central portion  16 A of the absorbent material  16 . Means  18 , cooperating with the cloth shell  12 , is provided for maintaining the positioning of the shell  12 . However, it is to be understood that the shell  12  could be made from a liquid permeable material which would stretch to maintain the positioning of the shell  12  as shown in FIGS. 8 and 9. 
     As illustrated in FIGS. 3 and 4 the shell  12 , is constructed of a stretchable liquid-permeable cloth fabric which may be cotten, knit, cotten blend, lycra, etc. Both back and front ends  13  &amp;  14 , respectively, of the shell  12  are substantially identical in shape although the back side  13  will be slightly larger. Extended from each corner of the shell  12  are tabs  20 ,  22   24 , and  26 . Each tab  20 ,  22   24  and  26  is covered on the inside with flannel material, the tab is then turned and topstitched. 
     The liquid impervious layer  15  is preferrably a polyester vinyl coated material and is generally of the same shape as the first layer  17  of absorbent material  16 . Five elongated shaped absorbent layers  28  of, for instance, birdseye fabric are centered and stitched to the first layer  17  of absorbent material  16 , which also may be birdseye fabric to form the central portion  16 A which includes a portion of the layer  17 . The size and number of layers  28  varies with the amount of absorbentsy desired. Pieces of elastic  30  and  32  gathers the first layer of absorbent material  17  and the impervious layer  15  at the stitching line  54  just off horizontal edges to fit different shell sizes. 
     All of the absorbent layers  28  are retained together with a finishing serged edge and sewn to the first absorbent layer  17 . The first absorbent layer  17  and the liquid impervious layer  15  are retained together with a finishing serged edge and are permanently attached to the shell  12  by lines of stitching  40  just off the vertical edges  42  and  44 , respectively, of the first absorbent layer  17  to create leg gussets  50  and  52 . Elastic  46  and  48  is also serged to the vertical edges  42  and  44 . Lines of stitching  54  hold the elastic  30  and  32  on the liquid impervious layer  15  and attach the liquid impervious layer  15  to the first layer  17  of absorbent material  16 . Although not preferred the central portion  16 A of the absorbent material  16  could extend between the stitching lines  40 — 40  and  54 — 54 . 
     Elastic  56  is serged to leg holes on the shell  12  turned and topstitched. Elastic  60  is also serged to the waistband area on the front  14  and back  13  of the shell  12 , turned and topstitched. In order to secure the front  14  of the shell  12  to the back  13  of the shell  12  and thus hold the diaper  10  up, VELCRO® hooks  64  and  66  are placed on the tabs  24  and  26  on the front  14  of the shell  12  and corresponding VELCRO® loops  68  and  69  are placed on the tabs  20  and  22 , respectively, of the back  13  of the shell  12 . 
     FIG. 5 is a front view of a diaper  70  folded in a position to be worn by a premature or newborn baby and constructed in accordance with the second embodiment of this invention. 
     A belly button area  72  is left open in the shell  12  for air circulation or medical needs, otherwise the diaper as shown in FIGS. 5,  5 A,  5 B and  5 C is constructed the same as the diaper of FIGS. 1 through 4. The shell in the belly button area  72  now has a U-shape to it as shown in FIG. 5A in which the back of a frontal area  73  is lined with flannel and an elastic is set in under the flannel between the flannel and the frontal area  73  and between the front tabs  24  and  26 . 
     FIG. 5B shows an outside view of the second embodiment of this invention FIG. 5C shows the interior of the premature or newborn baby diaper in accordance with the teachings of the second embodiment of this invention. 
     FIG. 6 illustrates a colostomy diaper  100  which represents the third embodiment of this invention with the diaper  100  folded in a position to be worn. This diaper  100  has a liquid impervious bag  102  on the interior frontal portion of the diaper  100  where a colostomy bag on a patient may be inserted in the bag  102  to protect the patient from any leakage from the colostomy bag. 
     FIG. 6A shows the interior of the diaper  100  with the bag  102  in the frontal area. The bag  102  and the diaper  100  are constructed in the same way as the diaper  10  in FIGS. 1 through 4, namely with an outer cloth shell  103 , an interior liquid impervious layer and last an absorbent section  104  on the interior side of the impervious layer. The top of the bag  102  at the inside is stitched to the top of the front  14  of the shell  12 . Owing to the medical need for the unobstructed passage of medical hoses, the VELCRO® hooks  64  and  66  are each in separated tabs, thus permitting the hoses to pass between separated tabs when the diaper  100  is in a position to be worn. 
     A fourth embodiment of this invention is shown in FIG.  7  and illustrates a lighter incontinent diaper  106  shown in a position to be worn. FIG. 7A shows the interior of this diaper wherein a central portion  108  of absorbent material is substantially smaller, for those who are less incontinent. A pad  110 , including the layers of absorbent material has less absorbent material than the preferred embodiment of FIGS. 1 through 4 but the diaper  106  still comprises the same three components of the basic system. The gussets  50  and  52  on the inside of the leg ensure the same leakage protection. 
     In accordance with the fifth embodiment of this invention the diaper, by eliminating the VELCRO hooks and loops on the preferred embodiment of FIGS. 1 through 4 the diaper is made into a pull-up diaper  114  for boys as shown in FIGS. 8 and 8A and for girls as shown in FIGS. 9 and 9A. As shown and constructed the diapers  114  and  116  are a single unitary structure at the waistband. Inside the diapers  114  and  116  are positioned and anchored the three main components of an assembled pad embodying the teachings of this invention. 
     The diapers embodying the teachings of this invention have several advantages. 
     The diaper as a reusable diaper has its components united as one with no pieces to put together. Having an outer shell of non plastic material, the diaper is extremely comfortable and is breathable so that little harm is done to the skin of the wearer. From an adult viewpoint the diaper is not only comfortable but it provides the dignity of little noise on movement of the body. The diaper of this invention also provides good absorption and little or no staining and thus little or no leakage problem. This diaper is also constructed and assembled so as to minimize labor costs. For instance, the shape of the main component parts of the diaper, being basically long sweeping lines, minimize the cutting and stitching time and permit the use of less skilled labor, thus minimizing labor cost. The fact that in cutting out the various components of the diaper there is no need to color match or configurate such things as stripes etc. there are no small pieces to assemble reducing the amount of material that must be used as well as the layout time, thus, minimizing material and labor costs.