Abstract:
A double gusset cloth diaper including an inner surface and an outer surface forming an hourglass shape, having a groin area proximate a center line of the reusable diaper and defining at least one recess therebetween. A fluid absorbent material is removably located in the recess through the opening. A first gusset is attached to the reusable diaper to form a first seal between the inner surface and the legs of the user. A second gusset is attached to the reusable diaper proximate the first gusset. The gussets are formed of an elastic material attached to the wrong side of the inner surface in a channel formed by stitching the inner surface to form channels.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 12/391,889, filed Feb. 24, 2009, entitled “Double Gusset Cloth Diaper Along With Method For Making The Same,” now allowed, which claims the benefit of priority of U.S. Provisional Patent Application No. 61/031,949, filed Feb. 27, 2008, entitled “Double Gusset Cloth Diaper,” the disclosure of each of which is hereby incorporated in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The technology of the present application relates generally to cloth or reusable diapers and, more particularly, to providing a double gusset on the cloth or reusable diaper to further inhibit fluid from leaking. 
     BACKGROUND 
     Many forms of protective garments are available today. Such protective garments include, for example, disposable diapers, reusable diapers, training paints, and the like. Each of these protective garments has an absorbent pad located proximate the groin of the person wearing the protective garment. Many absorbent pads are used in a single wearing and discarded after use. Some absorbent pads, such as those used with many reusable diapers, are washable to allow for reuse if desired. 
     While the absorbent pad is effective in absorbing a portion of any fluid, such as, for example, urine, it typically is incapable of immediately wicking the fluid from the surface of the diaper. Thus, diapers include a seal around, for example, leg openings to inhibit fluid from leaking past the leg openings to allow the urine to be wicked into the absorbent pad. 
     The most common complaint regarding cloth or reusable diapers relates to fluid leaking past the seal formed around the leg openings. Fluid leaking past the seal, typically formed of an elastic material coupled to the interior of the cloth diaper to hold the cloth snuggly to the leg of an infant or individual, can be messy and can be a health risk. This is especially true if the absorbent pad and/or cloth becomes saturated with fluid. 
     Thus, against this background, it would be desirable to provide a cloth or reusable diaper with an improved seal to inhibit leakage. 
     SUMMARY 
     Aspects of the technology of the present application include, for example, a reusable diaper. Generally, the double gusset cloth diaper includes an inner surface and an outer surface forming an hourglass shape, having a groin area proximate a center line of the reusable diaper and defining at least one recess therebetween. An opening in the inner surface provides access to the recess. A fluid absorbent material is removably located in the recess through the opening. The hourglass shape of the reusable diaper includes edge margins adapted to contact the legs of a user. A first gusset is attached to the reusable diaper about the edges adapted to form a first seal between the inner surface and the legs of the user. The first gusset is formed of an elastic material attached to the rough side of the inner surface in a channel formed by stitching the inner surface to form channels proximate the edges. A second gusset is attached to the reusable diaper proximate the first gusset. The second gusset is formed of an elastic material attached to the rough side of the inner surface in a channel formed by stitching the inner surface to form channels such that the second gusset is located between the first gusset and the groin area. The second gusset forms a second seal between the inner surface and the legs of the user to further inhibit fluid from leaking. 
     One embodiment of a double gusset diaper includes an exterior panel having a surrounding outer edge margin. An interior panel superposable with the exterior panel is joined to a majority of the outer edge margin. A first pair of elasticized gussets is disposed along the outer edge margin and adapted to engage a wearer&#39;s legs. A second pair of elasticized gussets, which are substantially parallel to each other, is disposed between the first pair of gussets. The interior panel may include a slit sized and adapted to receive an absorbent material therethrough such that it is interposed between the interior and exterior panels. 
     The diaper includes a front waistband portion, a rear waistband portion, and an intermediate portion extending between the front and rear waistband portions. The intermediate portion includes first and second arcuate side margins for confronting a wearer&#39;s legs. The first and second pairs of gussets each define a respective first and second auxiliary containment region therebetween, and each pair of gussets extends along an associated one of the first and second side margins. 
     The diaper includes a plurality of fasteners disposed on the front waistband portion and on the rear waistband portion operative to secure the diaper to a wearer. The fasteners may be cooperative snaps, hook and loop material, or adhesive tape, to name a few. 
     A protective garment system is contemplated that includes a diaper with an exterior panel comprising polyurethane laminate material and having a surrounding outer edge margin. An interior panel comprising micro-chamois material is joined to a majority of the outer edge margin. 
     A first pair of sealing means is disposed along the outer edge margin operative to engage the legs of a wearer and a second pair of sealing means is disposed between the first pair of sealing means. The system includes at least one absorbent pad removably insertable between the interior and exterior panels. The pad may be comprised of hemp material, for example. The system may include a pair of configurable absorbent pads that include cooperative fasteners for coupling the pads together. 
     Also contemplated is a method for making a diaper, including the step of attaching a first elastic strip to an interior panel, where the interior panel has a perimeter that includes first and second side margins for confronting a wearer&#39;s legs; the first elastic strip being offset inwardly from the side margins and attached to the interior panel at two or more locations. Also, a second elastic strip is attached at two or more locations along at least one of the side margins. An exterior panel is joined to the interior panel around a majority of the perimeter. The method may also include the step of attaching a third elastic strip to the interior panel at two or more locations and offset inwardly from the side margins. 
     Further aspects and features of the technology of the present application will become apparent from the detailed description provided below. In addition, any one or more aspects of the technology of the present application may be implemented individually or in combination with any one or more of the other aspects of the technology of the present application. It should be understood that the detailed description and examples provided therein are intended for purposes of illustration and should not be considered limiting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings described herein are for illustration purposes and are not intended to limit the scope or spirit of the technology of the present invention. 
         FIG. 1  is a perspective view of a double gusset cloth diaper according to an exemplary embodiment; 
         FIG. 2  is a top plan view of the double gusset diaper illustrating the interior of the diaper; 
         FIG. 3  is a cross-section of the double gusset diaper taken about line  3 - 3  as shown in  FIG. 2 ; 
         FIG. 4  is a bottom plan view of the double gusset diaper illustrating the exterior of the diaper; 
         FIG. 5  is a front view in elevation of the double gusset diaper configured as it would be worn by a wearer; 
         FIG. 6  is an enlarged partial perspective view of the left leg opening; 
         FIG. 7  is a top plan view of a pattern detail of an interior panel as viewed from the rough side; 
         FIG. 8  is a top plan view of a pattern detail of an exterior panel as viewed from the finish side; and 
         FIG. 9  is a top plan view of a pattern detail as viewed from the finish side illustrating an alternate construction of an exterior panel. 
     
    
    
     DETAILED DESCRIPTION 
     The technology of the present application will now be described with reference to the figures. Although described in the context of a cloth diaper, one of ordinary skill in the art would recognize that the technology may be used for other reusable protective garments. Moreover, the technology of the present application is explained with reference to exemplary embodiments. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Additionally, unless otherwise provided, all embodiments provided herein should be considered exemplary. 
       FIG. 1  illustrates an exemplary embodiment of a double gusset cloth diaper  10 . Diaper  10  includes a front waistband portion  12  and a rear waistband portion  14 . Diaper  10  also includes an exterior panel  40  having a surrounding outer edge margin and an interior panel  20  joined to a majority of the outer edge margin. Diaper  10  includes tabs  16  and  18  which support fasteners for securing the diaper to a wearer. Preferably, tabs  18  and  16  are constructed from an elastic or resilient material such as spandex. 
       FIG. 2  is a view of diaper  10  looking down on the rough side of interior panel  20 . Interior panel  20  is comprised of a micro-chamois material. One of ordinary skill in the art will recognize other materials are possible. The outer edge margin of diaper  10  includes side margins  13  and  15  which are configured to confront the legs of a wearer. In this case side margins  13  and  15  correspond to right and left legs respectively. The side margins  13  and  15  are generally arcuate as shown, but could have other shapes. A first pair of gussets  22 ( 1 ) and  22 ( 2 ) is disposed along the arcuate side margins  13  and  15  respectively. A second pair of gussets  24 ( 1 ) and  24 ( 2 ) is disposed between the first pair of gussets  22 ( 1 ) and  22 ( 2 ). It can be seen in  FIG. 2  that the first pair of gussets extends along the arcuate edge margins  13  and  15 , while the second pair of gussets are approximately parallel to each other and offset inward from the first pair of gussets. Second pair of gussets  24 ( 1 ) and  24 ( 2 ), alternatively, may conform to the shape or arc of first pair of gussets  22 ( 1 ) and  22 ( 2 ). 
     With further reference to  FIG. 3 , it can be seen that interior panel  20  also includes an opening  26  for receiving an absorbent material, shown here in the form of a pad  30 , such that it is interposed between interior panel  20  and exterior panel  40  in the interior  28  of diaper  10 . Opening  26  may be in the form of a slit with an accompanying elastic member  29 . The opening  26  may be reinforced by placement of reinforcing material, such as additional micro-chamois material, about the opening cut in the interior panel  20 . Opening  26  optionally may have a closure flap (not shown) as is generally known in the art; although a closure flap inhibits access to interior  28  and may hinder removal of soiled pad  30 . As shown in  FIG. 3 , it can be appreciated that the second pair of gussets  24 ( 1 ) and  24 ( 2 ) define a first or primary containment region  32 . The first pair of gussets  22 ( 1 ) and  22 ( 2 ), in conjunction with the second pair of gussets, defines a pair of auxiliary (or secondary) containment regions  34 ( 1 ) and  34 ( 2 ). For example, with reference to the right arcuate side margin  13 , gusset  22 ( 1 ) and  24 ( 1 ) create first auxiliary containment region  34 ( 1 ). In this embodiment, each gusset  22 ( 1 ),  22 ( 2 ),  24 ( 1 ), and  24 ( 2 ) includes a channel  21 ( 1 ),  21 ( 2 ),  27 ( 1 ), and  27 ( 2 ) respectively. Disposed in each of these channels is a respective elongate elastic member  23 ( 1 ),  23 ( 2 ),  25 ( 1 ), and  25 ( 2 ). 
     With reference to  FIG. 4 , the double gusset diaper  10  includes a plurality of fasteners disposed on the exterior panel  40  for fastening the diaper to a wearer as well as for adjusting the waist size and rise of the diaper to better conform to different sized wearers. For example, a pattern of fasteners  44  is provided along the front waistband portion  12  of diaper  10 , which is operative to fasten the diaper  10  to a wearer as well as to accommodate different waist sizes. In this case, the fasteners are cooperative snaps comprising female sockets and mating male studs. Pattern  44  includes sockets  45 ( 1 )- 45 ( 18 ). As can be better appreciated with further reference to  FIG. 5 , sockets  45 ( 1 )- 45 ( 18 ) are placed such that when the diaper is being worn, they are in a position to receive studs  43 ( 1 )- 43 ( 4 ). It can be appreciated that pattern  44  provides multiple locations at which tabs  16  and  18  may be fastened to front waistband portion  12 . Each column of pattern  44  may receive a corresponding pair of studs  43 . Accordingly, the waistband is adjustable in diameter such that it can conform to different waist sizes for larger and smaller wearers. While pattern  44  is shown here as an array of studs, the positions of the studs and mating sockets could be reversed. Also, shown in  FIGS. 4 and 5  are additional sockets  47 ( 1 ) and  47 ( 2 ), which may receive studs  43 ( 1 ) and  43 ( 2 ) respectively when diaper  10  is worn by a person with a waist sized such that in order to fit properly about their waist, tab  16  must overlap tab  18 . 
     The rise of diaper  10  is also adjustable by employing socket pattern  46 . Pattern  46  in this case, includes sockets  45 ( 19 )- 45 ( 27 ). Each row of pattern  46  may engage stud pattern  48 , which includes studs  43 ( 5 )- 43 ( 7 ). Accordingly, in this case, there are three rise adjustment rows. It should be understood that while the patterns are shown here with a particular number of rows and columns, the number of rows and/or columns may vary as well as the corresponding number of mating fasteners. Furthermore, different types of fasteners may be used other than those shown here. For example, cooperative hook and loop material, such as Aplix® 800, may be employed for the waistband adjustment and/or rise adjustments as is described more thoroughly below. 
       FIG. 6  is an enlarged view of left arcuate side margin  15  that, when in the worn state, substantially surrounds a left leg opening of diaper  10 . As shown, gussets  22 ( 2 ) and  24 ( 2 ) provide a double gusset which confronts a wearer&#39;s leg. This double gusset arrangement provides for both the primary containment region  32  and the auxiliary containment region  34 ( 2 ). Accordingly, the double gusset arrangement provided herein provides an added measure of containment in that if liquid and/or solid waste escapes from containment region  32  past gusset  24 ( 2 ), gusset  22 ( 2 ) will retain such spills in auxiliary containment region  34 ( 2 ). 
     With initial reference to  FIG. 7 , a method for making a reusable diaper with double gussets is provided. Interior panel  20  is made from a micro-chamois material having an overall length of approximately 19.5 inches and an overall width of 15.75 inches while the provided size is for typically babies or toddlers, the diaper may be sized accordingly for smaller babies, e.g., premature, older children, or even adults. Interior panel  20  may be prepared as shown in  FIG. 7  by marking the cuts and then cutting out the shapes and openings. This may be facilitated by a pattern template similar to that shown in  FIG. 7 . Throughout the description of the methods, the side of each piece that faces the interior  28  of the diaper is referred to as the wrong or rough side. Conversely, the side of each piece that is opposite the interior  28  of diaper  10  is referred to as the right or finish side of the material. 
     Viewing interior panel  20  from the rough side, as shown in  FIG. 7 , the construction of the inner gussets  24 ( 1 ) and  24 ( 2 ) is described. Elongate elastic members  25 ( 1 ) and  25 ( 2 ) are sewn to the interior panel. Elastic members  25 ( 1 ) and  25 ( 2 ) comprise ⅛ inch elastic and have a length of approximately 5.5 inches when in the relaxed state although other sizes of elastic are usable. Starting at the end closest to waistband portion  14 , the elastic members are tacked down using a forward and backward straight stitch to secure the elastic to the fabric. While the below descriptions are generally with relation to stitching, and in some cases specific stitches, one of ordinary skill in the art will recognize on reading the disclosure that other stitches may be used. Also, instead of stitching, connections may be made using adhesives, glues, tapes, welds, or the like. As an example, elastic piece  25 ( 1 ) is attached to the inner surface by zigzagging the stitch along the length of the elastic. Ideally, the stitch is just wide enough to zigzag over the elastic and catch on each side. The elastic is stretched as it is stitched into place resulting in a finished length of approximately 13 inches. At the end of the elastic member, a straight stitch is used to tack down the end of the elastic with forward and backward stitches. Elastic member  25 ( 2 ) is attached to interior panel  20  in substantially the same manner. 
     Next, each elastic member  25 ( 1 ) and  25 ( 2 ) is sewn into a channel  27 ( 1 ) and  27 ( 2 ) respectively. For instance, the wrong sides of the fabric are folded together using elastic member  25 ( 1 ) as a fold line to form a channel in which the elastic resides. Once folded, stitch guides  60 ( 1 ) and  60 ( 2 ) will overlap each other. Similarly, stitch guides  62 ( 1 ) and  62 ( 2 ) will overlap. Starting at the end closest to the rear waistband portion  14 , stitching is sewn along the full length of the elastic along stitch lines  60 ( 1 ) and  60 ( 2 ). A straight stitch is also sewn along stitch guides  62 ( 1 ) and  62 ( 2 ), which is ¼ inch out from the stitch guides  60 ( 1 ) and  60 ( 2 ). Channel  27 ( 2 ) is formed around elastic member  25 ( 2 ) in substantially the same way as described with respect to channel  27 ( 1 ) above. 
     Stretch tabs  52  and  54  are attached to interior panel  20  by placing the finish side of interior panel  20  facing up (opposite that shown in  FIG. 7 ) and the finish side of tab  52  down against the finish side of interior panel  20 . The ends of the materials are serged together along seam lines  64 ( 1 ) and  64 ( 2 ), which are aligned with each other. The attachment procedure for tab  54  is substantially the same as that for tab  52 . 
     With the finish side of interior panel  20  facing up (opposite that shown in  FIG. 7 ), pocket opening reinforcement piece  36  is placed finish side down. Reinforcement piece  36  is approximately 1.5.times.8 inches of micro-chamois and includes a cut that lines up with cut  37 . A straight stitch is sewn ⅛ inch from cut  37  around the full perimeter of the cut. The finish side of the interior panel  20  is placed down and the reinforcement piece  36  is pulled through cut  37 . Reinforcement piece  36  is then top stitched to the rough side of interior panel  20 . Reinforcement piece  36  is sewn around its perimeter at approximately ⅛ inches from the edge. Elastic member  29  is encased between the reinforcement piece and interior panel  20 . Each end of elastic member  29  is tacked down as the reinforcement piece is top stitched. Elastic piece  29  is ⅛ inch elastic and is approximately 3.5 inches long in the relaxed state. Once fully stretched, elastic piece  29  should be approximately 7 inches long corresponding to the length of cut  37 . 
     Referring now to  FIG. 8 , preparation and attachment of the exterior panel  40  is discussed. Exterior panel  40  is comprised of polyurethane laminate material (PUL). The exterior panel is shown in  FIG. 8  with the finish side up. Initially, both the stud and socket snap fasteners of patterns  44 ,  46 , and  48  are attached to the finish side of the exterior panel  40 . Stretch tabs  51  and  53  are attached to exterior panel  40  in substantially the same way as tabs  52  and  54  were attached to interior panel  20 , as described above. 
     Exterior panel  40  is placed with the finish side of the fabric up as shown in  FIG. 8  and interior panel  20  is placed directly on top with the rough side of the fabric up as shown in  FIG. 7 . At this point, the finish sides of both panels are touching. The full perimeter of the diaper is serged together. As the perimeter of the diaper is serged together, the tip of elastic piece  42  is attached at point “a.” The remaining free end of elastic piece  42  is attached at point “b.” At point “c”, the tip of elastic piece  23 ( 1 ) is attached. The remaining free end of elastic piece  23 ( 1 ) is attached at point “d.” The tip of elastic piece  23 ( 2 ) is attached at point “e” and the remaining free end of elastic piece  23 ( 2 ) is attached at point “f”, just before the diaper body meets the bottom of stretch tab  16 . Elastic pieces  42 ,  23 ( 1 ), and  23 ( 2 ) are each made from ¼ inch elastic that is 5.5 inches long when in the relaxed state. 
     After the diaper is serged together, the diaper will be inside out. The diaper is turned right side out by pulling it through the pocket hole opening  26 . The perimeter of the diaper is then top stitched clockwise along the rear waistband portion  14 , stitching in ½ inch from the edge of the diaper. The elastic member  42  should be between the needle and the edge of the diaper. This creates a “channel” for the elastic to run in and gather the fabric around it. Except for portions of the perimeter that contain elastic, the perimeter is top stitched approximately ⅛ inches in from the edge of the diaper. Where elastic is encased, the perimeter is sewn approximately ½ inches in from edge of the diaper, thus, creating a “channel” for each elastic member. 
     With the inside or interior panel of the diaper facing up (the micro-chamois),  2  studs  43 ( 1 )- 43 ( 4 ) are attached to both the right  16  and the left  18  stretch tabs with the studs facing up and their caps facing down. With the inside of the diaper facing down (the micro-chamois), and using the guide line provided in the pattern template for placement, 2 sockets  47 ( 1 ) and  47 ( 2 ) are attached to the left stretch tab  18  with the sockets facing up and the caps facing down. 
     In an alternate construction, the waistband fasteners of pattern  44  are replaced with hook and loop style fasteners. In this case, the diaper is constructed similarly to that as described above. However, exterior panel  140  shown in  FIG. 9 , includes a strip of loop material in place of pattern  44 . Also, tabs  16  and  18  are formed of spandex tabs  151  and  153 , which have a rounded configuration. Tabs  16  and  18  each include one hook and one loop piece. Each hook and loop piece is die cut to 1.times.1.5 inches. With exterior panel  140  facing up, the loop pieces are facing up and the hook pieces are facing down. Accordingly, each stretch tab is sandwiched between hook and loop die cut pieces. In this construction, the finish side of the interior panel includes a pair of laundry tabs  155 ( 1 ) and  155 ( 2 ). Laundry tabs  155 ( 1 ) and  155 ( 2 ) are die cut loop pieces attached to the finish side of the interior panel as shown in  FIG. 7 . The laundry tabs provide a means to secure the hook material on the stretch tabs thereby preventing the hook material from snagging the soft micro-chamois material of the interior panel during washing. 
     Accordingly, the double gusset cloth diaper has been described with some degree of particularity directed to the exemplary embodiment. It should be appreciated, though, that the double gusset cloth diaper is defined by the following claims construed in light of the prior art so that modifications or changes may be made to the exemplary embodiment without departing from the inventive concepts contained herein.