AU2004216538B2 - The nature nappy/diaper and material constructions - Google Patents

Description

PCT/AU2004/ 0 0 0 2 19 Received 02 June 2004 -1- COMPOSITION AND PRODIUCT FOR JSE THEREWITH Field of the Invention The present invention relates to a composition and a product for use therewith. The invention has been devised particularly, but not solely, for use as an absorbent composition in respect of a single use disposable nappy or diaper, or a like personal hygiene product or item of clothing.

Rackgronnd of the Invention The present invention relates to constructions of natural fibres and materials in the form of a wicking (top surface layer), an absorbent core and the overall outer and inner materials. These invented structures could be used in baby nappies/diapers, incontinence adult and children's diapers, sanitary wear, medical clothing, bed protectors, chair protectors, baby cot protectors, bibs or any other clothing, used as a complete structure or used as individual fabric constructions, without any limitations in design, structure, method and usage in any application.

Only natural fibres, liquids, waxes, natural protein gels and feathers are used in the present invention. The invented materials may be used individually or used as a complete structure as required. This invention shall not be limited to the products, design, manufacture and manufacturing methods discussed and claimed herein.

Many staple fibres have been used since the history of textile, such as hair, alpaca, angora, camel, cashmere, goat, llama, mohair, rabbit, vicuna wool, merino and other types of wool. Staple fibres are in the family of protein fibres and filament fibres.

Natural silk may be cultivated or wild. To date there is no evidence of an invented fabric that has been knitted or needle felted (non-woven) by natural feathers which may be from any bird species. There are no limitations to any species or birds' feathers that could be used in the present invention, now or in the future. The present invention has a value as a hydrophobic material that will be used in the present invention as a wicking.

AMEODED

SHF-ET

iPEAIAU PCT/AU2004/0 0 0 2 19 Received 02 June 2004 -2- It could also be used in any other form as a textile material. Feathers are a large global industry used for hats, crafts and shawls. Once gathered, feathers could be processed in the form of wool, silk, cashmere or in the needle felting method. The very first invented feather fabric will be produced as non-woven or knitted as required. The present invention may well provide one of the last missing components to the manufacturing of a 100% bio-degradable product. This would be a global achievement for a safer world.

The materials presently used in conventional, disposable nappies have a highly damaging impact on the environment as the plastic/chemical components used therein take hundreds of years to break down.

The invented feather fabric could be used in all forms of clothing. When used as a top layer or wicking in diapers, it would assure 100% dryness next to the skin. This is due to the waxed coating of natural feathers which, as the saying goes, is "like pouring water on a duck's back". The fabric is used without any limitations on diapers, incontinence garments, bed protectors, chair pads or covers, sanitary products, wipes, fabric for clothing, medical clothing, casual clothing and evening fashion wear. The present invention will however not be limited to the designs, structures and methods of manufacture discussed and claimed herein.

The outer cover in the present invention could be used for baby nappies/diapers, incontinence products and forms of clothing to provide natural air circulation to the skin. The natural fibre construction used in the single use products offers maximum health benefits and ecological sensibility with an ideal balance of comfort. At present, there is global concern about male infertility, nappy rash and other conditions leading to serious illnesses in babies due to the lack of skin breathability. With its unique properties of dryness on the skin, whilst allowing natural air circulation, the present invention could help prevent these and other potentially harmful conditions.

The present invention utilises as its outer cover the construction of a 100% cotton gauze fabric, mated with a 100% cotton felt and has the appearance and touch similar to woven fabric. This ensures a feeling of softness next to the skin. Due to the exclusive use of natural fibres, it is unlikely to cause allergies. It has outstanding absorption AMENDED

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PCT/AU2004/0 00 2 1 9 Received 02 June 2004 -3properties to wipe-dry water and oil, maintaining good softness, even in wet conditions.

With regard to environmental impact, the present invention reduces destruction of forest resources. It has excellent break-down properties which allow it to be decomposed by micro organisms and returned to nature in a short period of time. It can be easily incinerated without generating any bad odours or toxic gases. The present invention has excellent hygroscopic and moisture retention properties and will not conduct electricity, thereby rendering it safe to use in any form of clothing. The fabric contains a minimum amount of lint and is low piling. The fabric can undergo various kinds of sterilising treatment, without limitation, the present invention can be used in the manufacture of baby nappies/diapers, incontinence diapers, sanitary napkins, underwear, fashion garments, medical garments, bibs, breast pads, bedding, upholstery and in many other applications. The method of combining the mated fabrics will be in any form compiled by the inventor, now or in the future.

Babies' and infants' skin is a very important factor in considering the design of baby clothing. Outside the mother's womb, a new baby will react to fluctuating temperatures in its new environment. Baby clothing should be soft and pliable and never irritating. It should also be lightweight, yet warm. However, it is a must and a very important factor to provide ventilation around the skin to allow moisture to evaporate naturally.

With conventional nappies made from synthetic materials, statistics show that 78% of babies suffer from nappy rash. The main reason for this is lack of air circulation around the skin.

The present invention would be of assistance in dealing with the problem of uncontrollable discharge of urine, faeces or body fluid which is a universal problem in infants as well as patients, both young and old.

The present invention further relates to an absorbent structure and more particularly to a compressed absorbent composite containing natural material which absorbs large quantities of liquid, as detailed below: AMENIDE

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IP EAN V PCT/AU2004/000219 Received 02 June 2004 -4- Conventional disposable absorbent products have been known to include such products as disposable diapers, sanitary napkins and incontinence pads. All of these products incorporate an absorbent batt which is used to absorb and hold or contain body liquids.

The conventional disposable diaper/nappy uses a chemical substance called polyaciylate which is spread in powder form in the pulp to promote absorbency. Polyacrylate dehydrates the skin and leads to nappy rash and other related illnesses in babies.

The present invention does not include polyacrylate or any form of chemicals.

Absorption occurs by the inclusion of a natural absorbent protein gel (in powder form) which is incorporated in the natural fluffed pulp.

The natural fluffed pulp (unbleached or bleached, at the discretion of the inventor) is sprinkled with a protein gel powder which is known as gelatine. Gelatine is a very safe substance which is used in food and prescribed for invalids and babies. Both the protein gel in powder form and the fluffed pulp will be compressed in the method of manufacture.

The present invention also relates to a special method of water proofing. The absorbent core's final layer is treated with a natural wax. The wax is used to waterproof garments, sports gear and umbrellas. The present invention does not include any form of plastics.

The inventor requires the product to be 100% bio degradable and baby safe, allowing maximum natural air circulation to the skin this assuring safety, comfort and warmth which are the three main considerations for baby clothing.

The present invention further relates to using 100% natural soft rubber thread for the gathering of material around the waist and leg. Cotton adhesive tape, and cotton crepe, satin or sateen, pure silk or cotton decoratives, as well as adhesives, and for fastening together, as best known to the inventor is used. The present invention is not limited as to the natural materials or natural fibres that is used.

One of the present invention's primary purposes is to safeguard the environment. The AMENDED S

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PCT/AU2004/0 0 0 2 19 Received 02 June 2004 rapid filling of landfill sites with non-biodegradable plastics used in the conventional disposable nappy is a huge threat globally. Most mothers are concerned about global warming and the environment, yet our present lifestyle demands a product that assures convenience as well as safety for babies and the planet. The present invention meets all the above objectives and is 100% biodegradable.

With the present invention the inventor intends to reduce issues such as global warming which could result in ocean rising, land and coast line flooding causing millions of people to abandon their homes, low lying islands disappearing, droughts causing forests to die and food crops to fail, wild life population being wiped out and people facing severe food shortages.

Global warming impacts everywhere, it affects plants, animals and people everywhere.

The present invention offers one of the best solutions with potential to minimise ongoing threats human being faced from the effect of global warming. Heat waves, drought and other freak catastrophes of nature are emerging signs.

Designers and inventors play a major role in safeguarding the planet. Warning signs have been ignored by many and the threat is now severe. The inventor does not want to refer to any particular product or products which may have contributed to the present situation on a global scale. However, the inventor wants to assure the world that her present line of products, fabrics, and absorbers will definitely strike a balance between comfort for the user and ecological sensibility for the whole world.

The present invention will allow mothers to purchase a product or products without any guilt, but with a clear conscience that they are supporting efforts to save the planet.

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PCT/AU2004/0 0 0 2 1 9 Received 02 June 2004 -6- Summnry of the Invention The present invention disclosed herein is a disposable material of natural fibre construction used as an individual fabric or in a combination of structures that is used in diapers, nappies, incontinence products, bibs, bed protectors, medical products, and sanitary products and in any clothing or fashion articles or any other uses and applications now or in the future.

The diaper in particular has an outer cover made from material such as bandage cloth, gauze or leno or sateen or pure silk combined with 100% felt cotton fabric. These materials are sandwiched together to form the outer cover. The method of sandwiching may be by state of the art machinery or by a process of manual manufacturing.

In the present invention, the top surface layer of the absorbent core is the invented natural feather fabric which can be woven, non-woven or knitted. The natural feather fabric in the present invention is used for the first time in the textile industry. This top later of natural feather fabric would allow liquids such as body fluids to pass through while still keeping the skin 100% dry at all times.

In the present invention, the inner section of the absorbent core is natural fluffed pulp with the inclusion of a protein gel in power form. The natural fluffed pulp may be bleached or unbleached as best known to the inventor. The inclusion of the natural fluffed pulp would vary from 0% to 100% and the protein based gel may vary from 0% to 100%. The natural fluffed pulp and the protein gel will be in a compressed form as the main absorber of liquid.

The present invention has a unique waterproofing method used for the impervious outer layer of the structure. The present invention uses a water based or natural wax without limitations to the method or the wax substance used. This waterproofing method may be used in the outer cover or in the final layer of fabric that forms the absorbent core.

The present invention further relates to all natural rubber threads used for elasticity, AMI EDED &HEEI 1F~;q1 AU PCT/AU2004/000219 Received 1 November 2004 -7natural fibre trimmings and adhesive tapes.

The present invention uses one of the natural fabrics for a 100% bio-degradable bag to be used for the disposal of each individual used diaper/nappy.

In the past "super absorbent" materials which absorb several times their weight in liquid have been developed.

Attempts have been made to incorporate these materials in absorbent products such as diapers and sanitary napkins, to enhance their absorbent properties. Perhaps one of the first products to incorporate such absorbent materials is a disposable diaper disclosed in U.S. Patent No. 3670,731. This patent discloses an absorbent dressing comprising an absorbent layer sandwiched between a permeable facing and impermeable backing sheet. The absorbent layer contains water insoluble, cross linked, hydrocolloid polymer as the absorbent material.

Although super absorbent materials have been available for many years, they have not gained wide acceptance due to the health issues. The main reason for this lack of acceptance of superabsorbents is that they are chemically based and could lead to health problems or complications.

The present invention is introduced to the global market to overcome health and environmental problems.

Thus, in one form the present invention provides a multi-layered composition comprising a sandwiched outer cover of natural fabric and cotton felt, and an absorbent core comprising a top layer of natural feather fabric and a lower layer of a waterproof coating of wax.

The feather fabric may be woven, non-woven, felted or knitted fabric. The feather fabric may be compressed to form a compressed structure. Preferably, the feather fabric is formed of bird feathers. Preferably, the feather fabric has a weight of 0.02 to 350 grams AM1EDED U

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PCT/AU2004/000219 Received 1 November 2004 -8per square metre.

Preferably, the natural fabric comprises bandage cloth, gauze, cotton, fibre, leno, sateen or pure silk. The cotton may be a cotton felt of a light weight non-woven type.

The natural fabric preferably comprises a 100% cotton fabric mated with a 100% cotton felt.

In a preferred form, the absorbent core further comprises a second layer. The second layer preferably comprises natural fluffed pulp which may be bleached or unbleached.

The fluffed pulp is preferably viscose.

The second layer may alternatively comprise natural protein gel, and the protein gel may be powered gelatine.

Furthermore, the second layer could comprise a mixture of natural fluffed pulp and natural protein gel. The protein gel may be in a powdered form and incorporated in the fluffed pulp or inserted in the padding in a pocket form.

The waterproof coating of wax may be a natural wax and may be a water based wax.

The wax may be beeswax. The outer cover may have a weight of 0.02 to 300 grams per square metre and may be of breathable material.

The composition may be disposed in a structure, the structure being adapted for use to at least partially absorb waste body fluids of a user. For example, the composition may be disposed in a disposable nappy so as to absorb urine or other waste body fluids from an infant. Furthermore, the composition may be in the form of a panel in the structure conveniently positioned so as to at least partly absorb waste fluids from the body.

The structure may be any one of a diaper, nappy, sanitary pad, incontinence pad or diaper, sanitary ware, medical clothing, bed protector, chair protector, baby cot protector or a bib.

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PCT/AU2004/ 0 00219 Received 5 January 2005 -9- Furthermore, the invention provides a personal product, clothing item or protective item for at least partially absorbing waste body fluids comprising a multi-layered composition, the multi-layered composition comprising a sandwiched outer cover of natural fabric and cotton felt, and an absorbent core comprising a top layer of natural feather fabric and a lower layer of a waterproof coating of wax..

Preferably the absorbent core further comprises a second layer which is typically comprised of natural fluffed pulp or natural protein gel. Alternatively, the second layer may be comprised of both of natural fluffed pulp and natural protein gel The invention still further provides a method of preparing a multi-layered composition for a personal product, clothing item or protective item to at least partially absorb waste body fluids comprising: i) forming an outer cover by sandwiching together natural fabric and cotton felt; ii) forming an absorbent core comprising a top layer of natural feather fabric and a lower layer of a waterproof coating of wax; and iii) compressing the components resulting from steps i) and ii) to form the composition.

Preferably, the feather fabric forms a top layer of the absorbent core, and the absorbent 2 0 core further comprises a second layer. The second layer typically comprises natural fluffed pulp or natural protein gel, or both of these components.

Thus, the invention provides an environmentally friendly and generally allergy free composition and product due to the use of natural materials.

The use of the various components as described to form a personal product, clothing item or protective item has a number of benefits. The formation of the outer cover of cotton, in particular a 100% felted cotton, has the benefit of retaining a feeling of softness next to the skin whilst still having an appearance and a touch similar to woven fabric. The outer cover formed in this way is unlikely to cause allergies due to the use Amended Sheet

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PCT/AU2004/000219 Received 5 January 2005 10 of natural fibres and it allows ease of air circulation and breathability around the skin of the user. The use of the feather fabric in the top layer of the absorbent core which is positioned close to the skin of the wearer forms a soft, comfortable layer which allows moisture (from the waste product) to pass through to reach to the lower layer. The moisture is absorbed (or at least partially absorbed) by the lower layer whilst at the same time maintaining a generally dry environment close to the skin.

The use of a waterproof coating of wax ensures that moisture is at least partially retained within the product.

Throughout the specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Rrief Description of the Drawings The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of two layers forming the outer cover of the diaper or nappy of the embodiment; Figure 2 is a front view of the nappy of the embodiment; Figure 3 is a back view of the nappy of the embodiment; Figure 4 is a top view of the natural feather fabric of the absorbent core of the embodiment; Figure 5 shows a view of the absorbent core showing the top layer and lower layer of the embodiment; Amended Sheet

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PCT/AU2004/000219 Received 5 January 2005 11 Figure 6 shows the waterproof coating forming the second layer of the absorbent core of the embodiment; and Figure 7 shows the layers of the nappy of the present embodiment.

Desription of an Embodiment of the Present Invention The embodiment shows a nappy (20) incorporating a composition of the invention.

As can be seen in Figures 2 and 3, the nappy (20) comprises cotton adhesive tapes a cotton crepe band an outer cover and a soft edging As shown in Figure 3, the reverse side of the nappy (20) comprises the outer cover as well as a band label The label of course may comprise various pictures or logos as appropriate. Alternatively, the label may be left off the nappy.

As can be seen in Figure 1, the outer cover of the nappy (20) comprises two layers, a layer comprised of natural fabric such as bandage cloth or gauze, or leno or sateen cloth, or pure silk as well as a layer comprised of cotton felt construction. These two layers and form the outer cover of the nappy The two fibre constructions and are sandwiched (or mated) together to form a free natural air circulated fabric.

As can be seen in Figure 4, the composition of the nappy (20) further comprises an absorbent core the top layer of which is a woven, non-woven and/or knitted feather fibre construction The fabric is made of natural bird feathers, which may be bird feathers of any type.

Figure 5 shows that the absorbent core (40) is further made up of a second layer of natural fluffed pulp in the form of unbleached or bleached viscose fluff with the inclusion of protein gel (generally represented by the numeral The benefit of the protein gel is of course that it is a natural substance which does not include any harmful Amended Sheet

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PCT/AU2004/000219 Received 5 January 2005 12 chemicals.

Figure 6 shows the waterproof coating formed of wax (11) forming the lower layer of the absorbent core As already described, the layer 10OA comprises absorbent natural fluff pulp and natural gel. The waterproof layer (11) assists in preventing any leakages to the outside of the nappy It should be appreciated that any natural waxes may be used in this composition.

Figure 7 shows a schematic representation of the various layers in the nappy As can been seen, the outer cover (10) retains the inner absorbent core (40) and ensures a fit to the body of the wearer. The absorbent core (40) has a liquid pervious layer in the form of natural feather fabric This layer is placed in contact with the user to receive liquid deposited thereon. The natural fibre and natural gel (shown by 10A) receives, absorbs and dissipates liquid there within. The liquid impervious layer in the form of wax (11) is treated naturally and of natural resources and keeps the garment free of leaks and keeps it secure.

As will be appreciated the nappy (20) is bio-degradeable and chemical free and is intended for a single use as a disposable nappy.

It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention.

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Claims (44)

1. A multi-layered composition comprising a sandwiched outer cover of natural fabric and cotton felt, and an absorbent core comprising a top layer of natural feather fabric and a lower layer of a waterproof coating of wax.

2. A composition according to claim 1 wherein the feather fabric is woven, non- woven, felted or knitted fabric.

3. A composition according to claim 1 or claim 2 wherein, the feather fabric is compressed to form a compressed structure.

4. A composition according to any one of the preceding claims wherein the feather fabric is formed of bird feathers.

A composition according to any one of the preceding claims wherein the feather fabric has a weight of 0.02-350 grams per square metre.

6. A composition according to any one of the preceding claims wherein the natural fabric comprises bandage cloth, gauze, cotton, fibre, leno, sateen or pure silk.

7. A composition according to claim 6 wherein the cotton is a 100% cotton fabric.

8. A composition according to any one of the preceding claims wherein the cotton felt is a lightweight, non-woven cotton felt.

9. A composition according to any one of the preceding claims wherein the natural fabric comprises a 100% cotton fabric mated with a 100% cotton felt.

10. A composition according to any one of the preceding claims wherein the absorbent core further comprises a second layer.

11. A composition according to claim 10 wherein the second layer comprises natural fluffed pulp.

12. A composition according to claim 11 wherein the fluffed pulp is bleached or unbleached. Amended Sheet IPEA/AU PCT/AU2004/000219 Received 5 January 2005 14

13. A composition according to claim 11 or claim 12 wherein the fluffed pulp is viscose.

14. A composition according to claim 10 wherein the second layer comprises natural protein gel.

15. A composition according to claim 14 wherein the protein gel is gelatine.

16. A composition according to claim 14 or claim 15 wherein the protein gel is in powdered form.

17. A composition according to claim 10 wherein the second layer comprises a compressed mixture of natural fluffed pulp and natural protein gel.

18. A composition according to claim 17 wherein the protein gel is in powdered form.

19. A composition according to claim 18 wherein the powdered protein gel is incorporated in the fluffed pulp.

A composition according to any one of the preceding claims wherein the wax is a natural wax.

21. A composition according to any one of claims 1 to 19 wherein the wax is a water based wax.

22. A composition according to any one of claims 1 to 19 wherein the wax is a liquid wax.

23. A composition according to any one of claims 1 to 19 wherein the wax is beeswax.

24. A composition according to any one of the preceding claims wherein the outer cover has a weight of 0.02 to 300 grams per square meter. A composition according to any one of the preceding claims wherein the outer cover is formed of breathable material.

Amended Sheet IPEAIAU PCT/AU2004/000219 Received 5 January 2005 15

26. A composition according to any one of the preceding claims wherein a waterproofing treatment is provided in one or both of the outer cover and the absorbent core.

27. A composition according to any one of the preceding claims wherein the composition is disposed in a structure, the structure adapted to at least partially absorb waste body fluids of a user.

28. A composition according to claim 27 wherein the structure is in the form of a diaper comprising two leg apertures through which the legs of the wearer are positioned and an abdomen aperture through which the abdomen of the wearer is positioned, the structure having gathering around the leg aperture and the abdomen aperture, the gathering formed of 100% natural soft rubber thread.

29. A composition according to claim 28 wherein the structure further comprises adhesive fastening tapes to secure the diaper in position on the wearer, the fastening tapes formed of natural rubber and fibres.

30. A composition according to any one of claims 27 to 29 wherein the composition is in the form of a panel in the structure.

31. A composition according to claim 27 wherein the structure is any one of a diaper, nappy, sanitary pad, incontinence pad or diaper, sanitary wear, medical clothing, bed protector, chair protector, baby cot protector or a bib.

32. A personal product, clothing item or protective item for at least partially absorbing waste body fluids comprising a multi-layered composition, the multi-layered composition comprising a sandwiched outer cover of natural fabric and cotton felt, and an absorbent core comprising a top layer of natural feather fabric and a lower layer of a waterproof coating of wax..

33. A personal product, clothing item or protective item according to claim 32 wherein the feather fabric is woven, non-woven, felted or knitted fabric.

34. A personal product, clothing item or protective item according to claim 32 or 33 Amended Sheet LPEAIAU PCT/AU2004/000219 Received 5 January 2005 16 wherein the feather fabric is compressed to form a compressed structure.

A personal product, clothing item or protective item according to any one of claims 32 to 34 wherein the absorbent core further comprises a second layer.

36. A personal product, clothing item or protective item according to claim wherein the second layer comprises natural fluffed pulp.

37. A personal product, clothing item or protective item according to claim wherein the second layer comprises natural protein gel.

38. A personal product, clothing item or protective item according to claim wherein the second layer comprises a compressed mixture of natural fluffed pulp and natural protein gel.

39. A method of preparing a multi-layered composition for a personal product, clothing item or protective item to at least partially absorb waste body fluids comprising: i) forming an outer cover by sandwiching together natural fabric and cotton felt; ii) forming an absorbent core comprising a top layer of natural feather fabric and a lower layer of a waterproof coating of wax; and iii) compressing the components resulting from steps i) and ii) to form the composition.

40. A method according to claim 39 wherein the feather fabric is woven, non-woven, felted or knitted fabric.

41. A method according to claim 39 or claim 40 wherein the feather fabric is compressed to form a compressed structure.

42. A method according to any one of claims 39 to 41 wherein the absorbent core further comprises a second layer.

43. A method according to claim 42 wherein the second layer comprises natural Amended Sheet IPEA/AU PCT/AU2004/000219 Received 5 January 2005 17 fluffed pulp.

44. A method according to claim 42 wherein the second layer comprises natural protein gel. A method according to claim 42 wherein the second layer comprises a compressed mixture of natural fluffed pulp and natural protein gel. Amended Sheet IPEA/AU