WO1992012648A1

WO1992012648A1 - Waterproof gussetted diaper cover

Info

Publication number: WO1992012648A1
Application number: PCT/US1992/000402
Authority: WO
Inventors: Susan Lynne Craig
Original assignee: W.L. Gore & Associates, Inc.
Priority date: 1991-01-16
Filing date: 1992-01-14
Publication date: 1992-08-06

Abstract

The present invention relates to a novel and improved diaper cover (1) having seam-sealed waterproof and breathable gussets (1) around the leg areas providing additional protection for babies and incontinent adults against urine and feces seepage. The diaper covers (1) may be provided with inner padding and worn alone or may be worn outside of conventional cloth or disposable diapers.

Description

TITLE OF THE INVENTION

WATERPROOF GUSSETTED DIAPER COVER

FIELD OF THE INVENTION

The present invention relates to a novel and improved diaper cover having seam-sealed waterproof and breathable gussets around the leg areas providing additional protection for babies and incontinent adults against urine and feces seepage. The diaper covers may be provided with inner padding and worn alone or may be worn outside of conventional cloth or disposable diapers.

BACKGROUND OF THE INVENTION

Many types of diaper covers are well known in the prior art. The most basic type of diaper covers include the one piece of cloth that is wrapped about the diaper and held in place by safety pins or other similar means. This type of diaper cover adds an additional layer of protection however it fails to provide any protection from urine and other excrement from seeping out around the layer.

Other diaper covers include plastic panties which slip over the diaper and have elastic around the waist and legs. These diaper covers provide little absorbancy to urine and increase the chance for rashes and other skin problems developed by babies. Alternative plastic covers are also known in the art including those that are impermeable to water however none provide any protection against urine and excrement from seeping out, particularly through the leg gusset seams.

Cloth diaper covers are also once again becoming popular and attempt to address the problem of urine seeping out. Use of those diaper covers to minimize urine seepage have been met with below satisfactory success. U.S. Patent No. 4,596,568 provides a diaper cover which contains a multiplicity of different layers of specific material to provide permeability to air and impermeability to water and other liquids.

Other cloth diaper covers such as those that are commercially available including Ecology Kid®, a subsidiary of Diplomat

ITUTE SHEET Juvenile Corp. of Stony Point, New York; T.L. Care, Inc.; Baby Bunz & Co., of Sebas Topel, California provide cloth diaper covers similar to that described in U.S. Patent No. 4,596,568 but in addition are provided with gussets around the leg and crotch areas for additional protection. None of the above mentioned commercially available diaper covers nor the cover described in U.S. Patent No. 4,596,568 describes a cover that can be worn for longer periods of time without moisture build up and wicking of the different cloth layers particularly in the gusset area thus causing discomfort and skin irritation to the baby or incontinent adult, and seepage through the gusset seam line areas.

SUMMARY OF THE INVENTION

The present invention provides a diaper cover which comprises a diaper component outer shell that is waterproof and a pair of waterproof and breathable gussets, wherein a gusset is attached to each side of the shell and in which all seams of attachment are seam-sealed. Means for closing and holding the diaper cover in place are also provided.

Alternatively, a padded diaper cover is provided comprising (a) a diaper component having an outer waterproof shell and an inner liner comprising one or more layers of porous fabric in which both the outer shell and inner liner are in laminar relation to one another and have the same shape; (b) an optional inner pad of multiple layers of woven cloth positioned next to the inner liner and adjacent the wearer; (c) a waterproof and breathable gusset on each side of the diaper component in which seams are made with both the inner liner and outer shell and all seams are seam-sealed; and (d) means for closing and holding the diaper cover in place. The optional inner pad may be removed from the diaper cover so that the cover can be used repeatedly with a diaper change. Alternatively, the inner pad and diaper cover component may be used once before washing.

The outer shell for any of the above-mentioned embodiments is waterproof, may be breathable and is comprised of a laminate of one or more layers preferably including a composite of expanded polytetrafluoroethylene (PTFE) membrane and a hydrophilic material. For the diaper cover having only the shell and gussets,

SUBSTITUTE SHEET the shell is preferably comprised of a three-layer laminate including a knit inner layer, an intermediate composite of expanded PTFE membrane and hydrophilic layer and an outer layer of any aesthetically pleasing woven or knitted fabric. For the padded diaper cover, the diaper component has a shell similar to that described above except that the knit inner layer is substituted for a plurality of padding layers preferably two layers of 100% cotton flannel and an innermost layer of polyester brushed knit. The gussets for either embodiment are preferably comprised of laminates of knit and expanded PTFE membrane. All seams attaching the gussets to the diaper component are rendered waterproof preferably by seam-sealing techniques. The means for closing and holding the diaper cover in place are preferably a pair of male and female Velcro closing members and located so that they are closed by interengaging respective members.

These diaper covers are intended to be used with both babies and incontinent children and adults.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure la shows a front inside view of the diaper cover with gussets and with optional inner liner and inner pad in accordance with the present invention.

Figure 2 shows a front outside view of the diaper cover with gussets in accordance with the present invention. Figures 3a-3d show the gusset components. Figure 3a' shows a front view of each gusset component. Figure 3a shows a side view of the laminate comprising each gusset component. Figure 3b shows a front view of the small gusset component overlaying the knit side of the larger component. Figure 3c shows a perspective of the gusset components assembled for use. Figure 3d shows a side profile of the gusset assembly including the elastic band.

Figure 4 shows a front view of the right side (i.e. outer face) of the diaper cover shell with a gusset and closing means attached. Figure 4a shows a front view of the wrong side (i.e. inner face) of the diaper cover shell with the gusset attached and seam sealed. Also shown is the stitch line where the closing means was sewn to the shell .

TE SHEET Figure 5 shows a front view of the right side of the liner with inner pad attached.

Figure 6 shows a front view of the inner layer superimposed upon the shell of the diaper cover with right sides of the layer and shell facing each other and gusset attached.

Figure 7 shows a second embodiment of the diaper cover from the front inside view.

Figure 8 shows the gusset components used for the second embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention is best understood by reference to the accompanying drawings. Figure 1 shows a first embodiment of the diaper cover 1 from the inside perspective in which the inner layer 3 can be seen. Also shown in Figure 1 is the inner pad 5, waterproof and breathable gussets 7, and means for closing and holding the diaper cover in place, as illustrated in Figure 1 by the Velcro hooks 9_. Also shown in Figure 1, the back section of the diaper cover as indicated by "a" and side sections of gussets as indicated by "b" include elastic sewn within the material seams so that there is a tighter fit around the body.

Figure 2 shows the diaper cover 1 from the outside perspective in which the outer shell 2 can be seen. Also shown in Figure 2 are the gussets 2, and means for closing, in this case Velcro loops H. Similar to that shown in Figure 1, the back section of the diaper covers "a" and side sections "b" of the gussets are shown to be gathered and are provided with elastic T _. to ensure a tight but comfortable fit.

In use the diaper cover is placed on the infant or older person such that the inner pad 5 is in contact with the wearer. The front section "c" is folded up to the waist about the wearer and the side regions of the back "a" with the means for closing and holding fold around to mate with the opposing means of region "c". The gussets should fall on the inner leg-crotch region of the body. The assembly and more intricate details of the first embodiment are shown in Figures 3-6.

SUBSTITUTE SHEET Figures 3a-d show the waterproof and breathable gusset assembly.

Figure 3a shows the two major components of one gusset including a larger gusset piece 7 and a smaller piece 71 shaped to fit half the area of the larger piece. Each gusset component is preferably a laminate of a knit and a waterproof, hydrophobic membrane. The most preferable waterproof hydrophobic membrane is expanded porous polytetrafluoroethylene. Expanded porous polytetrafluoroethylene is best described in U.S. Patent Nos. 3,953,566 which teaches how to make the membrane and 4,187,390 which describes characteristics of the material. This material is manufactured at W. L. Gore & Associates, Inc. Figure 3a' shows a side profile of the laminate of either gusset component with the knit 6_ and waterproof, hydrophobic membrane 4. The preferable knit material is polyester knit.

Figure 3b shows the small gusset component overlaying the larger gusset component wherein the smaller component knit side faces the knit side of the larger. The larger component is then folded over (as indicated by the arrow) so as to sandwich the smaller component. The waterproof membrane side of the gusset should be the exterior or outside face of the assembly as shown in Figure 3c. Figure 3d shows a side profile of the assembly in which elastic 13 is included where the components are sewn together forming an assembly having three superimposed layers and is stretchable at the fold line.

Figure 4 shows the gusset assembly attached to the outside face of diaper cover shell fabric such that an upper layer of the gusset 70 is pulled away from the lower two layers 7. The lower two layers 7 with both exterior sides exposing the waterproof membrane are sewn to the right side of the diaper cover shell 2. A second gusset assembly is attached to the other side in the same manner. The seam connecting the gussets to the shell fabric at this point is seam-sealed 15 so that the seam is made waterproof, as shown in Figure 4a in which the inside face of the outer shell is exposed. Part of the means for closing and holding the cover in place such as the Velcro loops H may also at this point be sewn to the right side of the shell fabric.

The outer shell 2 is preferably comprised of a two layer laminated material. The outer layer may be any aesthetically

BSTITUTE SHEET appealing waterproof material. Suitable materials include woven or knitted fabrics including polyester, nylon, cotton, and various blends of the fabrics. The inner layer is waterproof and preferably water-vapor permeable. A preferable inner layer comprises a hydrophobic-hydrophilic composite material such as described in U.S. Patent No. 4,194,041. The most preferable hydrophobic-hydrophilic layer contains a waterproof hydrophobic membrane of expanded polytetrafluoroethylene, similar to that described above for the gusset components. Figure 5 shows an inner liner 3 having multiple layers of porous fabric of the same shape as the outer shell. Preferably, the layers have two or more layers of a 100% cotton flannel material and a top layer of an aesthetically pleasing polyester brushed knit. An inner pad 5 having multiple layers of fabric is also shown in Figure 5 attached to the front face of the liner. The inner pad 5 serves as the diaper part of the cover if it is desired that no separate diaper (disposable or washable) be used. The inner pad preferably consists of at least three layers of an absorbant material and most preferably comprises four layers of cotton flannel. The layers are surged together along all sides so that they are bound together. This inner pad 5 is an optional component for the diaper cover and if it is provided, it is preferable that it be detachable to the cover. The liner 3 is next attached to the shell 2 and unattached gusset layers 7. The right side of the liner is placed facing the right side of the shell and extended gusset layer. A band of elastic 13 is also stitched to the wrong side of the liner. The sides of the liner are also stitched to the knit side of the unattached gusset layer. A continuous seam is preferably made around the entire assembly except for a 4-5 inch opening.

Figure 6 shows an inside view of the diaper cover wherein the liner is attached to the shell fabric. Both gussets are seam-sealed and a stichline of the attaching means is designated by a dashed line. The gussets are illustrated showing half of the waterproof and breathable material and the remainder showing knit. The diaper cover assembly is turned right side out through the opening. This opening is then basted closed. The front and back (liner and shell) may be top stitched. The hook side 9 of the closing means is then sewn to the inner layer as seen in Figure 1. A second embodiment includes a diaper cover 1Q0 comprising a waterproof outer shell 102 with attached waterproof and breathable gussets 1Q7, of which the seams of attachment are seam-sealed; the diaper cover however, has no inner liner or inner pad. In this embodiment a conventional diaper (washable or disposable) is used underneath the diaper cover. Figure 7 shows this embodiment of the diaper cover 1QQ from the inside perspective. The outer shell 102 is waterproof and preferably water-vapor permeable and is comprised of a laminate of layers including a composite layer of expanded PTFE membrane and a hydrophilic material similar to the material of the outer shell in the first embodiment. The composite layer of expanded PTFE membrane and hydrophilic material as previously referenced is described in U.S. Patent No. 4,194,041. A preferable outer shell includes a laminate of an inner layer of polyester knit, the above-mentioned composite layer as an intermediate layer and an exterior layer of any aesthetically pleasing woven or knit fabric including polyester, nylon, cotton and various blends of these fabrics.

The construction of the gussets 100 for this embodiment is more simple than the construction described above. Figures 8 and 8a show the gusset pattern for this embodiment. Here, a gusset 107 of similar material as described for the gussets of the first embodiment and shown in Figure 8 is folded in half (as can be seen in Figure 8a) so that the hydrophobic membrane is facing out on each side. An elastic band 113 is also provided at the fold line. The gusset is attached to the diaper cover shell by placing the two layers along the right side of the shell and forming a seam line. The seam line is then seam-sealed using conventional seam-sealing technology. Means for closing and holding HI the diaper cover in place and elastic band provisions are also provided and located in similar positions to those described above.

Although specific embodiments of the invention have been described with specific reference to the drawings, it should be understood that such embodiments are by way of example and merely are illustrative of one of many embodiments which can represent applications of the principles of the invention. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit and scope of the invention as further defined in the appended claims.

SUBSTITUTE SHEET

Claims

I CLAIM:

1. A diaper cover comprising:

(a) an outer waterproof shell comprised of a multiple layer laminate having an intermediate layer that is a

5 waterproof composite layer;

(b) waterproof and breathable gussets attached to the outer shell in which all seams of attachment are seam-sealed; and

(c) means for closing and holding the diaper cover in place. 0 2. A diaper cover as described in Claim 1 wherein the multiple layer laminate of the outer shell is comprised of three layers including an inner knit layer, an intermediate layer that is a waterproof composite layer and an exterior aesthetically pleasing fabric layer. 5 3. A diaper cover as described in Claim 1 wherein the intermediate layer of the shell is a composite of expanded polytetrafluoroethylene membrane and a hydrophilic layer. 4. A diaper cover as described in Claim 1 wherein the means for closing are male and female Velcro closing members. o 5. A diaper cover comprising:

(a) a diaper component further comprising an inner layer having one or more layers of porous fabric and an outer waterproof shell, both the inner liner and outer shell being in laminar relation to one another and having the same shape;

(b) a waterproof and breathable gusset attached by seams to each side of the diaper component in which all attaching seams are seam-sealed; and

(c) means for closing and holding the diaper cover in place. 6. A diaper cover as described in Claim 5 further comprising an inner diaper pad having multiple layers of a woven fabric that is positioned next to the inner liner and adjacent a body when in use.

7. A diaper cover as described in claim 6 wherein the inner pad is removable from the diaper component.

8. A diaper cover as described in Claim 5 wherein the inner liner is comprised of three layers. 9. A diaper cover as described in Claim 8 wherein the three layers include two layers of 100% cotton flannel and a third innermost layer of polyester brushed knit.

10. A diaper cover as described in Claim 5 wherein the outer shell is comprised of laminate of polyester and a composite of expanded polytetrafluoroethylene membrane and hydrophilic layer.

11. A diaper cover as described in Claim 5 wherein the gussets are laminates of knit and expanded polytetrafluoroethylene membrane.

12. A diaper cover as described in Claim 5 further comprising:

(a) a pair of male Velcro closing members located on the inner lining of the diaper component wherein each male Velcro closing member is positioned on each side of said diaper component; and

(b) a pair of female Velcro closing members located on the outer shell of the diaper component corresponding to the locations of the male Velcro closing member so that the diaper cover may be closed by engaging the male Velcro members onto the female Velcro members.

13. A diaper cover as described in Claim 5 for use with babies.

14. A diaper cover as described in Claim 5 for use with incontinent children and adults.

SUBSTITUTE SHEET