Fixed Flat Cloth Diaper
20210386597 · 2021-12-16
Inventors
Cpc classification
A61F13/538
HUMAN NECESSITIES
A61F13/515
HUMAN NECESSITIES
A61F13/539
HUMAN NECESSITIES
A61F13/49
HUMAN NECESSITIES
International classification
Abstract
The diaper of the present invention is a fixed flat cloth diaper. The diaper is ‘fixed’, because an outer layer of the diaper resembles the final format of a flat, rectangular cloth diaper having been folded origami style into a shape suitable for donning on a wearer by a user. The outer layer functions primarily to retain the diaper upon the wearer and has a stomach panel for obtaining a good closure of the diaper on the wearer. The diaper is ‘flat’, because an inner layer of the diaper is attached to the outer layer, and the inner layer is a flat, rectangular shape which is customizable for absorbency and can be folded into a flat insert configuration of the user's choice prior to donning the diaper on the wearer. The inner layer functions primarily to absorb waste (urine and feces) excreted by the wearer.
Claims
1. A cloth diaper comprising: an outer layer having an overall shape of a modified obtuse triangle; and an inner layer having an overall shape of a rectangle; wherein the outer layer and the inner layer are attached to each other along an attachment seam.
2. The cloth diaper of claim 1, wherein the outer layer comprises a main panel having a trapezoid shape, and a stomach panel having an ellipse shape, which main panel is contiguous along a shorter width of the trapezoid shape with the stomach panel.
3. The cloth diaper of claim 2, wherein the main panel of the outer layer comprises a left hip wing and a right hip wing, which hip wings are contiguous with each other.
4. The cloth diaper of claim 3, wherein the stomach panel of the outer layer comprises a left stomach wing and a right stomach wing, which stomach wings are contiguous with each other.
5. The cloth diaper of claim 1, wherein the outer layer comprises an outer layer seam allowance which seam allowance bounds a perimeter of the outer layer.
6. The cloth diaper of claim 5, wherein the outer layer comprises at least a layer of fabric finished along the seam allowance.
7. The cloth diaper of claim 1, wherein the inner layer comprises a tab having an area above a tab line.
8. The cloth diaper of claim 7, wherein the inner layer comprises a left absorbency panel and a right absorbency panel, which panels are contiguous with each other.
9. The cloth diaper of claim 1, wherein the inner layer comprises an inner layer seam allowance which seam allowance bounds a perimeter of the inner layer.
10. The cloth diaper of claim 9, wherein the inner layer comprises at least a layer of fabric finished along the seam allowance.
11. The cloth diaper of claim 9, wherein the inner layer comprises two layers of fabric, which layers of fabric are overlaid upon each other and adjoined together as one piece and finished along the seam allowance.
12. The cloth diaper of claim 7, wherein the tab of the inner layer comprises the attachment seam, and the tab is attached along the attachment seam to a corresponding portion of the outer layer.
13. The cloth diaper of claim 12, wherein a direction of a fabric grain for the inner layer is aligned with and parallel to a center line of the inner layer.
14. The cloth diaper of claim 1, wherein the outer layer and the inner layer are constructed of a fabric having from about 3% to about 7% of synthetic, elastic fiber content.
15. The cloth diaper of claim 14, wherein a fabric used to construct the diaper is selected from the group consisting of stretch French terry, stretch fleece, and blends thereof.
16. The cloth diaper of claim 15, wherein the fabric is made of fibers selected from the group consisting of bamboo, cotton, organic cotton, hemp, soy, wool, Merino wool, lyocell, modal, and blends thereof.
17. A cloth diaper comprising: an outer layer having a main panel with a trapezoid shape with a left hip wing and a right hip wing, which hip wings are contiguous with each other, and having a stomach panel with an ellipse shape with a left stomach wing and a right stomach wing, which stomach wings are contiguous with each other, and the main panel is contiguous along a shorter width of the trapezoid shape with the stomach panel; and an inner layer having a rectangle shape with a left absorbency panel and a right absorbency panel, which panels are contiguous with each other, and having a tab with an area above a tab line, and an attachment seam; wherein the tab of the inner layer is attached along the attachment seam to a corresponding portion of the outer layer.
18. The cloth diaper of claim 17, wherein the outer layer comprises an outer layer seam allowance which seam allowance bounds a perimeter of the outer layer, and the inner layer comprises an inner layer seam allowance which seam allowance bounds a perimeter of the inner layer.
19. The cloth diaper of claim 18, wherein the outer layer comprises at least a layer of fabric finished along the seam allowance.
20. The cloth diaper of claim 18, wherein the inner layer comprises at least a layer of fabric finished along the seam allowance.
21. The cloth diaper of claim 18, wherein the inner layer comprises two layers of fabric, which layers of fabric are overlaid upon each other and adjoined together as one piece and finished along the seam allowance.
22. The cloth diaper of claim 17, wherein a direction of a fabric grain for the inner layer is aligned with and parallel to a center line of the inner layer.
23. The cloth diaper of claim 17, wherein the outer layer and the inner layer are constructed of a fabric having from about 3% to about 7% of synthetic, elastic fiber content.
24. The cloth diaper of claim 17, wherein a fabric used to construct the diaper is selected from the group consisting of stretch French terry, stretch fleece, and blends thereof.
25. The cloth diaper of claim 24, wherein the fabric is made of fibers selected from the group consisting of bamboo, cotton, organic cotton, hemp, soy, wool, Merino wool, lyocell, modal, and blends thereof.
26. A cloth diaper comprising: an outer layer having a main panel with a trapezoid shape with a left hip wing and a right hip wing, which hip wings are contiguous with each other, and having a stomach panel with an ellipse shape with a left stomach wing and a right stomach wing, which stomach wings are contiguous with each other, and the main panel is contiguous along a shorter width of the trapezoid shape with the stomach panel; and an inner layer having a rectangle shape with a left absorbency panel and a right absorbency panel, which panels are contiguous with each other, and having a tab with an area above a tab line, and an attachment seam; wherein the tab of the inner layer is attached along the attachment seam to a corresponding portion of the outer layer; wherein the outer layer comprises an outer layer seam allowance which seam allowance bounds a perimeter of the outer layer, and the inner layer comprises an inner layer seam allowance which seam allowance bounds a perimeter of the inner layer; wherein the outer layer comprises at least a layer of fabric finished along the seam allowance; wherein the inner layer comprises at least a layer of fabric finished along the seam allowance; wherein a direction of a fabric grain for the inner layer is aligned with and parallel to a center line of the inner layer; and wherein the outer layer and the inner layer are constructed of a fabric having from about 3% to about 7% of synthetic, elastic fiber content, and the fabric used to construct the diaper is selected from the group consisting of stretch French terry, stretch fleece, and blends thereof, and the fabric is made of fibers selected from the group consisting of bamboo, cotton, organic cotton, hemp, soy, wool, Merino wool, lyocell, modal, and blends thereof.
27. The cloth diaper of claim 5, wherein the outer layer comprises two layers of fabric, which layers of fabric are overlaid upon each other and adjoined together as one piece and finished along the seam allowance.
28. The cloth diaper of claim 18 wherein the outer layer comprises two layers of fabric, which layers of fabric are overlaid upon each other and adjoined together as one piece and finished along the seam allowance.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0031]
[0032]
[0033]
[0034]
[0035]
LIST OF REFERENCE NUMERALS
[0036] 2 diaper [0037] 4 outer layer [0038] 6 inner layer [0039] 8 outer layer seam allowance [0040] 10 inner layer seam allowance [0041] 12 inner layer tab [0042] 13 tab line D-D′ [0043] 14 attachment seam [0044] 16 outer layer center line A-A′ [0045] 18 inner layer center line B-B′ [0046] 19 main panel [0047] 20 left hip wing [0048] 22 right hip wing [0049] 23 panel line C-C′ [0050] 24 stomach panel [0051] 26 left stomach wing [0052] 28 right stomach wing [0053] 30 left absorbency panel [0054] 32 right absorbency panel
DETAILED DESCRIPTION OF THE INVENTION
[0055] The diaper of the present invention is a fixed flat cloth diaper. The diaper is ‘fixed’, because an outer layer of the diaper resembles the final format of a flat, rectangular cloth diaper having been folded origami style into a shape suitable for donning on a wearer by a user; wherein a wearer is a human newborn, infant, baby, child, or toddler. The outer layer functions primarily to retain the diaper upon the wearer. The diaper is ‘flat’, because an inner layer of the diaper is attached to the outer layer, and the inner layer is a flat, rectangular shape which is customizable and can be folded into a flat insert configuration of the user's choice prior to donning the diaper on the wearer. The inner layer functions primarily to absorb waste (urine and feces) excreted by the wearer.
[0056] The cloth diaper of the present invention requires little to no folding prior to or upon donning the diaper by the user on the wearer and the outer layer has a stomach panel for obtaining a good closure. The diaper of the present invention also has a flat insert inner layer which enables the user to obtain a customized absorbency for the wearer by folding the inner layer into any of numerous desired configurations.
[0057] The fixed flat cloth diaper of the present invention solves many issues posed by other cloth diapers. The diaper of the present invention does not become unfolded, as frequently happens with pre-fold, pre-flat, fitted, and all-in-one diapers. The diaper of the present invention washes well and dries quickly because it does not have multiple, thick layers, as compared to pre-fold, pre-flat, fitted, and all-in-one diapers which do. The diaper of the present invention also solves the issue of many pre-fold diapers and the mixed pre-flat diapers not allowing for a good leg seal due to cloth fabric bulk at the legs, crotch, and hips of the wearer.
[0058] With reference to
[0059] With reference to
[0060] With reference to
[0061] With reference to
[0062] The diaper 2 of the present invention is preferably constructed of cloths or fabrics made with natural fibers and having a low percentage of synthetic, elastic fibers, such as spandex, Lycra®, or elastane, from about 3% to about 7%. Such fabrics are stretchy and enable the diaper 2 of the present invention, when in use upon a wearer, to achieve the best stretch, leg seal, and absorbency. Suitable, preferred fabrics for construction of the diaper 2 of the present invention are stretch French terry, stretch fleece, and blends thereof. Suitable, preferred fabrics are also made from natural fibers, such as bamboo, cotton, organic cotton, hemp, soy, wool, Merino wool, lyocell, Tencel®, and blends thereof. Many of these fabric blends have an anti-microbial property that naturally fights bacteria and fungus in the fabric. The fabric blends such as bamboo, lyocell, and wool have properties that assist in preventing microbes from developing while promoting moisture movement, which in turn, gives maximum wear comfort to the wearer. These fabrics provide a higher quality to the diaper 2 and boost sanitation due to the nature of any diaper being in constant contact with human waste. Additionally, these fabric blends, when wet, will not feel cold and clammy to the wearer, thus, making the fabric blends the preferred fabrics for construction of the diaper 2 of the present invention. Hemp fabric blends are highly absorbent and outperform most other fabrics or textiles. Additionally, when hemp is paired with bamboo, the absorbency and softness of the resultant fabric are well-suited for use as the inner layer 6 of the diaper 2. Organic cotton is quick-absorbing and is a great fiber addition to any fabric blend used, including organic cotton blended with bamboo, for the diaper 2 and is well-suited for use in the diaper 2 as used for wearers who heavily wet, or flood, the diaper 2. Although jersey knit fabrics can be used to construct the diaper 2, these fabrics are less preferred, because they are not very absorbent and ounces of absorbency potential of the diaper 2 are lost when such fabrics are used.
[0063] Preferably, stretchy French terry fabric blends are used for the outer layer 4 of the diaper 2, because of the stretch and trimness of the fabric. Preferably, the inner layer 6 of the diaper 2 is also a stretchy French terry or a stretchy fleece blend. However, as stated herein, different fabric blends offer customizable absorption as needed for small, frequent wetter wearers, or for wearers with fast-flooding absorbency needs. All fabric combinations, for either the outer layer 4 or the inner layer 6, can be modified and adjusted to fit the user's specific absorption needs for the wearer.
[0064] Also, in construction of the diaper 2 of the present invention, preferred threads are used to finish or serge the seam allowances 8, 10 of the outer layer 4 and the inner layer 6, respectively, and to attach the outer layer 4 to the inner layer 6 along attachment seam 14. Any high quality serge or overlock thread can be used. A wooly nylon or stretch thread works best and creates a soft hem and allows for ultimate stretch as the user dons or wraps the diaper 2 around the wearer without the threads breaking. Additionally, using a flexible thread will extend the fit of the diaper 2 by providing optimal stretch of the fabric in use.
[0065] In use, the stretch of the fabric and thread allow the diaper 2 to be pulled and manipulated by the user in a way to achieve a perfect seal around the legs and stomach of the wearer. The diaper 2 can be stretched to the maximum by the user without fearing seam or fabric failure. Because the fabric can be pulled and manipulated, the user is able to achieve a leg seal on the wearer equivalent to that of a stretchy flat cloth diaper. The leg seal keeps the waste in the diaper 2 and prevents leaking on the waterproof cover of choice, as well as allows for breathable, cover-free wearing time by the wearer without leaks from the legs or back of the diaper 2.
[0066] The diaper 2 of the present invention is readily scalable to different sizes as may be needed by different ages and physical sizes of wearers. For example, a size small diaper 2 is suitable for wearers from about 5 pounds to about 15 pounds and has dimensions of about 12.5″ in length along the outer layer 4 center line A-A′ 16, and about 17.0″ in width across the outer layer 4 from an outer edge seam allowance 8 of the left hip wing 20 to an outer edge seam allowance 8 of the right hip wing 22; and 11.0″ in length along the inner layer 6 center line B-B′ 18, and about 20.0″ in width across the inner layer 6 from an outer edge seam allowance 10 of the left absorbency panel 30 to an outer edge seam allowance 20 of the right absorbency panel 32.
[0067] For example, a size medium diaper 2 is suitable for wearers from about 10 pounds to about 25 pounds and has dimensions of about 15.0″ in length along the outer layer 4 center line A-A′ 16, and about 21.0″ in width across the outer layer 4 from an outer edge seam allowance 8 of the left hip wing 20 to an outer edge seam allowance 8 of the right hip wing 22; and 13.0″ in length along the inner layer 6 center line B-B′ 18, and about 24.0″ in width across the inner layer 6 from an outer edge seam allowance 10 of the left absorbency panel 30 to an outer edge seam allowance 20 of the right absorbency panel 32.
[0068] For example, a size large diaper 2 is suitable for wearers from about 20 pounds to about 35 pounds and has dimensions of about 17.0″ in length along the outer layer 4 center line A-A′ 16, and about 25.5″ in width across the outer layer 4 from an outer edge seam allowance 8 of the left hip wing 20 to an outer edge seam allowance 8 of the right hip wing 22; and 15.0″ in length along the inner layer 6 center line B-B′ 18, and about 26.0″ in width across the inner layer 6 from an outer edge seam allowance 10 of the left absorbency panel 30 to an outer edge seam allowance 20 of the right absorbency panel 32.
[0069] For example, a size extra-large diaper 2 is suitable for wearers from about 30 pounds to about 75 pounds and has dimensions of about 19.0″ in length along the outer layer 4 center line A-A′ 16, and about 27.5″ in width across the outer layer 4 from an outer edge seam allowance 8 of the left hip wing 20 to an outer edge seam allowance 8 of the right hip wing 22; and 18.0″ in length along the inner layer 6 center line B-B′ 18, and about 28.0″ in width across the inner layer 6 from an outer edge seam allowance 10 of the left absorbency panel 30 to an outer edge seam allowance 20 of the right absorbency panel 32.
[0070] To construct the diaper 2 of the present invention, each of the outer layer 4 and the inner layer 6 are finished with serge or overlock stitching along the respective seam allowances 8, 10. The inner layer 6 is then attached to the outer layer 4 with serge or overlock stitching along the attachment seam 14 of the tab 12. Preferably, when attaching the inner layer 6 to the outer layer 4, the portion of the seam allowance 10 equivalent to the area of an attachment seam 14 of the tab 12 is attached to a corresponding portion of the seam allowance 8 of the outer layer 4 in one sewing pass as one continuous seam. This can be done by first serging the inner layer 6 along seam allowance 10 by starting at a top right corner of the tab 12, then serging along the seam allowance 10 in a clockwise direction, and upon reaching a top left corner of the tab 12, placing the outer layer 4 underneath the inner layer 6, aligning the center lines A-A′ 16 and B-B′ 18, and then serging is continued through both the inner layer 6 and the outer layer 4 along both seam allowances 8, 10 and along and across attachment seam 14, and then serging is continued on the outer layer 4 along seam allowance 8 in a clockwise direction, and the serging is ended either at a leading edge of, along, or at a following edge of, the attachment seam 14. For a strong and durable attachment seam 14 of the diaper 2 that will hold up during repeated use and laundering, the direction of the fabric grain for inner layer 6 should be aligned with and parallel to center line B-B′ 18.
[0071] Benefits of attachment seam 14 are that the outer layer 4 and the inner layer 6 of the diaper 2 stay attached during laundering, and allow the layers 4, 6 to flow freely of each other in the washer and dryer, which ensures not only that the diaper 2 gets as clean as possible, but also reduces the length of the wash and dry cycles. Also, during laundering of the diaper 2, water and detergent are able to flow freely through the fabric fibers of the layers 4, 6 avoiding the consistent issues of buildup of mineral or ammonia residues from human waste in the cloth or fabric. Another benefit of the attachment seam 14 is that diaper preparation is cut in half, with an easy to use, grab-and-go diaper 2, because the diaper 2 does not need to be folded or stuffed prior to use upon the wearer. The user can grab the diaper 2 out of the dryer, quickly fold the inner layer 6 into a rectangle, and put the diaper 2 on the wearer. Also, with the inner layer 6 attached to the outer layer 4, the wearer cannot unfold the diaper 2.
[0072] Another benefit of the minimal attachment seam 14 is that the inner layer 6 is free moving in relation to the outer layer 4, with the exception of the tab 12 connecting the layers 4, 6 of the diaper together. The minimal attachment seam 14 allows the user to fold the inner layer 6 completely clear of a seal line of the diaper 2 across and against a back of the wearer, and allows the diaper 2 fabric to stretch and manipulate around the wearer's body shape for perfect back and leg seals of the diaper 2 on the wearer every single time with very little effort by the user. Even the user with little cloth diaper experience can easily use the diaper 2 of the present invention.
[0073] To use the diaper 2 of the present invention with the wearer, the user first lays the diaper 2 flat in an initial folded configuration as show in
[0074] Another benefit of the diaper 2 of the present invention is that due to the stretch of the fabric used in the diaper 2, the user does not have to worry about pulling too hard on the diaper 2 while donning the diaper 2 on the wearer. When using the Good Key Method to secure the diaper 2 of the present invention on the wearer, the user can achieve a good leg seal and a separate, outer cover with elastic on the leg and body openings is not needed to keep waste contained in the diaper 2. Although very absorbent, the diaper 2 of the present invention is not waterproof, and a separate waterproof cover is recommended.
[0075] Other benefits of the stomach panel 24 are that when the diaper 2 is worn by the wearer, the stomach panel 24 sits right where the wearer's legs meet the hips. When the stomach panel 24 is in place, it also adds extra layers of fabric over the wearer's stomach area under the belly button and over each hip bone adding protection from diaper fasteners. The stomach panel 24 also serves to keep a front of the diaper 2 from drooping while worn by the wearer, and adds extra absorption in the front of the diaper 2.
[0076] Other benefits of the diaper 2 of the present invention are that the tab 12 of the inner layer 6 may be turned by the user downward and into the inside of the diaper 2, thus allowing from about 0.25″ to about 0.5″ of fabric to be rolled into the back of the diaper 2 to achieve a good seal against the wearer's back when the diaper 2 is worn. The shape of the outer layer 4 of the diaper 2, and use of a stretch fabric for the outer layer 4, allows the user to roll and stretch the fabric of the diaper 2 at the legs, hips, and waist of the wearer, and ensures the best back seal and leg seal possible, keeping waste in the diaper 2 and not on the wearer's clothing. Additionally, because there is no unneeded or excess fabric for the outer layer 4, and the inner layer 6 can be folded away from the wearer's leg seal line, the diaper 2 is very trim, and has bulk only and exactly where needed for waster absorbency.
[0077] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although the present invention has been described with reference to specific embodiments, and to preferred methods and materials, it is understood that any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, and that modifications and variations of the present invention are possible without departing from the scope of the invention, which is defined by the claims set forth below.