The invention relates to non-disposable diapers, and particularly to cloth diapers that are fitted and include fasteners that are used to adjust the diaper to various sizes of infants.
Given the stressful and busy lives of parents and infant caretakers, it is desirable to have form-fitting and adjustable diapers for infants and for older toddlers. Given the environmental impact of disposable diapers, it is desirable to provide a well-fitting, adjustable, washable and reusable diaper. Many attempts at these goals are represented in the prior art, for example, in the following patents: Redfern (U.S. Pat. No. 4,402,690, issued Sep. 6, 1983); Sorenson, et al. (U.S. Pat. No. 4,801,298, issued Jan. 31, 1989); Coates (U.S. Pat. No. 5,137,526, issued Aug. 11, 1992); Zehner, et al. (U.S. Pat. No. 5,366,453, issued Nov. 22, 1994); Coates (U.S. Pat. No. 5,725,518, issued Mar. 10, 1998); LaVon, et al. (U.S. Pat. No. 6,932,800, issued Aug. 23, 2005); Karlsson (Application Publication 2002/0042602, published Apr. 11, 2002); Abrahamsson (Application Publication 20021/0091366, published Jul. 11, 2002); Nakaoka, et al. (Application Publication 2002/0138061, published Sep. 26, 2002); Erdman (Application Publication 2007/0073258, published Mar. 29, 2007); Coates (Application Publication 2005/0022291, published Feb. 2, 2005); and Baskeiville (Application Publication 2004; 0153045, published Aug. 5, 2004).
Still, there is a need for a reusable, well-fitting, cloth diaper that is not prone to leaking, and that is highly adjustable and highly durable. The present invention meets these needs.
Objects of the invention include providing a diaper that is fitted, washable and reusable, highly unlikely to leak, and extremely durable. The invented diaper comprises fabric preferably on both the outermost surface and the inner most surface that is stretchable, soft, and has hydrophilic and wicking properties. The invented diaper comprises an inner absorbent layer(s) between said wicking fabric layers. This results in the preferred hydrophilic, wicking fabric becoming dryer as time passes after wetting, as liquid is wicked into the highly-absorbent layers between the outer layers of the diaper. As a result, the outermost fabric layer of the diaper becomes very dry to the touch within a few minutes.
A fastening system is provided that may be used to adapt the diaper to fit a wide range of sizes of infants and toddlers, for example, from birth up to four years old. The preferred fastening system adjusts the width (waist size) and height of the diaper continuously within wide ranges, making an effective and comfortable fit possible without the use of incremental fasteners such as snaps. The fastening system allows a substantial amount of the front side of the diaper to be folded inside the diaper, significantly changing the overall size of the diaper to accommodate small infants. In this much-reduced-size configuration, a substantial amount of the outermost layer of the diaper is folded inward against the child's skin, but, due to the structure of the diaper, soft, wicking fabric is maintained against the child's skin, and the fastener system does not interfere with absorbency. The preferred “V” fastener component of the fastener extends far down on the front side of the diaper, to allow fastening of the diaper even when about seven inches of the front side of folded inward. The preferred “V” fastener component also has “wings” of fastener extending out from each upper end of the V-fastener, which allow substantial adjustment of the waist size of the diaper for the largest of children using the diaper. The preferred “V” fastener arms and wings are integral portions of the preferred one-piece “V,” so there are no seams or ridges along the “V” that could irritate or scrape the infant.
The preferred V-fastener is a “hook compatible fabric” rather than a conventional hook and loop strip with rigid or semi-rigid backing such as Velcro™. The hook-compatible fabric is soft, and has soft edges, so that it will rest against the infant's skin, in the reduced-size configuration, without irritating, scraping, or poking the skin. In other words, the preferred loop material for the V-fastener is made of soft, low-pile loop fabric that will not irritate the baby's skin when folded in to fit a newborn. Further, when the front of the diaper is folded in and the hook tabs are fastened to the loop V-fastener, the baby is still able to wet on the hydrophilic wicking fabric that is between the widely-spaced arms of the “V”. Thus, the loop “V” closure system may provide a snug, comfortable fit from birth to 4 years old.
The preferred pattern of the diaper includes a contour cut or “scoop” in the top edge of the back of the diaper, which allows the diaper to fit comfortably at baby's lower back and reduces the need for excessive elastic to insure a snug, leak free fit. This preferred scoop in the pattern also eliminates the typical pooch of fabric at the back of cloth diapers, making it more trim under clothing.
Elastic is provided in the back of the diaper but is gentle and minimal. Preferably, a fairly loose elastic is slightly gathers only the scoop area of the back edge of the diaper. This short length of elasticized edge is enough to gently pull the right and left portions of the back edge toward the scooped area, so that overall the back edge fits to the back of the infant to blocking leaks from the back, but without squeezing the waist too tightly and without gouging into the infant's skin. Thus, the back elastic does not irritate baby's sensitive skin by over-gathering the fabric into deep, tight gathers that tend to mark the skin at pressure-points.
Elastic is provide substantially around the leg holes formed by diaper, that is, around most of the leg hole formed by the diaper in the reduced-sized configuration, and around about at about the bottom half of the leg hole formed by the diaper in the full-size configuration. The elastic is thus positioned to be gentle enough for wide legs on toddlers and still close the diaper snugly around newborn legs to prevent leaks. The edges of the diaper that form the leg hole lack of top stitching over the leg opening elastic, which reduces gathering of the fabric into deep and/or tight gathers that would tend to mark the skin at pressure points. Hence, the leg holes and their elastic are more gentle on baby skin than conventional elastic-gathered garments.
Referring to the Figures, there are shown two, but not the only, embodiments, of the invented fitted, highly-adjustable cloth diaper.
The preferred diapers 1, 100 comprise very stretchy, soft, fabric panels 10. 10′ with hydrophilic and wicking properties, wherein said panels 10 are the outermost and innermost panels of the diaper, as shown to best advantage in
The super absorbent inner layer(s) 11 is/are provided in between panels 10, 10′. Preferred layers 11 may be composed of any number of (preferably several) rectangular fabric pieces that are attached to the inside panel 10 of the diaper and sewn in permanently and out of sight when the diaper is finished. Thus, panels 10, 10′ completely cover and surround layers 11. Layers 11 preferably are made of fabrics that will reduce bacterial growth. Preferably, layers 11 are made of synthetic/non-natural fibers that are preferably hypoallergenic and that minimize bacterial growth inside the diaper.
The preferred diaper structure of entirely synthetic fabrics tends to be safe for infants' skin, clean and unlikely to harbor bacteria, and durable enough to be washed repeatedly and vigorously without quick damage or degradation. The preferred embodiments do not degrade when washed an average of 2-3 times per week for a minimum of 3 years, which is very beneficial for families or institutions that want a given diaper to last during use on an infant over many months and even up to 4 years of age.
A contour or “scoop” 12 cut in back of pattern (in the upper, back edge of the diaper as it will be worn) allows diaper 1, 100 to fit comfortably at baby's lower back, reducing the need for elastic to insure a snug, leak free fit. This scoop 12 in the pattern also eliminates the typical pooch of fabric at the back of cloth diapers, making it more trim under clothing. Back elastic 13 is included, preferably, only along the length of the upper, back edge of the diaper that is scooped inward toward the center of the diaper (scoop 12). The elastic is gentle and minimal, that is, pulling only gently (and not tightly and strongly) on the adjacent edge portions 112, 212, while still being effective in blocking leaks because the fabric at scoop 12 gathered to be against the infant's skin. The elastic 13 in the area of scoop 12 does not irritate baby's sensitive skin by over-gathering the fabric. The call-out lines for elastic 13 is shown in dashed lines pointing to the gentle gathers in
Leg elastic 14 is positioned along the side edges of the diaper 1, 100, and is also adapted to be gentle, rather than strongly-pulling on the edge areas of the leg holes. It is desirable for elastic 14 to be gentle enough for wide legs on toddlers and still close the diaper snugly around newborn legs to prevent leaks. Elastic 14 is shown in
The fastening system preferably includes a “V” shaped piece of loop fabric (or “hook compatible fabric” 15), that adjusts the width and height of the diaper, making an effective and comfortable fit possible without the use of limited snap or other incremental settings/fasteners. The loop “V” is made of soft, low-pile loop fabric that will not irritate the baby's skin when folded in to fit a newborn. It is preferred that the V-shaped piece of fabric be nylon knitted loop fabric, or other fabric that has a soft “hand” and no laminated or other stiffener or stiff backing. While a conventional loop fastener such as Velcro™ might work for connecting to the hook portions of the preferred fastening system, said conventional loop fastener strips have stiff backings with edges that can be harsh, abrasive, and/or irritating to skin. Therefore, a hook-compatible material (a term known in the fabric field) is desired rather than a conventional hook-and-loop strip comprising loops and rigid or semi-rigid backing and edges.
Preferably, the V-shaped fastener 15 has two aims 115, 215 that extend upwards from the point of the “V” at an angle to each other of about 55-75 degrees (and more preferably about 65 degrees). The top edge of each arm is about 6-7 inches vertically (h1) from the bottom of the “V” (see
By using the preferred hook-compatible fabric, without stiffener or stiff edges, as the fastener, and by forming the V fastener to have wide-spread arms and to extend down far along the front side 50 of the diaper, said front side 50 may be folded over, inward toward the infant and toward the rear side 60 of the diaper, and fastened to configure the diaper into a newborn or other very small child diaper. The flattened diaper (see
In
When the front side of the diaper is folded and the hook tabs 17 are fastened, the baby is still able to wet on an area of hydrophilic wicking fabric of the flap 16, between the arms of the V of the flap 16. This folding-over of the front side portion 50′ is more than a mere small tuck-in or small fold-over to prevent wetting of the infant's belly-button area; it is a major change in the size, and particularly the height of the diaper. For example, the diaper configured in its full height (see
Thus, the “V” fastener 15 allows the diaper to adjust the diaper's width and height freely and continuously, which is not possible with a fixed, incremental snap-based adjustment system. The loop “V” closure system provides a snug, comfortable fit from birth to potty training (approx. 5-35 lb.).
The use of hook coins (die-cut circles of hook tape) is preferred for the hook tabs 17, instead of square pieces of hook assures that sharp corners do not peel up and scratch the baby. Also, laundry tab covers (rectangles of loop tape) 18 are preferably sewn next to the tabs 17 in order to provide a contact point for the tabs 17 when washing and drying the diaper. By attaching the tabs 17 to their laundry tab covers, the hooks of the tabs 17 are kept clean of lint and fabrics are free from snagging on open hooks.
The entire diaper, excluding the leg openings. is preferably top stitched in order to create a trim, finished diaper that is more durable due to the second set of stitches. Threads designed for outdoor wilderness sports apparel (such as those used in skiing and boating) are used in order to insure the most durable construction possible.
The preferred, unique V-shaped hook-and-loop fastening system allows the diaper to adjust in width and depth at the same time, and in a continuous, rather than incremental way. This system also eliminates the restrictions and potential discomfort of a limited, snap-based, adjustable fastening system. The range of adjustability provided by the diaper eliminates the need for purchasing multiple sizes of fitted, cloth diapers as a baby grows, providing economic and ecological benefits. The diaper will adjust to fit the majority of babies from birth through potty training (approx. 5-35 lb.).
The durable materials used in the preferred diaper eliminate the need for special care or line-drying. The shape of the diaper is form-fitting, and becomes more form-fitting as a baby grows and increases in mobility. The hook and “hook compatible fabric” fastening system is extremely easy to use. The basic functions of a diaper (wicking liquid away from the baby's skin and absorbing it) are heightened by the materials used in the diaper. No separate diaper “cover” is needed, and parents and caregivers should find the preferred diapers easy to use, wash, dry, and reuse.
To place the diaper on a larger baby or toddler, the parent or caregiver fastens the hooked tabs 17 to the upper portion of the V-shaped section 15 of looped fabric on the front of the diaper. To place the diaper on smaller babies, the parent or caregiver folds the front panel of the diaper down inside the diaper, and attaches the hooked tabs 17 to the lower portion (as low at the point of the V) of the looped fabric. The V-shape of the looped fabric allows the primary fabric (panel 10′) of the diaper to absorb liquid when it is folded down inside the diaper, as preferably both panels 10, 10′ are the same fabric. The looped fabric of the V fastener, and also panels 10, 10′ are soft and do not irritate a baby's skin.
Although this invention has been described above with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to these disclosed particulars, but extends instead to all equivalents within the broad scope of the following claims.
This application claims priority of Provisional Application 60/860,933, filed Nov. 24, 2006, the entire disclosure of which is incorporated herein by this reference.
Number | Date | Country | |
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60860933 | Nov 2006 | US |