stiffening fabric may also be stitched between the two polyester layers 60, and are secured to the central polyplies of body 12 in the area of tabs 25, 27 and front face ester layer 61 by stitching along either longitudinal edge 73 to provide a stiffening and smoother appearance. which extends through only felt layers 62 and layer 61.
For easier cleaning of the garment, as will be de- The three-piece sandwich thus formed is then in turn
scribed in further detail below, the panels 22 at either 5 contained between layers 63, 65 by stitching which
end of the diaper are preferably sewn through the wa- extends only through the outer edges of layers 61, 63,
terproof layer 16 and the two-ply body 12 along semi- 65. This creates a softer outer edge of the insert. Sharp
circular lines 77 at both ends. A waterproof channel or edges are further avoided by staggering the ends of
pocket 8 is thus formed along the central axis of the layers 62.
garment with its lower surface formed by waterproof 10 Another form of insert 32 which can be used in the fabric 16 and bordered at either end by stitch lines 77 invention is a single layer of absorbent felt material and panels 22, and along either side by walls 17, 18. covered with a non-wicking "stay dry" material such as To use the diaper, an absorbent insert 80 is inserted polyester. The felt layer may be 100% rayon, a blend of into pocket 8. Such insert is sized to fit snugly in pocket rayon and polyester, or a microporous acrylic such as 8 and may be a disposable insert, or it may be a reusable, 15 that sold under the trademark SUPERSORB. As an washable insert. In respect of a disposable insert 80, alternative to the felt layer, a multiple layer of cotton such insert may be manufactured from a super-absorb- fabric, of a flannelette or bird's eye weave, may be used, ent polymer, including air-laid thermal-bonded materi- When used in cover 30, insert 32 is inserted to fit als of the type available for adult incontinence pads smoothly in the interior of cover 30, and cover 30 is manufactured by Merfin Hygienic Products Ltd. The 20 inserted into pocket 8 of the diaper 10 with opening 36 insert may be not only disposable but also flushable and pointing towards the interior of the garment. Due to the biodegradable. ("Flushable" means the insert disinte- curvature of the garment, the dimensions of edges 38,40 grates in water to a particulate size which can be han- and the tightening action of strip 54, the edges 38,40 are died by a municipal sewage system.) For example a caused to be raised in relation to insert 30. This causes a product marketed under the trademark PRIMA by 25 damniing effect on liquid within cover 30. The waterJohnson & Johnson Inc. provides a bio-degradable ab- proof container formed by cover 30 allows time for the sorbent pad for sanitary napkins and the like composed liquid to be absorbed by the absorbent insert. Squeezing partly of peat moss. In such an application, an unused of cover 30 may cause liquid to exit from insert 32 but absorbent insert is inserted in pocket 8 with its ends it will still be retained in cover 30 and reabsorbed into under panels 22. The diaper is then placed on the infant 30 the insert when pressure is released. After the insert has in the usual way. Once the insert has been wetted or been wetted, the garment is removed, the cover slipped soiled, the insert is removed from the pocket 8 and out of the garment, the cover is rinsed or washed in either flushed down the toilet or placed in a waste dis- warm water, the insert is replaced with a clean insert (or posal container. If the diaper 10 has been wetted or the insert in question is washed), and the cover is resoiled it can be rinsed, and periodically will require 35 placed in the garment. The waterproof cover allows the washing. Stitching 77 may be used to prevent waste saturated inserts to be removed with minimum contact from getting in to square interior corners which would of the user's hands.
make cleaning more difficult. The cover 30 permits any number of inserts to be Re-usable inserts may also be used in the invention, inserted into the cover depending on the user's needs. In and FIG. 2 illustrates an absorbent insert cover 30 40 each case, the cover is readily inserted like a cassette, which may be used to hold the absorbent insert 80 regardless of the number of absorbent inserts. The low (whether disposable or washable) for insertion into friction coating of the cover makes this insertion easier, pocket 8. The cover 30 is formed of a single piece of Thus by using the cover 30 of the invention and either waterproof coated nylon 34, so that it is water impend- a reusable or disposable insert, soiling of diaper 10 is ous. A polyurethane or PVC coated nylon, washable 45 further reduced and the diaper can be re-used a number and resistant to heat, bleach, detergent and ultra-violet of times without washing. The user simply inserts the radiation is suitable. It has a front opening 36 to receive cover with the desired type and number of inserts in the and expose the absorbent insert, for example of the type crotch area of the diaper, opening inwardly, and puts illustrated as 32. The cover 30 has live (natural) rubber the diaper on the infant in the usual way. The cover 30 strips approximately 1 cm. in width hemming the edges 50 (and insert) need not be hour-glass shaped as shown, but 38, 40 of opening 36 which cross over at ends 42, 44 to rather can have straight, parallel sides, provide a flatter profile. The cover is a one-piece con- FIG. 7 through 13 illustrate a preferred manner of struction so that edges 46, 48 are seamless to prevent forming the waterproof channel and attaching it to the leaking. Ends 50, 52 are waterproof seams formed by fabric body 12 of the diaper. In the embodiment shown sonic welding or other waterproof seam means. An 55 in FIG. 7 and 8, the body 12 is preferably formed again optional strip 54 of fast wicking spun polyester mesh is of a layer 100 of a tight woven, breathable, water repelstitched at either end thereof to the inner edge (bottom) lant 100% polyester fabric, woven from a micro-fibre or of rubber hem 38,40 where they met the nylon backing a high multi-filament count polyester yarn. This promaterial 34. Strip 54 does not stretch along its length, vides a soft comfortable finish to the diaper. The center but may across its width in the longitudinal direction of 60 waterproof channel or pocket 108 is formed again of a the cover 30. As with the inserts, dimensions of the nylon fabric 109 with a waterproof coating such as a cover will vary according to the particular size of dia- polyurethane or polyvinyl chloride material and is per. formed with unitary walls 117, 118 by forming flanges FIG. 3 illustrates one embodiment of the absorbent 120,122 and sonic welding along lines 123,125 to weld reusable insert 32 which may be used alone or in the 65 the upper ply of the flange to the lower ply along the cover 30. Insert 32 is formed of three layers 60 of lower edge of the wall. The ends of the channel 108 are brushed polyester, and two layers 62 of absorbent felt. folded over to form panel 132 which may be stitched to The two felt layers 62 are slightly narrower than the the underlying material 109 along semicircular line 133