THIS INVENTION relates to a laminated material and to a diaper or a pair of pants formed therefrom which has particular utility for swaddling or incontinent persons.

A problem which has always existed with diapers or pants for ' swaddling or incontinent persons has been the necessity of frequent changing of the diaper or pants to enable the person wearing the same to remain comfortable and avoid the outbreak of rashes or the like which arise from the skin of the person being exposed to, and being rubbed against damp clothing in the groin area.

In the case of babies and incapacitated adults it is necessary for another person to assume responsibility for changing the diapers or pants of such persons, which over time can become very demanding. Accordingly, in this day and age where most persons are responsible for a ^" multitude of tasks, it is often the case that frequent changing of diapers and pants is neglected. As this can become unsightly by wetting the outer clothing worn by the swaddling or incontinent person, steps have been taken by the introduction of plastic pants to prevent leakage from the diapers or pants to the outer clothing. This development has in fact created a more serious problem whereby the diapers or pants have effectively been made airtight so that air is prevented from circulating in the loin region. This combined with the fact that it is harder to detect when the particular diapers or absorbent pants of the swaddling or incontinent person require changing has led to the wearer being kept in wet diapers or absorbent pants for much longer periods than is acceptable

for health purposes, quite apart from considerations of the comfort of the wearer.

Accordingly, it is an object of the present invention to provide a laminated material from which diapers or absorbent pants can be formed which seeks to maintain one surface thereof, which is impinged by liquid, relatively dry and be relatively permeable to such impinging liquid to enable absorption of the same by an absorptive lamina removably disposed within the laminated material.

In accordance with one aspect of the present invention, there is provided a laminated material for diapers comprising:- a first lamina having an outer side and an inner side and being permeable to liquid contacting said outer side through to said inner side; and a second lamina having an outer and an inner side disposed in superposition with said first lamina so that the inner side of said second lamina is adjacent to the inner side of said first lamina and being relatively impermeable to liquid contacting the inner side thereof through to said outer side; wherein said first and second laminae are interconnected so as to form a pocket for accommodating an intermediate absorbent lamina therebetween, said intermediate lamina being removable from said pocket when saturated with absorbed liquid and replaceable by another intermediate absorbent lamina for further absorptive purposes.

Preferably, the laminated absorbent material includes an outer lamina disposed in superposition with the outer side of said second lamina to cover said second lamina, said outer lamina being provided with an outer surface which is non-irritating against the skin of a user of said material.

In accordance with another aspect of the invention, there is provided a diaper or a pair of pants formed of laminated absorbent material as defined in the preceding aspect of the invention wherein the pocket is disposed in the crotch of said pants and is provided with an opening through which said intermediate absorbent lamina may be withdrawn or inserted for replacement purposes.

The invention will be better understood in the light of the following description of two specific embodiments thereof. The description is made with reference to the following drawings, wherein: -

Fig. 1 is a perspective view of the diapers in accordance with the first embodiment with side connecting studs detached from each other;

Fig. 2 is a fragmentary view of ι_he diapers in their fully opened state showing, the different layers of the laminated material;

Fig. 3 is a plan view of the diapers showing the position of the pocket opening;

Fig. 4 is a front plan view of a pair of pants in accordance with the second embodiment;

Fig. 5 is a rear plan view of the pants shown at Fig. 4; and

Fig. 6 is a top view of the pants shown at Figures 4 and 5.

The first embodiment is directed towards a pair of diapers 11 for a baby as shown in Figures 1 to 3 of the drawings, which are formed from a laminated material and shaped to define a rear flap portion 11a, a front flap portion lib and an intermediate crotch portion lie therebetween.

The opposite sides 13 of the crotch portion lie are concavely curved to accommodate positioning of the diaper between the legs of the baby so that the crotch portion lie covers the groin area of the baby, the rear flap portion 11a covers the buttocks and extends around the rear of the waist of the baby, and the front flap portion 1lb covers the genital area and extends around the front of the waist of the baby.

The opposing sides 15a and 15b of the rear and front flap portions 11a and lib respectively are provided with corresponding parts of a fastening means in the form of plastic press studs 17, so that when the diapers are positioned correctly around the loins and waist of the baby, the corresponding sides of the front and rear flat portions of the diaper may be fastened together so that the opposite ends 19 of the diaper encircle the waist of the baby.

The opposite ends 19 of the diaper are formed, with an elasticised waist band to facilitate close fitting of the diaper around the waist of the baby. Similarly, the concavely curved sides 13 of the crotch portion lie are also elasticised to facilitate close fitting of the diaper around the legs of the baby, and additionally are covered with a ribbing material to form a comfortable seal around the baby's leg to prevent any leakage of the contents of the diaper.

As previously described , .the diapers are formed from layered, material which comprises essentially three permanently disposed laminae and one replaceable lamina.

Moreover, the laminated material comprises a first lamina 21, a second lamina 23 and an outer lamina 25 which constitute the permanently disposed laminae and an intermediate absorbent lamina 29 which constitutes the replaceable lamina. The permanently disposed laminae are superposed upon each other and are appropriately hemmed along their peripheral edges to form the desired shape of the diaper as shown in the drawings.

The first lamina 21 is formed in two parts so as to form a transversely extending opening 27 near the junction between the front flat portion lib and crotch portion lie. Consequently, this opening, in conjunction with the interconnection of the first and second laminae, forms a pocket within which may be disposed the intermediate absorbent lamina 29.

The first lamina 21 is provided with an outer side 21a for contacting the skin of the baby. The inner side 21b of the lamina defines an inner side of the pocket and thus confronts the intermediate absorbent lamina which is accommodated in the pocket. The first lamina 21 is breathable and substantially permeable to liquid impinging the outer side 21a thereof. The first lamina is formed from either polyester, polypropylene or a composite of either or both of these materials so as to be non- absorbent to liquid impinging the same.

The outer side 21a of the lamina is knitted in a ribbed pattern to be comfortable and non-irritating against the skin of the baby whilst allowing air to circulate through

to the skin of the baby and urine or the like impinging the outer side to pass through the lamina onto the intermediate absorbent lamina 29. Accordingly, due to the non-absorbent nature of the first lamina and the ribbed pattern of the same, once the liquid has been absorbed by the intermediate absorbent lamina, it does not easily permeate back through the inner side to the outer side of the first lamina, and so the combined effect of the first and intermediate laminae keeps the skin of the baby relatively dry.

The second lamina 23 is similarly provided with an inner side 23a, which forms the other inner side of the pocket and confronts the other side of the intermediate absorbent lamina 29, and an outer side 23b which is juxtaposed with the outer lamina 25. The second lamina 23 is also breathable but is relatively impermeable to liquid contacting the inner side 23a thereof. The second lamina is made from either woven wool, felted rayon provided with a moisture proof coating, or a composite including either or both of these materials.

The second lamina 23 may have a small degree of permeability and absorbency to absorb some of the liquid which impinges the inner side thereof until the intermediate lamina 29 is sufficiently activated to absorb this liquid.

The intermediate lamina forms the principal absorbent component of the laminated material and is intended to absorb all of the liquid which permeates through the first lamina 21. The intermediate lamina is formed from anyone of a multitude of materials such as felted rayon, rayon, cotton, flannelette, paper or other material impregnated with a superabsorbent polymer or the like, such as

biodegradable paper impregnated with granules of an absorptive swellable polymer in a substantially anhydrous state, or a composite of any of these materials.

In all cases, the intermediate lamina would be preformed or arranged into an elongate pad of sufficient length to cover the crotch portion lie of the diaper upon insertion into the pocket. The pad is inserted into the pocket through the opening 27 to be interposed between the first and second lamina and to extend between the rear and front flap portions respectively.

The opening 27 is arranged so that there is a partial overlapping of the first lamina 21 adjacent to the sides of the opening. Moreover, part of the first lamina extending from the front flap portion lib towards the crotch portion lie of the diaper projects into the pocket and is overlaid by part of the first lamina extending from the crotch portion lie towards the front flap portion lib of the diaper defining the opening 27 therebetween. In this manner, the end of the intermediate lamina 29 adjacent to the opening 27 when inserted into the pocket may be tucked underneath the inner projecting portion of the first lamina to repose entirely between the first and second laminae, whereby the overlapping portions of the first lamina defining the opening 27 effectively form a closure for the pocket.

The outer lamina 25 is superposed with the second lamina 23 to completely cover the same, thereby protecting the outer surface of the second lamina from wear. As in the case of the other laminae, the outer lamina is breathable and is importantly formed from a relatively comfortable and non-irritating material to the skin such as woven

polyester, cotton or a composite of one or both of these materials.

In using the diaper, a clean intermediate lamina 29 is arranged in an elongate form and inserted into the pocket in the manner previously described so as to form an absorbent pad in the crotch portion lie of the diaper. For example, if the intermediate lamina ^' 29 is a flannelette nappy, this is initially folded into an elongate form and is inserted into the pocket so as to pervade the entire crotch portion lie of the diaper spacing the first and second laminae apart. Once the intermediate lamina is positioned, the diaper can be positioned around the loins of the baby and the press studs fastened around the hips of the baby to form a snug fitting pair of pants.

Once in position if the baby wets the nappy, the urine or liquid permeates through the first lamina 21 and is absorbed by the intermediate lamina 29. Due to the relatively non-permeable nature of the second lamina 23, no liquid from the intermediate lamina when saturated can pass through to the outer lamina 25, thereby preventing any outer -clothing from getting wet.

Furthermore, the non-absorbent nature of the inner side of the first lamina and spacing created by the ribbed pattern of the first lamina against the skin, does not facilitate passage of liquid back through to the first lamina to the skin of the baby. Thus, the liquid upon being absorbed by the intermediate lamina is largely confined between the first and second laminae, enabling the skin of the baby in the loin region to remain relatively dry, and thus enable the diaper to remain in position for longer periods

without causing nappy rash or any substantial discomfort to the baby.

Furthermore, the breathable nature of the first and second laminae enables air to pass through to the skin of the baby in the loin region and thus mitigates the build up of heat and thus any likelihood of nappy rash occurring.

When the intermediate lamina becomes saturated or at a convenient time for the purposes of changing the diaper, the diaper is simply unfastened at the hips and the intermediate absorbent lamina withdrawn from the pocket of the diapers .

If the baby has only urinated, it is possible for the diapers to be used again by simply inserting another dry intermediate absorbent lamina into the pocket in the manner previously described and re-fasten the diapers about the baby's loin area as also previously described.

Many advantages are conferred by the use of the laminated material hereinbefore defined including the following:- .

1. Liquid upon impinging the first lamina is effectively trapped between the first or second laminae, thereby maintaining the outer sides of the first and second laminae relatively dry;

2. The first lamina by being formed of a material which does not hold or retain liquid facilitates maintaining a relatively dry outer side against the skin of the baby;

3. Due to the non-irritating nature of the outer side of the first lamina, rubbing or moving of the same

against the baby's skin mitigates the likelihood of nappy rash;

4. The breathable nature of the laminae allows air to circulate through to the baby's skin thereby inhibiting the build up of heat and consequently also mitigating the possibility of nappy rash;

5. The material from which the second lamina is formed provides an insulative effect against the cold even when the intermediate lamina and the second lamina are wet themselves;

6. The non-irritating nature of the outer lamina prevents rubbing of the skin of the baby outside of the diaper upon the second lamina, thereby mitigating wear of the second lamina and also irritation that would otherwise be caused by the second lamina rubbing against such skin.

The second embodiment is substantially similar to the first embodiment except that it is directed towards a pair of pants for use by comparatively large persons or adults who may have an incontinence problem. Accordingly, the construction of the pants is modified to suit wearing by such persons .

As shown in Figures 4 to ^* 6 of the drawings, the pants 31 are provided with three openings, one large opening 33 for the waist and two smaller openings 35 for the legs of the wearer.

The pants 31 are formed of similar laminated material as the diapers in the preceding embodiment, except that the first lamina is fleecy lined on the outer side for comfort

and warmth of the wearer, whilst still being non-absorbent but permeable for the passage of liquid contacting the outer side through to the inner side. Importantly, the inner side of the first lamina is closely knitted to form a relatively impermeable surface to the passage of liquid from the inner side to the outer side of the first lamina. Thus the first lamina provides a better trap for liquid between the first and second laminae than in the case of the diapers. The fleecy lining of the outer side, however, causes more heat to be generated than in the case of the knitted fabric of the diapers, tending to make it less suitable for use with babies.

The second lamina is not superposed upon the entire extent of the first lamina due to larger size of the pants. Moreover, the second lamina is disposed so as to cover the entire crotch portion of the pants and extend through the rear and back portions of the pants to attach to the front and rear waist respectively. However, it is unnecessary for the second lamina to extend laterally around the hip portions of the pants as is the case with the diapers, since there is little likelihood of these portions becoming wet as a result of the incontinence of the wearer.

The pocket of the pants is virtually identically disposed to that if the diapers except that a pair of openings 37 are provided adjacent to the junctions between the front and rear portions of the pants respectively and the waist.

Other than the aforementioned differences, the function and advantages of the pants of the present embodiment are identical with those of the diapers of the preceding embodiment.

It should be appreciated that the scope of the present invention is not limited to the description of the specific embodiments of the specification and accordingly, modifications and variations from the pants and diapers described in the preceding embodiments, such as would be apparent to a skilled addressee, are deemed to be within the scope of the present invention. In particular, the present invention is not limited to embodiment in the form of diapers or pants and alternative forms of embodiment may be contemplated.