FIELD OF THE DISCLOSURE

[0001] This disclosure relates generally to a disposable diaper and method of making the same, and more particularly, to a disposable diaper and method of making same for absorption and containment of bodily discharges, the diaper including an integrated container for storing items such as wipes.

BACKGROUND

[0002] It is well known that diapers must be frequently changed, and a wearer's skin cleansed between changes. For this reason, cleansing cloths or wipes are needed for each diaper change, but a parent or caregiver may be out of, or unable to locate, wipes when a diaper change is needed. In addition, wipes are generally pre-moistened for convenience, and require a leak proof container to keep the wipes from drying out and to protect surrounding surfaces from the moist wipes. Often, these containers are left opened allowing an entire container full of wipes to dry out thereby becoming less effective. In addition, other diaper administering items may be needed, such as powder or lotions, and which also require a separate container for storage. It is also well known that diaper wearers, most often infants, can grow at such rates that they outgrow the diapers purchased for them thereby leaving a parent or caregiver with an unusable supply of outgrown diapers.

[0003] Previous attempts to provide a solution to these challenges, such as the one disclosed in U.S. Patent No. 9,320,659 to Richardson, incorporated herein by reference in its entirety, involve forming a pocket on the external surface of the diaper. However, a pocket on the external surface of the diaper comes into contact with surfaces on which the wearer sits or lays, and a caregiver will often hold the wearer through contact with the external surface of the diaper, thereby exposing the pocket to possible wear and tear.

[0004] Accordingly, improved disposable diapers having integrated containers are needed, as well as method for producing such diapers, for overcoming one or more of the technical challenges described above.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar to identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.

[0006] FIG. 1 is a schematic of a diaper having an integrated container in accordance with the present disclosure.

[0007] FIG. 2 is a schematic of a diaper having an integrated container in accordance with the present disclosure.

[0008] FIG. 3 is a schematic of a container for inclusion in a diaper in accordance with the present disclosure.

[0009] FIG. 4 is a perspective view of a back side of the diaper of FIG. 1 in a fastened position in accordance with the present disclosure.

[0010] FIG. 5 is a perspective view of a back side of the diaper of FIG. 1 in a fastened position in accordance with the present disclosure.

DETAILED DESCRIPTION

[0011] Disposable diapers and methods for producing disposable diapers are provided herein that advantageously integrate a container within the diaper between the layers of the diaper, thereby providing a container for holding, e.g., disposable wipes while advantageously protecting the container from external mechanical contact that could result in failure. The fabrication of a diaper with integrated container as described herein also advantageously requires minimal modification to existing diaper fabrication processes. The present disclosure includes non-limiting embodiments of diapers and diaper production systems. The embodiments are described in detail herein to enable one or ordinary skill in the art to practice the diapers and methods for producing diapers, although it is to be understood that other embodiments may be utilized and that logical changes may be made without departing from the scope of the disclosure.

[0012] Throughout this disclosure, various aspects are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6, etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

[0013] Any known material, size, and shape for a diaper can be produced having the integrated container described herein. For example, a diaper of a suitable size and shape for an infant may be produced, or a diaper of a suitable size and shape for a toddler may be produced.

[0014] Disposable diapers have been developed having an integrated container for, e.g., storing disposable wipes. The integrated container is positioned between the layers of the diaper. In some embodiments, the integrated container may be formed of a liquid impermeable material to both maintain moisture within the container and to prevent unwanted moisture or liquids from entering the container. By positioning the integrated container between the layers, the diaper can be fabricated in a typical layer-wise production system by merely adding another layer comprising the container.

[0015] Embodiments of the diaper include a seal for opening and resealing the container.

[0016] Diapers having an Integrated Container

[0017] Diapers having an integrated container are disclosed herein. In some embodiments, the diaper includes a chassis and an absorbent core and a container within the chassis. The chassis may include a front end, a back end, a liquid permeable layer extending from the front end to the back end, and a liquid impermeable layer extending from the front end to the back end. The diaper may include an absorbent core disposed between the liquid permeable layer and the liquid impermeable layer, the liquid permeable layer, liquid impermeable layer, and the absorbent core arranged to form a layered stack. In some embodiments, the diaper includes a container disposed between the liquid impermeable layer and the liquid permeable layer. In some embodiments, the container may be disposed between the liquid impermeable layer and the absorbent core.

[0018] As used herein, the “front end” refers to the portion of the diaper that covers the wearer’s front side, and the “back end” refers to the portion of the diaper that covers the wearer’s back side. [0019] As used herein, a “liquid impermeable” layer refers to a material, such as a fabric or plastic, that does not allow liquid water or other liquid to pass through it. The liquid impermeable layer may be polyethylene or another plastic.

[0020] As used herein, a “liquid permeable” layer refers to a material, such as a fabric, that permits liquid water or other liquid to pass through it.

[0021] As used herein, an “absorbent core” is a layer that absorbs liquid and distributes the liquid across the volume of the absorbent core. The absorbent core comprises absorbent material that may be formed of a polymer. The absorbent material may be formed of cellulose, polyacrylate, another suitable material, or a combination thereof.

[0022] The use of relational terms, such as, but not limited to, “front,” “back,” “top,” “bottom,” “between,” and the like are used in the written description for clarity in specific reference to the Figures, or to refer to the relative disposition of the diaper layers described herein, and are not intended to further limit the scope of the invention or the appended claims.

[0023] As used herein, “comprise,” “comprising,” and “comprises” are open ended terms, each specifies the presence of what follows, e.g., a component, but does not preclude the presence of other features, e.g., elements, steps, components known in the art, or disclosed herein.

[0024] As used herein, “disposable” is used in its ordinary sense to mean an article that is disposed or discarded after a limited number of usage events over varying lengths of time, such as less than about 20 events, or less than about 10 events, or less than about 5 events, or less than about 2 events.

[0025] As used herein, “Diaper" refers to an absorbent article generally worn by infants and incontinent persons about the lower torso so as to encircle the waist and legs of the wearer and that is specifically adapted to receive and contain urinary and fecal waste.

[0026] As used herein, “nonwoven” is a manufactured sheet, web or batt of directionally or randomly orientated fibers, bonded by friction, and/or cohesion and/or adhesion, excluding paper and products which are woven, knitted, tufted, stitch-bonded incorporating binding yams or filaments, or felted by wet-milling, whether or not additionally needled. The fibers may be of natural or man-made origin and may be staple or continuous filaments or be formed in situ. Commercially available fibers have diameters ranging from less than about 0.001 mm to more than about 0.2 mm and they come in several different forms: short fibers (known as staple, or chopped), continuous single fibers (filaments or monofilaments), untwisted bundles of continuous filaments (tow), and twisted bundles of continuous filaments (yam). Nonwoven fabrics can be formed by many processes such as meltblowing, spunbonding, solvent spinning, electrospinning, and carding. The basis weight of nonwoven fabrics is usually expressed in grams per square meter (gsm).

[0027] In some embodiments, the liquid impermeable layer includes a port or an area of weakness proximate the container for forming a port for accessing the container. In some embodiments, the container includes a seal. The seal may be re-sealable, such that the container may be opened and resealed. In some embodiments, the seal of the container is accessible by tearing the area of weakness in the liquid impermeable layer. In some embodiments, the area of weakness comprises a perforation.

[0028] As used herein, a “seal” refers to any means by which the container may be sealed and opened or in some embodiments, resealed. The seal may be a re-sealable zipper. The seal may include a tacky substance that retains its tackiness after repeated use.

[0029] In some embodiments, the container is formed from a liquid-impermeable material. The container may be formed out of the same material as the liquid impermeable layer. Thus, in some embodiments, the container is flexible. Furthermore, in some embodiments, the container is a flat flexible pouch.

[0030] In some embodiments, the container is configured to hold disposable wipes, including disposable wet or dry wipes. The container may be configured to hold another suitable material, such as powder, lotion, or the like.

[0031] In some embodiments, the container is disposed at the back end of the diaper. Furthermore, in some embodiments, the diaper has a crotch portion between the front end and the back end, the back end includes an upper portion opposite the crotch portion, and the container is disposed proximate the upper portion of the back end.

[0032] In some embodiments, the liquid permeable layer is adhered to the liquid impermeable layer and the container is adhered to at least one of the liquid permeable layer or the liquid impermeable layer. In some embodiments, the diaper layers may be sealed together using an adhesive, heat sealing, ultrasonic bonding, or the like, or combinations thereof. The adhesive may be rubber glue or another suitable adhesive. In some embodiments, the adhesive may be configured to be cured by heat and pressure. [0033] FIG. 1 is a schematic of a diaper 100 having a stack 102 of layers: liquid impermeable layer 104, container 106, absorbent core 108, and liquid permeable layer 110. The container 106 includes a seal 112 through which the contents of the container 106 may be accessed. The seal 112 of the container 106 is located proximal to an area of weakness, which in this embodiment, is a perforation or line of perforations 114 included in the liquid impermeable layer 104. The perforation 114 is configured to be tom open by a caregiver to provide access to the seal 112 of the container 106, thereby providing access to the contents of the container. In some embodiments, the area of weakness in the liquid impermeable layer 104 may be a slit, series of slits, an area of reduced thickness, an abraded area, or the like, which create an area that may be reasonably easily tom by a user or caregiver to form a port for accessing the container 106.

[0034] In many embodiments, liquid impermeable layer 104, container 106, absorbent core 108, and liquid permeable layer 110 may be made whole or in part of flexible materials such as, for example, non-woven materials.

[0035] The container 106 is configured to be positioned between and surrounded by liquid impermeable layer 104 and the liquid permeable layer 110 and, in some embodiments, the absorbent core 108. In some embodiments, the container 106 is formed of a liquid impermeable material so as to preserve the moisture of the contents of the container. In other embodiments, the container 106 is formed of a liquid impermeable material so as to prevent moisture from entering the container. In some embodiments, the container 106 is formed from the same liquid impermeable material as the liquid impermeable layer 104. In some embodiments, the seal 112 is positioned on an edge of the container.

[0036] In other embodiments, the seal 112 is positioned proximal to an edge of the container 106 but a short distance towards the opposing edge, so that an overlap exists between the container and the liquid impermeable layer 110. By creating an overlap, the area of weakness or perforation 114 in the liquid impermeable layer 110 may have a lessened impact on any leakage of liquids that may result from tearing open the area of weakness or perforation. In some embodiments, the area of weakness or perforation 114 in the liquid impermeable layer 110 provides access to the seal 112 of the container 106, but no portion of the absorbent core 108 is exposed.

[0037] FIG. 2 is a schematic of a diaper 100. Diaper 100 includes fasteners or tabs 202 for securing the diaper to the wearer at both the front end 204 and the back end 206. Tabs 202 are integrated with the liquid impermeable layer 104 and thus extend beyond the liquid permeable layer 110. The liquid impermeable layer 104 and liquid permeable layer 110 form a chassis 207 for containing the container 106 and the absorbent core 108. The absorbent core 108 is positioned between liquid permeable layer 110 and liquid impermeable layer 104. In order to ensure the liquid that passes from the wearer, through liquid permeable layer 110, and into absorbent core 108, stays within absorbent core 108, absorbent core 108 is smaller than liquid permeable layer 110 in the x- and y- directions. Thus, absorbent core 108 is enclosed on all sides by the liquid permeable layer 110 and the liquid impermeable layer 104.

[0038] The diaper 100 has a front end 204 and a back end 206 and the liquid permeable layer 110 and the liquid impermeable layer 104 extend from the front end to the back end. The diaper 100 also has a crotch portion 209 between the front end 204 and the back end 206 and the back end 206 includes an upper portion 208 opposite the crotch portion 209. In some embodiments, the container 106 is disposed proximate the upper portion 208 of the back end 206, substantially in the back half 211 of diaper 100 as defined by midline 210. Positioning the container 106 proximate the upper portion 208 of the back end 206 provides easy access to the container 106 for the user or caregiver, is comfortable for the wearer, and keeps the container from interfering with the absorbent function of the diaper 100.

[0039] In a preferred embodiment, the container 106 is positioned substantially in the back half 211 or the back end of the diaper 100, as depicted in FIG. 2. In alternative embodiments, the container 106 is positioned substantially in the front half 212 or front end 204 of the diaper 100. In alternative embodiments, the container 106 is disposed proximate the upper portion 213 of the front end 204, substantially in the front half 212 of diaper 100 as defined by midline 210. The container 106 may be positioned in both the front half 212 or front end 204 and the back half 211 or back end 206. The seal 112 of the container 106 may be positioned at an edge 214 of the container 106 proximal to the upper portion 208 in the back end 206 of the diaper 100. The seal 112 of the container 106 may be positioned at an edge 215 of the container 106 proximal to the front end 204 of the diaper 100. The seal 112 of the container 106 may be positioned at an edge of the container facing the “left” or “right” sides of the diaper.

[0040] In some embodiments, the container 106 has a substantially square shape. In other embodiments, the container 106 has a substantially rectangular shape. In other embodiments, the container 106 is shaped like an irregular polygon having angles other than 90 degrees. In other embodiments, the container 106 has a triangular shape, circular shape, or any suitable shape for integration within the layers of a diaper.

[0041] FIG. 3 is a schematic of a container 106 for inclusion in diaper 100. The container 106 includes wipes 302. In some embodiments, the area of weakness 114 is positioned proximal to the seal 112 of the container 106 such that an overlap 304 exists that prevents moisture from bypassing the liquid impermeable layer through the area of weakness.

[0042] FIG. 4 is a perspective view of a diaper 100 having back end 206 and front end 204. Fasteners or tabs 202 secure the diaper 100 to the wearer. When secured to the wearer, diaper 100 forms leg holes 402. Container 106 is sandwiched between the layers of diaper 100, containing wipes 302. Area of weakness 114 is depicted in a closed or untom configuration.

[0043] FIG. 5 is a perspective view of the diaper 100 of FIG. 4 with area of weakness 114 depicted in an open or tom configuration, with wipes 302 accessible and removable from container 106.

[0044] Methods for Producing Diapers Having Integrated Containers

[0045] Methods for producing diapers having integrated containers are also disclosed herein. In one aspect, the method includes providing any one of the diapers or layers as described herein. In some embodiments, the method includes providing a liquid impermeable layer; positioning a container adjacent the liquid impermeable layer; positioning an absorbent core adjacent the liquid impermeable layer; positioning a liquid permeable layer adjacent the absorbent core and the container such that the absorbent core and the container are disposed between the liquid impermeable layer and the liquid permeable layer, and the liquid permeable layer, liquid impermeable layer, and the absorbent core are arranged to form a layered stack; and forming the diaper from the layered stack.

[0046] In some embodiments, the step of forming the diaper further comprises adhering the liquid permeable layer to the liquid impermeable layer and the container to at least one of the liquid impermeable layer or the liquid permeable layer.

[0047] In some embodiments, the step of forming the diaper comprises forming a front end and a back end such that the liquid permeable layer and the liquid impermeable layer extend from the front end to the back end and the step of positioning the container comprises disposing the container at the back end.

[0048] In some embodiments, the step of forming the diaper comprises forming a front end and a back end such that the liquid permeable layer and the liquid impermeable layer extend from the front end to the back end and the step of positioning the container comprises disposing the container at the front end.

[0049] In some embodiments, step of forming the diaper further comprises forming a crotch portion between the front end and the back end, the back end including an upper portion opposite the crotch portion, and the step of positioning the container comprises disposing the container proximate the upper portion of the back end.

[0050] In some embodiments, step of forming the diaper further comprises forming a crotch portion between the front end and the back end, the front end including an upper portion opposite the crotch portion, and the step of positioning the container comprises disposing the container proximate the upper portion of the front end.

[0051] In some embodiments, the method of forming the diaper further comprises forming an area of weakness in the liquid impermeable layer proximate the container for creating a port to access the container.

[0052] In some embodiments, the method of forming the diaper further comprises forming an area of weakness in the liquid impermeable layer proximate the container for creating a port to access the container. In some embodiments, the step of forming the area of weakness comprises forming a perforation in the liquid impermeable layer. In some embodiments, the container includes a seal and the step of positioning the container further comprises positioning the seal of the container proximal to the area of weakness in the liquid impermeable layer.

[0053] In some embodiments, the step of forming the diaper includes shaping the layered stack after it has been formed. In other embodiments, each layer in the layered stack is shaped prior to positioning the layers.

[0054] As used herein, “shaping” the diaper and/or layers refers to cutting, forming, or otherwise changing the shape of the diaper, layered stack, and/or layers into the final diaper shape. Shaping may refer to a punch, where a die in the desired shape is used to cut through one or more layers to produce a layer or layered stack having the desired shape. Any suitable means of shaping the layers and/or diaper may be used. [0055] In some embodiments, the container includes a seal, and the step of positioning the container on the liquid impermeable layer further includes positioning the seal of the container proximal to a port or an area of weakness, such as a perforation, in the liquid impermeable layer.

[0056] In some embodiments, the method includes applying an adhesive to the layered stack before each subsequent layer is positioned. In some embodiments, the step of applying an adhesive further includes curing the adhesive by heat and/or pressure. In some embodiments, the diaper layers may be sealed together using an adhesive, heat sealing, ultrasonic bonding, or the like, or combinations thereof.

[0057] Disposable diapers and methods for producing disposable diapers have been provided. The diapers include an integrated container for holding contents, such as wet wipes. The container is a separate, independent layer that is accessed through a perforation in the liquid impermeable layer, rather than a pocket formed in the liquid impermeable layer itself. This reduces the complexity of the diaper, reduces modifications needed in existing diaper production systems, and reduces the likelihood of failure of the container in use.

[0058] While the disclosure has been described with reference to a number of embodiments, it will be understood by those skilled in the art that the disclosure is not limited to such embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not described herein, but which are commensurate with the spirt and scope of the disclosure. Conditional language used herein, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, generally is intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements or functional capabilities. Additionally, while various embodiments of the disclosure have been described, it is to be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure it not to be seen as limited by the foregoing described, but is only limited by the scope of the appended claims.