US3339548A - Diaper contoured by shrinking - Google Patents

Diaper contoured by shrinking Download PDF

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US3339548A
US3339548A US362785A US36278564A US3339548A US 3339548 A US3339548 A US 3339548A US 362785 A US362785 A US 362785A US 36278564 A US36278564 A US 36278564A US 3339548 A US3339548 A US 3339548A
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diaper
fabric
sections
yarns
medial section
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US362785A
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Norman L Seltzer
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Kendall Co
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Kendall Co
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    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/45Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
    • A61F13/49Absorbent articles specially adapted to be worn around the waist, e.g. diapers
    • A61F13/49003Reusable, washable fabric diapers

Definitions

  • the present invention relates to diapers and more particularly to diapers which are contoured along side edges thereof to provide a better and more comfortable fit for a wearer. Still more particularly, the present invention relates to such contour diapers which have substantial lateral stretchability and recoverability.
  • Diapers have been formed for many years from sheets of fabric material of either single layer or multi-layer construction by folding these sheets into a rectangular configuration.
  • certain diapers normally referred to as prefold diapers and which are becoming increasingly popular, the folded fabric is secured in the rectangular configuration by stitching the layers thereof together.
  • Such conventional diapers are relatively inexpensive to manufacture, have high absorptive capacity, easy cleanability and various other well-known desirable characteristics.
  • Another object of the present invention is to provide a diaper which is so constructed that when the same is washed or laundered, as is usually done with new diapers
  • a further object of the present invention is to provide a novel diaper of the character described which has substantial stretchability and recoverability laterally thereof for further enhancing the fit of the diaper on a wearer.
  • FIGURE 1 is a plan view of a diaper according to the present invention in unfolded condition
  • FIGURE 2 is a somewhat schematic sectional view taken substantially along line 22 in FIGURE 1;
  • FIGURE 3 is a plan view of the diaper in folded condition before shrinkage thereof;
  • FIGURE 4 is a plan view of the diaper shown in FIG- URE 3 after being shrunk;
  • FIGURE 5 is a plan view of another form of dia-per in unfolded condition and incorporating the features of the present invention.
  • FIGURE 6 is a perspective view of the diaper shown in FIGURE 5 in folded condition and before shrinkage ing longitudinally in a fillingwise direction between selvages 12 and 13 at opposite ends of diaper blank 10; a pair of elongate intermediate or pinning bar section or panels 14 and 15 disposed on opposite sides of and interwoven with medial section 11 and also extending between selvages 12 and 13; and a pair of elongate non-raveling or pinking bar sections or panels 16 and 17 disposed on opposite sides of and interwoven with pinning bar sections 14, 15 and defining opposite side edges of diaper blank 10.
  • Diaper blank 10 is formed of a fabric of interwoven sets of warp and filling yarns and which is preferably of m'ulti-layer construction to provide the desired absorbency and softness.
  • medial section 11 is preferably formed of three layers of fabric 20, 21 and 22 (FIG- URE 2) woven together at least at selvages 12 and 13 and at opposite sides of medial section 11 where the same is joined to pinning bar sections 14 and 15.
  • pinning bar sections 14 and 15 preferably comprise two layers of fabric 23, 24 and 25, 26, respectively, the layers of each pinning bar section being woven together at selvages 12 and 13 and to one side of medial section 11 and to one of the pinking bar sections 16 and 17.
  • Pinking bar sections 16 and 17 are preferably of single layer construction and have the outer side edges thereof pinked to resist raveling.
  • a band 27 of reinforcing warp yarns extends transversely of the central portion of diaper blank 10 and is interwoven with the sections thereof.
  • Band 27 defines a fold area along which diaper blank 10 is adapted to be folded to superpose opposite halves thereof and to form an elongate folded diaper 30 (FIGURE 3) which is preferably secured to this folded condition by spaced lines of longitudinally extending stitching 31, 32.
  • the fabric forming diaper 30 can be woven in such a manner and of such warp and/or filling yarns that the aforesaid contour can be provided therein at no appreciable increase in the cost of manufacture thereof over conventional non-contour diapers of comparable layer construction, and also without any decrease in absorbency thereof, and without any material wrinkling or puckering of the fabric thereof.
  • This contour is achieved by weaving the fabric so that at least the fabric layers forming medial section 11 of diaper 30 are shrinkable laterally of the diaper to reduce the width thereof and to drawn in opposite side edges thereof to impart a concave configuration thereto.
  • This shrinkability in at least the medial section 11 of diaper 30 is preferably achieved by having at least those yarns, preferably the filling yarns, extending transversely of medial section 11 of water-swellable cellulosic material such that the fabric including the same shrinks in the direction of these yarns upon being subjected to a conventional washing or laundering process, which is usually done before new diapers are used to enhance the softness thereof.
  • such yarns, as originally woven into the fabric have a high twist multiple within the range of 4.50 to 7.50 to enhance this shrinkability of the fabric. More preferably, these filling yarns are of cotton or high wet modulus rayon and have a twist multiple within the range of about 5.50 to about 6.75 for good shrinkage characteristics while still having good absorbency, softness and economic feasibility.
  • all of the sections of diaper 30 are woven in the above set forth manner utilizing the same filling yarns throughout the diaper for economy in the manufacture thereof. Therefore, all sections of diaper 30 are shrinkable laterally thereof, but medial section 11 is woven so as to have greater shrinkability than the remaining sections thereof.
  • This greater shrinkability in the layers of fabric in medial section 11 is provided by each of these fabric layers 20, 21, 22, as originally woven, having less yarn interlacings per inch than each of the fabric layers 23, 24, and 25, 26 of pinning bar sections 14 and 15, and the single layer of each of the pinking bar sections 16, 17, as originally woven.
  • the pinning bar sections or panels are preferably woven with less yarn interlacings per inch than the pinking bar sections or panels for greater shrinkability therein.
  • an example of a fabric construction providing these varied yarn interlacings per inch in the various sections of the diaper would be a fabric having a warp end count of 32 and filling pick count of 46 in each of the layers 20, 21, 2,2 of medial section or panel 11; a warp end count of 48 and filling pick count of 32 in each of the layers 23, 24, 25, 26 of the pinning bar sections or panels; and a warpend count of 96 and filling pick count of 64 in each of the pinking bar sections or panels 16, 17. It is noted that this fabric construction provides a greater total number of yarns in medial section 11 of the diaper than in the remaining sections for providing greater absorbency therein, where the same is most needed. It should be understood that this fabric construction is one example only and many fabric constructions within the purview of the foregoing description may be used without departing from the scope of the present invention.
  • the wrap yarns in the fabric of diaper 30 are also preferably of cellulose material, such as cotton or high wet modulus rayon, for absorbency and economic reasons.
  • these warp yarns have a standard twist multiple providing lower twist therein than in the filling yarns to provide a softer fabric.
  • the medial section 11 preferably has a dimension longitudinally of the diaper no greater than two-thirds of the overall length of the diaper.
  • this fabric After originally weaving the fabric of diaper 30 in the manner set forth above for providing the aforesaid contour therein, but before separating the same into diaper blanks 10, this fabric preferably is drawn warpwise through a caustic treating bath with no appreciable fillingwise tension therein.
  • This caustic treatment increases the normal sinuosity of the filling yarns in the fabric to a degree such that the fabric has substantial stretchability and a high degree of inherent recoverability in the fillingwise direction.
  • this stretchability may be characterized as easy stretchability wherein a relatively small force will cause the fabric to stretch as compared with prior stretchable fabrics having elastomeric or rubber yarns therein, and also, this inherent recoverability is also slower or easier than in such prior stretchable fabrics which is desirable for comfort to a wearer.
  • diaper 30 formed therefrom has substantial lateral stretchability and recoverability which, for example, readily permits distention .and contraction of the badys abdomen without binding or becoming undesirably loose and, hence, provides a better and more comfortable fit for a wearer of the diaper. It is further to be noted that the lateral shrinking of diaper 30 upon laundering thereof to impart the aforesaid contour thereto, enhances the sinuosity of the filling yarns, and hence, the lateral stretchability of the diaper, by causing these yarns to recover from an elongated or stretched condition if the same have not previously recovered therefrom.
  • FIGURES 5-9 of the drawings there is shown another form of diaper, generally indicated at 40, which is formed in similar manner to diaper 30 to be shrinkable to provide the aforesaid contour therein and to have substantial stretchability and recoverability for the reasons set forth above.
  • Diaper 40 differs from diaper 30 primarily in the layer construction of the fabric and the manner of folding the same to form the diaper.
  • a diaper blank 41 (FIGURE 5) is provided which includes an elongate medial section or panel 42 preferably extending longitudinally between selvages 43, 44; and elongate intermediate sections or panels 45, 46 on opposite sides of and interwoven with the medial section 42 and likewise extending between selvages 43, 44.
  • medial section 42 is preferably of two-layer fabric construction throughout, and intermediate sections 45, 46 are preferably of single layer construction throughout.
  • a pair of spaced bands 47, 50 (FIGURE 5) of reinforcing Warp yarns extend transversely of and are interwoven with the sections of diaper blank 41.
  • Bands 47, 50 define fold areas along with diaper blank 41 is adapted to be folded to form diaper 40, in which bands 47, 50 define reinforced side edges and the medial and intermediate sections extend laterally between these reinforced side edges.
  • This folding of diaper blank 41 to form diaper 40 provides therein a longitudinally extending central portion which comprises three superposed two-layer portions 51, 52 and 53 (FIGURE 7) in medial section 42 and three superimposed single layer portions, 54, 55 and 56 (FIG- URE 8) in each of the intermediate sections 45, 46.
  • longitudinally extending side portions of diaper 40 are provided on opposite sides of the aforementioned central portion and each comprises a pair of superposed twolayer portions 60, 61 (FIGURE 7) in medial section 42, and a pair of superposed single layer portions 62, 63 (FIGURE 8) in each of the intermediate sections 45, 46.
  • Diaper 40 is preferably secured in this folded condition by spaced lines of stitching 64,65 extending longitudinally of and adjacent the sides of the central portion thereof and by overedge stitching 66, 67 across opposite ends thereof, which overedge stitching also prevent raveling and define non-raveling end sections.
  • the fabric forming diaper 40 is originally woven to be shrinkable with greater shrinkability in medial section 42 than in intermediate sections 45, 46 and non-raveling end sections 66, 67.
  • the differential shrinkability is preferably provided in the same manner as in diaper 30 as described above and, hence, this description will not be repeated.
  • diaper 40 has substantial stretchability and recoverability laterally thereof which is also provided therein in the same manner as described above in connection with diaper 30. Therefore, when diaper 40 is laundered in conventional manner, the fabric thereof will shrink with medial section 42 shrinking a greater amount later-ally of diaper 40 than intermediate sections 45, and 46 and non-raveling end sections 66, 67. This shrinkage is accomplished without appreciable increased cost, without reduced the absorbency thereof, and without material wrinkling or puckering of the fabric.
  • FIGURE 9 Such a shrunken diaper 40' is illustrated in FIGURE 9 and it is readily apparent that the reinforced side edges 47', 50 thereof have a concave configuration imparted thereto.
  • medial section 42 preferably has a dimension longitudinally of diaper 40 no greater than two-thirds of the-overall length of the diaper to enhance the contour effect imparted thereto.
  • the present invention provides novel stretchable contour diapers having the desirable characteristics of conventional non-contour diapers, but wherein the width of material in the medial sections thereof is reduced without reducing the absorbency thereof, without material wrinkling or puckering of the fabric therein, and without materially increasing the cost of manufacture thereof.
  • An elongate, interwoven, multi-layer, absorbent diaper comprising'non-raveling sections defining opposite ends of the diaper, intermediate sections between and connected-to said non-raveling sections, and a medial section between said intermediate sections and connected thereto, said diaper sections each comprising layers of fabric each formed of interwoven sets of warp and filling yarns, one set of said yarns being cellulosic and extending laterally of said diaper andat least in said medial section, asoriginally woven in the fabric, having a high twist with the twist multiple thereof being between 4.50 and 7.50 to enhance the shrinkability thereof, each of the layers of fabric in said medial section, as originally woven, having less yarn interlacings per inch than each layer of fabric in said non-raveling and intermediate sections, and said fabric of the diaper being shrinkable with fabric in said medial section having greater shrinkability in the direction of said one set of yarns than the fabric in said non-raveling and intermediate sections to provide a concave curvature to opposite side edges of the diaper
  • An elongate, interwoven, multi-layer, asborbent diaper comprising non-raveling sections defining opposite ends of the diaper, inter-mediate sections between and connected to said non-raveling sections, and a medial section between said intermediate sections and connected thereto, said diaper sections each comprising; layers of fabric each formed of interwoven sets of warp and filling yarns of a cellulosic material selected from the group consisting of cotton and high wet modulus rayon, said filling yarns extending laterally of said diaper and, as originally woven in said fabric, having a high twist with the twist multiple thereof being between about 5.50 and about 6.75 and having less interlacings per inch with said Warp yarns in each layer of fabric in said medial section than in each layer of fabric in said non-raveling and intermediate sections, and said fabric of the diaper being shrinkable with the fabric in said medial section having greater shrinkability in the fillingwise direction than the fabric in said non-raveling and intermediate sections of said diaper to provide a concave curvature to opposite side
  • nonraveling sections comprise elongate pinking bar panels having the outer side edges thereof pinked to prevent raveling.
  • nonraveling sections comprise over-edge stitched end sections of the diaper.
  • An elongate, interwoven, multi-layer, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising non-raveling sections defining opposite ends of the diaper, intermediate sections between and connected to said non-raveling sections and a medial section between and connected to said intermediate sections, said diaper sections each comprising layers of fabric each formed of a set of warp yarns interwoven with a set of filling yarns, one set of said yarns extending laterally of the diaper, and at least in said medial section having a high twist with the twist multiple thereof being between 4.50 and 7.50 as originally woven into the fabric, and each of the layers of fabric in said medial section, as originally woven, having less yarn interlacings per inch than each layer of fabric in said nonraveling and intermediate sections, and said diaper being shrunk at least in the lateral direction thereof with the fabric in said medial section being shrunk a greater amount than the fabric in said non-raveling and intermediate sections and providing
  • An elongate, interwoven, multi-layer, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising non-raveling sections defining opposite ends of the diaper, intermediate sections between and connected to said non-raveling sections, and a medial section between and connected to said intermediate sections, said diaper sections each comprising layers of fabric each formed of a set of cellulosic warp yarns interwoven with a set of cellulosic filling yarns, said filling yarns extending laterally of said diaper between side edges thereof and, as originally Woven in the fabric, having a high twist with the twist multiple thereof being between 4.50 and 7.50 and having less interlacings per inch with said warp yarns in each of the layers of fabric in said medial section than in each of the layers of fabric in said non-raveling and intermediate sections, and said fabric of said diaper being shrunk with the fabric in said medial section having said less yarn interlacings per inch being shrunk a greater
  • An elongate, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising a pair of spaced apart, elongate pinking bar panels defining opposite ends of the diaper and having the outer side edges thereof pinked to prevent raveling, a pair of elongate intermediate pinning bar panels between and interwoven with said pinking bar panels, and a medial panel between and interwoven with said pinning bar panels, each of said panels having a plurality of layers of fabric formed of sets of interwoven cotton warp and filling yarns, said medial panel having a greater number of layers of fabric therein than said pinning bar panels, said pinning bar panels having a greater number of layers of farbic therein than said pinking bar panels, each layer of fabric in said medial panel, as originally woven, having less yarn interlacings per inch and less fabric density than each layer of fabric in said pinning bar panels, each layer of fabric in said pinning bar panels, as originally woven,
  • An elongate, multi-layer, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising over-edge stitched end sections defining opposite ends of the diaper, intermediate sections between and interwoven with said end sections, and a medial section between and interwoven with said inter.- mediate sections, said diaper sections each comprising layers of fabric each formed of sets of interwoven cotton warp and filling yarns, said medial sections having a greater number of layers of fabric than said intermediate and end sections, the central portion of said medial section having a greater number of layers of fabric therein than the side portions of said medial section, the central portions of said intermediate and end sections having a greater number of layers of fabric therein than the side portions of said intermediate and end sections, said filling yarns extending transversely of said diaper between side edges thereof and, as originally woven in the fabric, having a twist multiple between about 5.50 and about 6.75 and having less interlacings per inch with said warp yarns in each of the
  • An elongate, interwoven multilayer absorbent diaper comprising non-raveling sections defining opposite ends of the diaper, intermediate sections betwen and connected to said non-raveling sections, and a medial section between said intermediate sections and connected thereto, said diaper sections each comprising layers of fabric each formed of interwoven sets of warp and filling yarns, one set of said warp and filling yarns extending laterially of said diaper and being formed of cellulosic material, said one set of yarns at least in said medial section, as originally woven in the fabric, having a high twist with the twist multiple thereof being between 4.50 and 7.50 to enhance the shrinkability thereof, the other set of yarns, as originally woven in the fabric, having less yarns per inch in each of the layers of fabric in said medial section than in each layer of fabric in said non-raveling and intermediate sections, and said fabric of the diaper being shrinkable with the fabric in said medial sections having greater shrinkability in the direction of said one set of yarns than the fabric in said non-raveling and intermediate

Description

N. L. SELTZER Sept. 5, 1967 SHRINKYNG DIAPER CONTOURED BY 2 Sheets-Shem '1 Filed April 2'7, 1964 mm BAN 4;
p 5, 1967 N. L SELTZER 3,339,548
DIAPER CONTOURED BY SHRINKING Filed April 27, 1964 2 Sheets-Sheet 23 gt l WARPW SE- Q] bA o' INVENTORZ NORMAN L. SELTZER J BWM MW' ATTORNEYS United States Patent 3,339,548 DIAPER CONTOURED BY SHRINKING Norman L. Seltzer, Princeton, N.J., assignor to The Kendall Company, Boston, Mass, a corporation of Massachusetts Filed Apr. 27, 1964, Ser. No. 362,785 16 Claims. (Cl. 128284) The present invention relates to diapers and more particularly to diapers which are contoured along side edges thereof to provide a better and more comfortable fit for a wearer. Still more particularly, the present invention relates to such contour diapers which have substantial lateral stretchability and recoverability.
Diapers have been formed for many years from sheets of fabric material of either single layer or multi-layer construction by folding these sheets into a rectangular configuration. In certain diapers, normally referred to as prefold diapers and which are becoming increasingly popular, the folded fabric is secured in the rectangular configuration by stitching the layers thereof together. Such conventional diapers are relatively inexpensive to manufacture, have high absorptive capacity, easy cleanability and various other well-known desirable characteristics.
However, when such conventional diapers are applied to infants, the medial portions thereof lie between the infants legs and the Width of the diaper material in these medial portions tends to spread the legs of the infants into unnatural positions. Also, such conventional diapers become greatly wrinkled or puckered in their medial portions when being worn, which wrinkles or puckers are a source of irritation to the wearers and are subject to excessive wear.
Various attempts have been made to solve the problems encountered in the use of such conventional diapers, but all of these attempts have been unsuccessful. One example of such an attempt is a contour diaper formed by cutting, folding and stitching the diaper fabric in such a manner that the side edge portions of the diaper have a concave configuration. This contour diaper, however, has several deficiencies, one of which is the irritation of the skin of the wearer by the sewn cut edges defining the contou-r areas. Another deficiency of this prior contour diaper is that the cutting, folding and sewing thereof is quite time consuming and laborious and, therefore, this diaper is considerably more expensive to manufacture than corresponding non-contour diapers.
Another example of a prior contour diaper is shown in United States Patent No. 2,866,459 to Sobelson and comprises a folded diaper which has transversely extending elastic stitching the medial portion thereof, which stitching was initially placed therein in a stretched condition, and then permitted to relax and draw in the side edges of the medial portion to impart a concve configuration thereto. However, this drawing in of the diaper material by the elastic stitching results in considerable wrinkling of the diaper fabric which is undesirable since it irritates the wearer and is subject to excessive wear. Also, the elastic stitching becomes brittle and frequently breaks after only a few launderings of the diaper. Further, this elastic stitching is relatively expensive and the stitching operation is also time consuming and laborious and, hence, the resulting diaper is expensive.
With the foregoing in mind, it is an object of the present invention to provide a novel contour diaper having the desirable characteristics of conventional non-contour diapers of corresponding layer construction and wherein the aforementioned deficiencies of prior contour diapers are obviated.
Another object of the present invention is to provide a diaper which is so constructed that when the same is washed or laundered, as is usually done with new diapers A further object of the present invention is to provide a novel diaper of the character described which has substantial stretchability and recoverability laterally thereof for further enhancing the fit of the diaper on a wearer.
Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which- FIGURE 1 is a plan view of a diaper according to the present invention in unfolded condition;
FIGURE 2 is a somewhat schematic sectional view taken substantially along line 22 in FIGURE 1;
FIGURE 3 is a plan view of the diaper in folded condition before shrinkage thereof;
FIGURE 4 is a plan view of the diaper shown in FIG- URE 3 after being shrunk;
FIGURE 5 is a plan view of another form of dia-per in unfolded condition and incorporating the features of the present invention;
FIGURE 6 is a perspective view of the diaper shown in FIGURE 5 in folded condition and before shrinkage ing longitudinally in a fillingwise direction between selvages 12 and 13 at opposite ends of diaper blank 10; a pair of elongate intermediate or pinning bar section or panels 14 and 15 disposed on opposite sides of and interwoven with medial section 11 and also extending between selvages 12 and 13; and a pair of elongate non-raveling or pinking bar sections or panels 16 and 17 disposed on opposite sides of and interwoven with pinning bar sections 14, 15 and defining opposite side edges of diaper blank 10.
Diaper blank 10 is formed of a fabric of interwoven sets of warp and filling yarns and which is preferably of m'ulti-layer construction to provide the desired absorbency and softness. In this respect, medial section 11 is preferably formed of three layers of fabric 20, 21 and 22 (FIG- URE 2) woven together at least at selvages 12 and 13 and at opposite sides of medial section 11 where the same is joined to pinning bar sections 14 and 15. Also, pinning bar sections 14 and 15 preferably comprise two layers of fabric 23, 24 and 25, 26, respectively, the layers of each pinning bar section being woven together at selvages 12 and 13 and to one side of medial section 11 and to one of the pinking bar sections 16 and 17. Pinking bar sections 16 and 17 are preferably of single layer construction and have the outer side edges thereof pinked to resist raveling.
Preferably, a band 27 of reinforcing warp yarns extends transversely of the central portion of diaper blank 10 and is interwoven with the sections thereof. Band 27 defines a fold area along which diaper blank 10 is adapted to be folded to superpose opposite halves thereof and to form an elongate folded diaper 30 (FIGURE 3) which is preferably secured to this folded condition by spaced lines of longitudinally extending stitching 31, 32.
It has been determined that the fabric forming diaper 30 can be woven in such a manner and of such warp and/or filling yarns that the aforesaid contour can be provided therein at no appreciable increase in the cost of manufacture thereof over conventional non-contour diapers of comparable layer construction, and also without any decrease in absorbency thereof, and without any material wrinkling or puckering of the fabric thereof. This contour is achieved by weaving the fabric so that at least the fabric layers forming medial section 11 of diaper 30 are shrinkable laterally of the diaper to reduce the width thereof and to drawn in opposite side edges thereof to impart a concave configuration thereto. This shrinkability in at least the medial section 11 of diaper 30 is preferably achieved by having at least those yarns, preferably the filling yarns, extending transversely of medial section 11 of water-swellable cellulosic material such that the fabric including the same shrinks in the direction of these yarns upon being subjected to a conventional washing or laundering process, which is usually done before new diapers are used to enhance the softness thereof. Also, such yarns, as originally woven into the fabric, have a high twist multiple within the range of 4.50 to 7.50 to enhance this shrinkability of the fabric. More preferably, these filling yarns are of cotton or high wet modulus rayon and have a twist multiple within the range of about 5.50 to about 6.75 for good shrinkage characteristics while still having good absorbency, softness and economic feasibility.
Preferably, all of the sections of diaper 30 are woven in the above set forth manner utilizing the same filling yarns throughout the diaper for economy in the manufacture thereof. Therefore, all sections of diaper 30 are shrinkable laterally thereof, but medial section 11 is woven so as to have greater shrinkability than the remaining sections thereof. This greater shrinkability in the layers of fabric in medial section 11 is provided by each of these fabric layers 20, 21, 22, as originally woven, having less yarn interlacings per inch than each of the fabric layers 23, 24, and 25, 26 of pinning bar sections 14 and 15, and the single layer of each of the pinking bar sections 16, 17, as originally woven. In addition, the pinning bar sections or panels are preferably woven with less yarn interlacings per inch than the pinking bar sections or panels for greater shrinkability therein.
In a plain weave construction, which is preferred for all sections of diaper 30, an example of a fabric construction providing these varied yarn interlacings per inch in the various sections of the diaper would be a fabric having a warp end count of 32 and filling pick count of 46 in each of the layers 20, 21, 2,2 of medial section or panel 11; a warp end count of 48 and filling pick count of 32 in each of the layers 23, 24, 25, 26 of the pinning bar sections or panels; and a warpend count of 96 and filling pick count of 64 in each of the pinking bar sections or panels 16, 17. It is noted that this fabric construction provides a greater total number of yarns in medial section 11 of the diaper than in the remaining sections for providing greater absorbency therein, where the same is most needed. It should be understood that this fabric construction is one example only and many fabric constructions within the purview of the foregoing description may be used without departing from the scope of the present invention.
However, such a fabric construction having progressively increasing interlacings per inch in the layers of fabric from the medial section outwardly to the pinking bar sections is particularly preferred since the same not only provides medial section or panel 11 with greater shrinkability than pinning bar sections or panels 14, 15, but also provides pinning bar sections or panels 14, 15 with greater shrinkability than pinking bar sections or panels 16, 17. Therefore, upon shrinking of diaper 30, a pronounced contour is provided therein, as is illustrated in FIGURE 4 which shows a diaper 30' in which the concave configuration imparted to opposite sides edges is readily seen.
While not necessary, the wrap yarns in the fabric of diaper 30 are also preferably of cellulose material, such as cotton or high wet modulus rayon, for absorbency and economic reasons. However, these warp yarns have a standard twist multiple providing lower twist therein than in the filling yarns to provide a softer fabric. Further, to enhance the contour effect imparted to diaper 30 upon washing thereof, the medial section 11 preferably has a dimension longitudinally of the diaper no greater than two-thirds of the overall length of the diaper. This assures that the greater shrinkage in the medial section of the diaper is provided in the portion thereof which will lie between the wearers legs, which is the portion of the diaper wherein the width of material is desired to be reduced, and avoids an undue or undesirable shortening of the waist encircling portion of the diaper.
After originally weaving the fabric of diaper 30 in the manner set forth above for providing the aforesaid contour therein, but before separating the same into diaper blanks 10, this fabric preferably is drawn warpwise through a caustic treating bath with no appreciable fillingwise tension therein. This caustic treatment increases the normal sinuosity of the filling yarns in the fabric to a degree such that the fabric has substantial stretchability and a high degree of inherent recoverability in the fillingwise direction. It is noted that this stretchability may be characterized as easy stretchability wherein a relatively small force will cause the fabric to stretch as compared with prior stretchable fabrics having elastomeric or rubber yarns therein, and also, this inherent recoverability is also slower or easier than in such prior stretchable fabrics which is desirable for comfort to a wearer.
Therefore, diaper 30 formed therefrom has substantial lateral stretchability and recoverability which, for example, readily permits distention .and contraction of the badys abdomen without binding or becoming undesirably loose and, hence, provides a better and more comfortable fit for a wearer of the diaper. It is further to be noted that the lateral shrinking of diaper 30 upon laundering thereof to impart the aforesaid contour thereto, enhances the sinuosity of the filling yarns, and hence, the lateral stretchability of the diaper, by causing these yarns to recover from an elongated or stretched condition if the same have not previously recovered therefrom.
Referring now to FIGURES 5-9 of the drawings, there is shown another form of diaper, generally indicated at 40, which is formed in similar manner to diaper 30 to be shrinkable to provide the aforesaid contour therein and to have substantial stretchability and recoverability for the reasons set forth above. Diaper 40 differs from diaper 30 primarily in the layer construction of the fabric and the manner of folding the same to form the diaper. In this regard, a diaper blank 41 (FIGURE 5) is provided which includes an elongate medial section or panel 42 preferably extending longitudinally between selvages 43, 44; and elongate intermediate sections or panels 45, 46 on opposite sides of and interwoven with the medial section 42 and likewise extending between selvages 43, 44.
As illustrated in FIGURES 7 and 8, medial section 42 is preferably of two-layer fabric construction throughout, and intermediate sections 45, 46 are preferably of single layer construction throughout. Preferably, a pair of spaced bands 47, 50 (FIGURE 5) of reinforcing Warp yarns extend transversely of and are interwoven with the sections of diaper blank 41. Bands 47, 50 define fold areas along with diaper blank 41 is adapted to be folded to form diaper 40, in which bands 47, 50 define reinforced side edges and the medial and intermediate sections extend laterally between these reinforced side edges.
This folding of diaper blank 41 to form diaper 40 provides therein a longitudinally extending central portion which comprises three superposed two- layer portions 51, 52 and 53 (FIGURE 7) in medial section 42 and three superimposed single layer portions, 54, 55 and 56 (FIG- URE 8) in each of the intermediate sections 45, 46. Also, longitudinally extending side portions of diaper 40 are provided on opposite sides of the aforementioned central portion and each comprises a pair of superposed twolayer portions 60, 61 (FIGURE 7) in medial section 42, and a pair of superposed single layer portions 62, 63 (FIGURE 8) in each of the intermediate sections 45, 46. Diaper 40 is preferably secured in this folded condition by spaced lines of stitching 64,65 extending longitudinally of and adjacent the sides of the central portion thereof and by overedge stitching 66, 67 across opposite ends thereof, which overedge stitching also prevent raveling and define non-raveling end sections.
As was the case with diaper 30, the fabric forming diaper 40 is originally woven to be shrinkable with greater shrinkability in medial section 42 than in intermediate sections 45, 46 and non-raveling end sections 66, 67. The differential shrinkability is preferably provided in the same manner as in diaper 30 as described above and, hence, this description will not be repeated. Also, diaper 40 has substantial stretchability and recoverability laterally thereof which is also provided therein in the same manner as described above in connection with diaper 30. Therefore, when diaper 40 is laundered in conventional manner, the fabric thereof will shrink with medial section 42 shrinking a greater amount later-ally of diaper 40 than intermediate sections 45, and 46 and non-raveling end sections 66, 67. This shrinkage is accomplished without appreciable increased cost, without reduced the absorbency thereof, and without material wrinkling or puckering of the fabric.
Such a shrunken diaper 40' is illustrated in FIGURE 9 and it is readily apparent that the reinforced side edges 47', 50 thereof have a concave configuration imparted thereto. As with diaper 30, medial section 42 preferably has a dimension longitudinally of diaper 40 no greater than two-thirds of the-overall length of the diaper to enhance the contour effect imparted thereto.
It will therefore be apparent that the present invention provides novel stretchable contour diapers having the desirable characteristics of conventional non-contour diapers, but wherein the width of material in the medial sections thereof is reduced without reducing the absorbency thereof, without material wrinkling or puckering of the fabric therein, and without materially increasing the cost of manufacture thereof.
In the drawings and specification there have been set forth preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims. g I
g 1. An elongate, interwoven, multi-layer, absorbent diaper comprising'non-raveling sections defining opposite ends of the diaper, intermediate sections between and connected-to said non-raveling sections, and a medial section between said intermediate sections and connected thereto, said diaper sections each comprising layers of fabric each formed of interwoven sets of warp and filling yarns, one set of said yarns being cellulosic and extending laterally of said diaper andat least in said medial section, asoriginally woven in the fabric, having a high twist with the twist multiple thereof being between 4.50 and 7.50 to enhance the shrinkability thereof, each of the layers of fabric in said medial section, as originally woven, having less yarn interlacings per inch than each layer of fabric in said non-raveling and intermediate sections, and said fabric of the diaper being shrinkable with fabric in said medial section having greater shrinkability in the direction of said one set of yarns than the fabric in said non-raveling and intermediate sections to provide a concave curvature to opposite side edges of the diaper after the diaper is shrunk for obtaining a better and more comfortable fit for a wearer.
2. A diaper according to claim 1 wherein said one set of yarns is disposed in a sinuous path with the sinuosity thereof providing lateral stretchability and recoverability in the diaper.
3. A diaper according to claim 1 wherein said medial sections extends uninterruptedly between the side edges of the diaper and each layer of fabric therein is of substantially the same construction throughout.
4. A diaper according to claim 1 wherein both sets of yarns are cellulosic and said one set of yarns is the set of filling yarns.
5. An elongate, interwoven, multi-layer, asborbent diaper comprising non-raveling sections defining opposite ends of the diaper, inter-mediate sections between and connected to said non-raveling sections, and a medial section between said intermediate sections and connected thereto, said diaper sections each comprising; layers of fabric each formed of interwoven sets of warp and filling yarns of a cellulosic material selected from the group consisting of cotton and high wet modulus rayon, said filling yarns extending laterally of said diaper and, as originally woven in said fabric, having a high twist with the twist multiple thereof being between about 5.50 and about 6.75 and having less interlacings per inch with said Warp yarns in each layer of fabric in said medial section than in each layer of fabric in said non-raveling and intermediate sections, and said fabric of the diaper being shrinkable with the fabric in said medial section having greater shrinkability in the fillingwise direction than the fabric in said non-raveling and intermediate sections of said diaper to provide a concave curvature to opposite side edges of the diaper after the diaper is shrunk for obtaining a better and more comfortable fit for a wearer.
6. A diaper according to claim 5 wherein said medial section has a dimension longitudinally of the diaper no greater than two-thirds of the over-all length of the diaper to enhance the contour thereof upon shrinkage.
7. A diaper according to claim 5 wherein said medial section has a greater number of layers of fabric therein than said non-raveling and intermediate sections and each layer of fabric in said medial section, as orginally woven, has less fabric density than each layer of fabric in said non-raveling and intermediate sections.
8. A diaper according to claim 5 wherein said nonraveling sections comprise elongate pinking bar panels having the outer side edges thereof pinked to prevent raveling.
9. A diaper according to claim 5 wherein said nonraveling sections comprise over-edge stitched end sections of the diaper.
10. An elongate, interwoven, multi-layer, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising non-raveling sections defining opposite ends of the diaper, intermediate sections between and connected to said non-raveling sections and a medial section between and connected to said intermediate sections, said diaper sections each comprising layers of fabric each formed of a set of warp yarns interwoven with a set of filling yarns, one set of said yarns extending laterally of the diaper, and at least in said medial section having a high twist with the twist multiple thereof being between 4.50 and 7.50 as originally woven into the fabric, and each of the layers of fabric in said medial section, as originally woven, having less yarn interlacings per inch than each layer of fabric in said nonraveling and intermediate sections, and said diaper being shrunk at least in the lateral direction thereof with the fabric in said medial section being shrunk a greater amount than the fabric in said non-raveling and intermediate sections and providing a concave curvature to opposite side edges of the diaper to provide the aforesaid contour therein.
11. An elongate, interwoven, multi-layer, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising non-raveling sections defining opposite ends of the diaper, intermediate sections between and connected to said non-raveling sections, and a medial section between and connected to said intermediate sections, said diaper sections each comprising layers of fabric each formed of a set of cellulosic warp yarns interwoven with a set of cellulosic filling yarns, said filling yarns extending laterally of said diaper between side edges thereof and, as originally Woven in the fabric, having a high twist with the twist multiple thereof being between 4.50 and 7.50 and having less interlacings per inch with said warp yarns in each of the layers of fabric in said medial section than in each of the layers of fabric in said non-raveling and intermediate sections, and said fabric of said diaper being shrunk with the fabric in said medial section having said less yarn interlacings per inch being shrunk a greater amount in the filling direction than the fabric in said non-raveling and intermediate sections and providing a concave curvature to opposite side edges of the diaper to provide the aforesaid contour therein.
12. A diaper according to claim 11 wherein said filling yarns are disposed in a sinuous path with the sinuosity thereof providing lateral stretchability and recoverability in the diaper.
13. An elongate, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising a pair of spaced apart, elongate pinking bar panels defining opposite ends of the diaper and having the outer side edges thereof pinked to prevent raveling, a pair of elongate intermediate pinning bar panels between and interwoven with said pinking bar panels, and a medial panel between and interwoven with said pinning bar panels, each of said panels having a plurality of layers of fabric formed of sets of interwoven cotton warp and filling yarns, said medial panel having a greater number of layers of fabric therein than said pinning bar panels, said pinning bar panels having a greater number of layers of farbic therein than said pinking bar panels, each layer of fabric in said medial panel, as originally woven, having less yarn interlacings per inch and less fabric density than each layer of fabric in said pinning bar panels, each layer of fabric in said pinning bar panels, as originally woven, having less yarn interlacings per inch and less fabric density than each layer of fabric in said pinking bar panels, said filling yarns extending transversely of said diaper between side edges thereof, and, as originally woven in the fabric, having a twist multiple between about 5.50 and about 6.75, and said diaper being shrunk with the fabric in said medial panel being shrunk a greater amount in the filling directions than the fabric in said pinning bar panels and with the fabric in said pinning bar panels being shrunk a greater amount in the filling direction than the fabric in said pinking bar panels and providing a concave curvature in opposite side edges of the diaper to provide the aforesaid contour therein.
14. An elongate, multi-layer, absorbent diaper characterized by being contoured along side edges thereof to provide a better and more comfortable fit for a wearer, said diaper comprising over-edge stitched end sections defining opposite ends of the diaper, intermediate sections between and interwoven with said end sections, and a medial section between and interwoven with said inter.- mediate sections, said diaper sections each comprising layers of fabric each formed of sets of interwoven cotton warp and filling yarns, said medial sections having a greater number of layers of fabric than said intermediate and end sections, the central portion of said medial section having a greater number of layers of fabric therein than the side portions of said medial section, the central portions of said intermediate and end sections having a greater number of layers of fabric therein than the side portions of said intermediate and end sections, said filling yarns extending transversely of said diaper between side edges thereof and, as originally woven in the fabric, having a twist multiple between about 5.50 and about 6.75 and having less interlacings per inch with said warp yarns in each of the layers of fabric in said medial section than in each of the layers of fabric in said intermediate and end sections, and said diaper being shrunk with the fabric in said medial section being shrunk a greater amount in the filling direction than the fabric in said intermediate and end sections and providing a concave curvature to opposite side edges of the diaper to provide the aforesaid contour therein.
15. An elongate, interwoven multilayer absorbent diaper comprising non-raveling sections defining opposite ends of the diaper, intermediate sections betwen and connected to said non-raveling sections, and a medial section between said intermediate sections and connected thereto, said diaper sections each comprising layers of fabric each formed of interwoven sets of warp and filling yarns, one set of said warp and filling yarns extending laterially of said diaper and being formed of cellulosic material, said one set of yarns at least in said medial section, as originally woven in the fabric, having a high twist with the twist multiple thereof being between 4.50 and 7.50 to enhance the shrinkability thereof, the other set of yarns, as originally woven in the fabric, having less yarns per inch in each of the layers of fabric in said medial section than in each layer of fabric in said non-raveling and intermediate sections, and said fabric of the diaper being shrinkable with the fabric in said medial sections having greater shrinkability in the direction of said one set of yarns than the fabric in said non-raveling and intermediate sections to provide a concave curvature to the opposite side edges of the diaper after the diaper is shrunk for obtaining a better and more comfortable fit for a wearer,
16. A diaper according to claim 15 wherein said high twist yarns are filling yarns and said medial section of the diaper has a greater number of layers of fabric therein than said intermediate and non-raveling sections with the warp yarns being substantially equally divided between the layers of fabric in said medial section to thereby provide less warp yarns per inch in each layer of fabric in the medial section than in each layer of fabric in said intermediate and non-raveling sections.
References Cited UNITED STATES PATENTS 1,842,623 1/1932 Moore 139385.5 1,842,729 l/l932 Moore 139-3855 1,941,868 1/193-4 Leavy 128284 2,588,113 3/1952 Harrison 128---284 2,649,858 8/1953 Le Bolt 128--284 2,713,359 7/1955 Dangel et al.
2,754,824 7/1956 Blaufus 128-284 2,833,282 5/1958 Moore 128284 2,845,069 7/1958 Jamison et al 128284 2,991,786 7/1961 Sullivan l28-284 2,995,154 7/1961 Seltzer 128284 3,150,693 9/1964 Seltzer 128284 X 3,247,872 4/ 1966 Jamison 128-284 X RICHARD A GAUDET, Primary Examiner.
RQSENBAUM, Examiner.
UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No 3 ,339 548 September 5 1967 Norman L. Seltzer It is hereby", certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.
Column 1, line 54, for "concve" read concave column 2 lines 19 and 26 for "shrinkage" each occurrence read shrinking line 32 after "taken" insert substantially line 42 for "section" read sections line 71 for "to" read in column 3 line 12 for "drawn" read draw column 4 line 38 for "bady 5" read baby's line 68, for "with" read which column 5 line 1 for "superimposed" read superposed line 18 for "The" read This line 30 for "reduced read reducing column 6 line 8 for "sections" read section column 7 line 54 for "directions" read direction Signed and sealed this 13th day of August 1968.
(SEAL) Attest:
EDWARD M.FLET( IHER,JR. EDWARD J BRENNER Attestlng OfflCeT Commissioner of Patents

Claims (1)

1. AN ELONGATE, INTERWOVEN, MULTI-LAYER, ABSORBENT DIAPER COMPRISING NON-RAVELING SECIONS DEFINING OPPOSITE ENDS OF THE DIAPER, INTERMEDIATE SECIONS BETWEEN AND CONNECTED TO SAID NON-RAVELING SECIOTNS, AND A MEDIAL SECITON BETWEEN SAID INTERMEDIATE SECTIONS AND CONNECTED THERETO, SAID DIAPER SECTIONS EACH COMPRISING LAYERS OF FABRIC EACH FORMED OF INTERWOVEN SETS OF WARP AND FILLING YARNS, ONE SET OF SAID YARNS BEING CELLULOSIC AND EXTENDING LATERALLY OF SAID DIAPER AND AT LEAST IN SAID MEDIAL SECTION, AS ORIGINALLY WOVEN IN THE FABRIC, HAVING A HIGH TWIST WITH THE TWIST MULTIPLE THEREOF BEING BETWEEN 4.50 AND 7.50 TO ENHANCE THE SHRINKABILITY THEREOF, EACH OF THE LAYERS OF FABRIC IN SAID MEDIAL SECTION, AS ORIGINALLY WOVEN, HAVING
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US3422815A (en) * 1966-02-17 1969-01-21 Johnson & Johnson Prefolded woven diaper with single ply widthwise edge portions
US3512529A (en) * 1967-06-22 1970-05-19 Johnson & Johnson Diaper
US4490146A (en) * 1983-03-01 1984-12-25 The Kendall Company Laparotomy sponges
US4543154A (en) * 1983-11-04 1985-09-24 The Procter & Gamble Company Method for severing a laminated web containing a dimensionally heat unstable layer to produce non-linear shirred edges
US4563185A (en) * 1983-11-04 1986-01-07 The Procter & Gamble Company Disposable diaper having elasticized waistband with non-linear severed edge
US4676787A (en) * 1983-06-27 1987-06-30 Gerber Products Company Diaper
US4895568A (en) * 1988-08-18 1990-01-23 Kimberly-Clark Corporation Diaper liner with selectively elasticized portions
US5413570A (en) * 1984-07-02 1995-05-09 Kimberly-Clark Corporation Diapers with elasticized side pockets
US5415644A (en) * 1984-07-02 1995-05-16 Kimberly-Clark Corporation Diapers with elasticized side pockets
US5611790A (en) * 1990-06-18 1997-03-18 The Procter & Gamble Company Stretchable absorbent articles
US5658269A (en) * 1990-10-29 1997-08-19 The Procter & Gamble Company Extensible absorbent articles
US5674212A (en) * 1990-10-29 1997-10-07 The Procter & Gamble Company Extensible absorbent articles
US5713884A (en) * 1990-06-18 1998-02-03 The Procter & Gamble Company Stretchable absorbent articles
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US5415644A (en) * 1984-07-02 1995-05-16 Kimberly-Clark Corporation Diapers with elasticized side pockets
US5413570A (en) * 1984-07-02 1995-05-09 Kimberly-Clark Corporation Diapers with elasticized side pockets
US5599338A (en) * 1984-07-02 1997-02-04 Kimberly-Clark Corporation Diapers with elasticized side pockets
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US5674212A (en) * 1990-10-29 1997-10-07 The Procter & Gamble Company Extensible absorbent articles
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