Washable diaper and methods of assembly and manufacture

A method of assembling a washable diaper, the method comprising:

• obtaining a reusable outer article having a front end edge, a back end edge, a medial portion with opposing side edges extending between the front and back end edges thereof, an outer surface and an inner surface, wherein the inner surface includes a first substantially liquid impervious compartment formed between overlapping first and second layers of substantially liquid impervious material defining the front end edge and portions of the opposing side edges of the reusable outer article and a second substantially liquid impervious compartment formed between overlapping third and fourth layers of substantially liquid impervious layers defining the back end edge and portions of the opposing side edges of the reusable outer article, the front end edge, back end edge, and opposing side edges define an outer perimeter of the outer article;
• obtaining at least one washable article having a first and a second end and inner and outer surfaces;
• and
• detachably coupling the at least one washable article to the reusable outer article and positioning the first end of the at least one washable article within the first substantially liquid impervious compartment between the overlapping first and second layers of substantially liquid impervious material of the reusable outer article and the second end of the at least one washable article within the second substantially liquid impervious compartment between the overlapping third and fourth layers of substantially liquid impervious material of the reusable outer article, and
• wherein when the inner liner system is assembled with the outer article and the washable diaper is worn by a user, the first and third layers of substantially liquid impervious material are each positioned between the user and the washable article,
• wherein the first and second ends of the washable article define opposing ends of the inner liner system, and
• wherein at least the portions of the outer perimeter of the outer article defined by the first and second substantially liquid impervious compartments include at least one substantially liquid impervious member sewn thereover with substantially non-wicking thread.

A method of manufacturing a washable diaper, the method comprising:

• manufacturing an outer article of the washable diaper comprising:
• forming a first substantially liquid impervious portion of a shape that includes a front end, a back end, a medial portion with opposing side edges extending between the front and back ends, an outer surface and an inner surface;
• folding a first compartment portion of the first substantially liquid impervious portion that is adjacent to the front end over the inner surface and towards the back end thereof such that the inner surfaces of the first compartment portion and the adjacent portion of the first substantially liquid impervious portion overlap to form a first substantially liquid impervious compartment therebetween with a substantially liquid impervious edge at the fold which forms a front end edge of the outer article, and an opening accessible from the inner surface of the medial portion of the first substantially liquid impervious portion;
• coupling substantially liquid impervious banding over at least the side edges and the front end edge of the first substantially liquid impervious compartment with substantially non-wicking thread such that the side edges and the front end edge of the first substantially liquid impervious compartment are substantially liquid impervious;
• folding a second compartment portion of the first substantially liquid impervious portion that is adjacent to the back end over the inner surface and towards the front end thereof such that the inner surfaces of the first compartment portion and the adjacent portion of the first substantially liquid impervious portion overlap to form a second substantially liquid impervious compartment therebetween with a substantially liquid impervious edge at the fold forming a back end edge of the outer article and an opening accessible from the inner surface of the medial portion of the first substantially liquid impervious portion;
• and
• coupling substantially liquid impervious banding over at least the side edges and the back end edge of the second substantially liquid impervious compartment with substantially non-wicking thread such that the side edges and the back end edge of the second substantially liquid impervious compartment are substantially liquid impervious.

An inner liner system for use with a substantially liquid impervious outer article of a washable diaper, comprising:

• an elongate washable article defining a first longitudinal length greater than a first lateral width and including an internal cavity and a longitudinally extending opening in a medial portion of the first width in communication with the internal cavity that defines a second longitudinal length, wherein the washable article is substantially liquid pervious and absorbent,
• an absorbent pad that is substantially liquid pervious and absorbent that defines a third longitudinal length, and
• coupling mechanisms for coupling to the substantially liquid impervious outer article of the washable diaper,
• wherein the absorbent pad and the internal cavity of the washable article are configured such that the absorbent pad can be carried within the cavity when the inner liner system is used with the substantially liquid impervious outer article, and
• wherein the cavity is a hollow space within the interior of the washable article that is substantially surrounded by the washable article except for the opening thereof.