DETAILED DESCRIPTION OF THE INVENTION

[0069] As described herein, garment refers to a disposable article of wear having leg openings and a front opening panel with closure means. The garment is applied to the user by opening the front panel before the wearer ‘steps into’ the garment and after pulling it around the torso, fastening the tape.

[0070] Intended as a containing garment for one or more absorbent pads depending on use, and given the selection of stretchable materials available, the garment ‘container’, together with pads of pre-selected shape and placement, provides absorbent protection used for infants and children, adults for incontinent use and feminine hydiene applications.

[0071] In FIG. 1, a disposable garment 1 is assembled from two mirror image segments; outer segment 5 and inner segment 6 which faces the user's body.

[0072] For use, the garment is folded transversely about line F-F′ before tapes 19-19′ are attached to define a waist and leg openings.

[0073] The unfolded garment 1 has a rear panel 2, front panel 3 and by virtue of cutouts 10,10′ a crotch region 4. The garment segments extend from rear panel end margin 7 to front panel end margin 8.

[0074] In FIG. 1, segments 5, 6 are overlapped in a central region 9 and each has a width substantially equal to half the width W of the garment plus about half the width of the overlap. Segment width is increased slightly to add elastic strands adjacent cutouts 10, 10′ to form ‘cuff’

[0075] It is understood that segments of non-woven or paper comoposite materials have a wide range of functional characteristics including porosity and extensibility, and that longitudinal or registered patterns of impervious coating can be applied to contain liquids.

[0076] Also, depending on pre-selected pad width, the amount of overlap between segments can be varied with the same segment widths to change size of garment width and waist openings without functional effect on these products.

[0077] In FIG. 1, before outer segment 5 and inner segment 6 are superposed and overlapped an amount 9, a linear series of dots 12, 12′ between side margins 11, 11′ bond the segments to form a unitary rear panel 2. Bonding does not occur between facing surfaces of the segments in the front panel area 3 thus defining a front panel opening 14.

[0078] For closure and use, tape 20 connects segments 5 and 6 in the front panel region 3.

[0079] In FIG. 1, liner sheets 21, 22 are removed by cutaway to expose underlying components including absorbrent pad 15 enclosed by and bonded to top overwrapping substrate 23 and bottom substrate 24 which are sealed together in adjacent pad end margins 16,16′ and side margins 17,17′.

[0080] In FIG. 1, a narrow area of bonding 25,25′ secures the liner sheets 21, 22 along segment margins. Longitudinal edge reinforcing strip 26 encloses one margin of the liner, pad and substrates, and segment 5. (also shown in FIGS. 5, 6).

[0081] Front release tape 20 and side margin tapes 19, 19′ have extensible portions for stretch of the waist enclosure during use.

[0082] In FIG. 1 and similar embodiments of FIGS. 7,8 absorbent pad 15, comprised of air laid fibers with bonding agents to impart monolithic density and strength, is between segments 5 and 6 and attached to the inside surface of outer segment 5. Pad 15 extends from the front end of segment 5 to adjacent the fold line F-F′.

[0083] In FIG. 2, segment assembly 5′ and 6′ are bonded together in rear panel area 2 with bonding patterrn 12, it being understood that a series of dots, lines or areas can be used and bonding can include adhesives, heat sealing or sonic bonding.

[0084] For FIG. 2, the bonding legend describes attachment of superposed elements to join them into an outer segment assembly 5′ and inner segment assembly 6′.

[0085] The bonding legend for FIG. 2 also applies to FIGS. 3, 7.

[0086] In FIG. 2, bonding means include: 29—outer segment 5 to lower substrate 24: bonding 30—lower substrate 24 to pad 15: bonding 31—top of pad 15 to upper substrate 23; bonding 32—substrates 23 to 24; bonding 33—liner 21 to upper substrate 23; bonding 34—liner 21 to outer segment 5 to form assembly 5′.

[0087] In FIG. 2 bonding means also include: bonding 35—liner 22 to inner segment assembly 6′; and bonding 12—between overlapping assemblies 5′ and 6′.

[0088] In FIG. 2, absorbent pad 15 is sealed between upper non-pervious substrate 23 having perforations in a selected central area and lower non-pervious substrate 24. Pad 15 and substrates 23, 24 are enclosed between segment 5 an liner sheet 21 which faces toward the user's body.

[0089] In FIG. 2,an absorbent pad 15 enclosed within non-pervious film or coated substrates 23, 24 forms a pad assembly described in detail in FIGS. 4A and 4B.

[0090] In FIG. 2, outer segment assembly 5′ is bonded to overlapping assembly 6′ to form the unitary rear panel and left unbonded in the front panel area.

[0091] In FIG. 2, the top pad encloseing substrate 23 is shown dashed to indicate a perforated or apertured pervious surface 23 which allows fluids to pass into the absorbent pad. The bottom substrate 24 is non-pervioud to retain fluids inside the pad enclosure. In FIGS. 2, pad end seal areas are designated 27,27′.

[0092] In FIG. 3A, the pad side seals 28, 28′ are completed to leakproof the pad enclosure as detailed in FIG. 4A below.

[0093] In FIG. 3A, the same bonding attachments as in FIG. 2 enclose pad 15 which is bonded to the inside surface of segment 5 in the overlap area of front panel 3.

[0094] The pad assembly of FIGS. 2 and 3 is confined to the front panel area for urinary or menstral leakage.

[0095] In FIG. 3B, attachments involve segment 5, pad enclosures 23, 24 (without the pad) and liner sheet 21 bonded together as an outer assembly 5′. Inner segment 6 and liner sheet 22 form inner assembly 6′. Assemblies 5′ and 6′ are bonded together as at 12 to form a unitary rear panel, and remain unbonded in the front panel area to define the panel opening 14.

[0096] In FIG. 4A pad 15 has a length of less than the distance between end margins of the underlying segment to provide space for end seals.

[0097] In FIG. 4A, items 16, 16′ and 17, 17′ are the pad end and side margins respectively.

[0098] In FIG. 4A, pad 15 is enclosed between upper substrate 23 and lower substrate 24, both impervious materials such as film or coated substrates.

[0099] In FIG. 4A, seals 27,27′ and side seals 28,28′ are bonded by means described above. With film,a perforated area 23′ allows fluid passage to the pad.

[0100] Perforations are preferably registered (FIG. 4A) and stop short of the ends thus providing positive seals on four sides and a central area of pervious material for fluid transmission to the enclosed pad.

[0101] Other substrates properly coated for top and bottom seals can be registered for positive end and side seals, or can be continuous and non-registered to provide positive sealing along the sides but with some limited fluid leakage in the end seal central area described in FIG. 4B.

[0102] In FIG. 4B, pad portions are spaced from both ends. Upper substrate 23 is a film or pervious material 36 strip coated or laminated along side margins with a non-pervious agent.

[0103] Lower substrate 24 is coated full width to provide a leakproof bottom surface to retain fluid for absorption by the enclosed [ad 15. In this instance, the side seals 28,28′ enclose pad 15 sides, but pad ends can transmit fluid through upper end material 23.

[0104] It is understood that the enclosure of 4A is preferred because of positive sealing all sides despite some manufacturring advantages with the embodiment of FIG. 4B.

[0105] In FIG. 5, pad 15 with the enclosure of FIG. 4A extends from end margin 7 of the rear panel to end margin 8 of front panel 3.

[0106] In FIG. 5, end seal 16 of the longer pad is adjacent rear panel end margin 7 rather than terminating near the fold line F-F′ as in FIGS. 1-3.

[0107] Details of bonding for FIG. 5 are accurately shown in the bonding legend of FIG. 2. The garment with extended pad is shown in FIG. 6.

[0108] In FIG. 6, pad 15′ is positioned in central area 9 between segment assemblies 5′, 6′. and bondably attached to the inside surface of outer segment 5. Segment assemblies 5′ and 6′ are only bonded together in the rear panel region 3.

[0109] The detailed bonding legend described in FIG. 2 applies to FIG. 7.

[0110] In FIG. 7, bonding between assemblies 5′, 6′ creates the unitary rear panel and the absence of bonds in the front defines the opening 14.

[0111] In the simplified end elevation of FIG. 8A, pad 15 is bonded at 24 to the inside of segment 5 and left unbonded between segments 5, 6 for a front panel opening 14.

[0112] In FIG. 8B, pad 15 is bonded at 24 to segment 5 and bonded on the top surface at 12 to join segment assemblies 5′, 6′ in the rear panel area 2.

[0113] FIGS. 9A to 9C show a two-tier combination garment that includes a pad between segment assemblies.

[0114] In FIG. 9A, a sealed absorbent pad 115′ with two wings is attached to the inside surface of inner segment assembly 6′ comprised of segment 6, sealed pad assembly 115′ with enclosing elements, and a liner sheet (not referenced for clarity).

[0115] In FIG. 9B, a sealed pad 115 with two wings is bonded for attachment to the outer segment assembly 5′ comprised of segment 5, sealed pad 115 with substrates and a liner (not referenced).

[0116] In FIG. 9C, the inner segment sub-assembly 6′ is superposed over outer sub-assembly 5′ in central overlapped region 9 and bonded to the rear panel region 12. to create a unitary rear panel having unbonded front panel overlap for a front opening.

[0117] In FIG. 10, pad 115 with two extending wings is bonded to outer segment 5 in overlapping cooperation with a pad 115′ bonded to inner segment 6.

[0118] Pads 115,115′ are spaced from ends 7, 8 to provide room for end seals 27, 27′, and spaced from side margins for side seals 28,28′.

[0119] Each pad is enclosed with a top substrate 23 having a pervious area 23′.

[0120] In FIG. 10, bottom substrate 37 enclosing pad 115 is coated full width to prevent leakage to underlying segment 5. Top substrate 23 for pad 115 as well as both top 23 and bottom 24 substrates for pad 115′ have pervious central regions to allow fluid transmission to underlying elements.

[0121] While providing double pads in the central area of overlap (see FIG. 5) the four single thickness wings are sealed adjacent cutout margins 28, 28′ and side margins (see 28″ for pad 115′). Pad 115 linear and side seals are not visible and not shown in phantom for clarity,

[0122] In FIG. 10, the outside edge of film or coated substrate extends across the cutout crotch portions and the outline edge 40 of segment 5 and 41 of segmnt 6

[0123] Liner sheets 21, 22 are on the inside of each segment subassembly and in combination, provide a soft hourglass shaped two piece surface on the inside of the garment.

[0124] In FIG. 11, selected elements previously described are not shown for clarity, including side margin 19 and front closure 20 tapes,reinforcing strip 26, elastic strands 18 on both segments and side areas 28.

[0125] In FIG. 11, the outlines for segments 5,6 are referenced near the bottom as 40, 41 respectively and include segment extensions 42, 42′ so that foldover insures closing the side gap between front and rear panels.

[0126] In FIG. 11 with the liner sheet cutaway, outside edges for film or coasted substrates 38, 39 indicate that film portions 43, 43′ extend beyond outer pad margins and are capable of being bonded to seal side margins and portions 27, 27′ of the end seals not in the pervious central area of overlap 9.

[0127] In FIG. 11, each segment assembly 5′, 6′ includes a segment, sealed pad as described above and a liner sheet.

[0128] In FIG. 11, a cutaway of the top pervious film shows pad 115′.

[0129] In FIG. 11, pads are sealed in end areas 27 and side areas 28 (see FIGS. 4A, 4B), and enclosed between liner sheet 21 and segments 5, and between liner 22 and segment 6.

[0130] In FIG. 12, the overlapped mirror image segments 5, 6, and similar cooperating pads 115,115′ (each with two extended wings) are shown with another pad 215 to provide triple pad thickness in the central area and single thichkness in each of the wing areas

[0131] Outer segment assembly 5′ consists of segment 5, pad 115 with wings enclosed by film or substrates for margin seals which are positioned between segment 5 and liner sheet 22 (not shown).

[0132] Segment assembly 6′ includes the same members in mirror image cooperation with pad 115′.

[0133] In FIGS. 9A-11, the overlapping segments and pads as well as types of sealing are described in detail and used on the garment of FIG. 12.

[0134] FIG. 12 is viewed from the inside. Pad 115 is bonded to and supported by panel 44 of pre-seleced width.

[0135] Panel 44 is attached at both ends to inner segment 6 (see dashed spots at ends of the overlapped area).

[0136] In FIG. 12, stretched elastic strands 45 are attached at spaced intervals to panel 44 and when the garment is folded about line F-F′ form shirred ‘cuff’ edges 46 of panel 44 see FIG. 13 also).

[0137] In FIG. 13, panel 44 is attached at both ends to segment 6. Pad 115 is bonded to segment 5 along its full length. Outer assembly 5′ (segment 5 and pad 115 shown) is bonded to inner assembly 6′ (segment 6 and pad 115′) as at 12 in the rear panel only.

[0138] The absence of bonding 12 in the front panel creates front panel opening 14..

[0139] In FIG. 13, front and rear panels are attached with side margin tapes 19,19′. The front opening 14 between segment assemblies 5′,6′ is closed by attaching front closure tape 20 to a front panel portion of segment 6.

[0140] In FIG. 14, a completed garment in use is opened by detaching closure tape 20 to expose pad 115 bonded to the front panel of outer segment 5.

[0141] In FIG. 14, a supplemental pad 47 is placed between pad 115 and the inside surface of segment 6 for additional absorbency.

[0142] Tab 48 extends beyond the margin of opening 14 and is grasped to remove the supplemental pad 47 for inspection or replacement.

[0143] In FIG. 15, supplemental pad 47 is shown in place for use. Adhesive areas 48 are secured to the inside of segment 6.

[0144] In FIG. 15 the pad is sealed along edges as at 50. Removalbe cover strips for adhesive 49 and a liner sheet are not shown.

[0145] In FIG. 16A support panel 44 is attached at both ends to inside segment 6 and has stretched elastic strands that contract to form a shirred ‘pocket’ 46 (see FIG. 17) when the garment if folded for use.

[0146] Aperture 51 allows a catheter tube to pass through panel 44.

[0147] In FIG. 16B, aperture 52 in inside segment 6 allows the tube to pass through segment 6 and be directed rearward obove pad 15 affixed to the inside surface of segment 5.

[0148] In FIG. 16C, segments 5, 6 are bonded together in area 12 of the rear panel. (see also FIG. 17). Pad 15 is bonded to a front portion of segment 5. The catheter tube is passed over pad 15 and through aperture 53 to an external reservoir.

[0149] In FIG. 17, a garment is folded near in crotch area 4. Stretched elastic strands 45 contract the panel along both side margins to form shirred side edges 46 of a ‘pocket for body parts and a catheter or an absorbent pad.

[0150] In FIG. 17, the catheter path is shown dashed and passes through three apertures, 51 in support panel 44, 52 in segment 6, and 53 in outer segment 5.

[0151] It is further to be understood that the present invention may be embodied in other specific forms without departing from the spirit or special attributes; and it is therefore, not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.