Absorbent garment and method of making the same

Abstract

The present application discloses an absorbent garment and a method for manufacturing the same. The garment comprises a body, the body comprising a front portion, a back portion, and a lining connecting the front portion and the back portion. The lining has left and right transverse edges that partially define respective left and right leg openings of the body. An absorbent material is coupled to the inner surface of the body at least at the lining. A waterproof material is sandwiched between the body and the absorbent material. Left and right elastic bands are coupled to the outer transverse edges of the absorbent material. The left and right elastic bands are bonded to the waterproof material, and the waterproof material is attached to the body adjacent to the respective left and right transverse edges of the lining.

Description

Technical Field

[0001] The present application relates to garments and, more particularly, to garments having an absorbent gusset configured to be worn about the crotch of a wearer. Background Art

[0002] US Patent Application Publication No. 2014 / 0039432 discloses an undergarment that includes a multi-layer barrier pad that wicks moisture, hinders bacteria, prevents leaks, and resists staining.

[0003] U.S. Patent Application Publication No. 2018 / 0014983 discloses a soaker pad for use in clothing, comprising: a liquid-permeable layer; a functional layer above the liquid-impermeable layer; and a liquid-impermeable barrier material, wherein the functional layer is capable of acquiring and distributing liquid and / or absorbing liquid, and the liquid-impermeable barrier material is bonded to at least the liquid-impermeable layer and the functional layer around the periphery of the layer by bonding means other than stitching. The soaker pad may form part of a garment.

[0004] U.S. Patent Application Publication No. 2020 / 0222256 discloses a protective insert that is operably attachable to an inner, body-facing layer of a garment. The protective insert generally comprises: a first, operatively inner layer comprising moisture-wicking, odor-resistant, fluid-absorbent fibers with or without a waterproof laminate film; and a second, operatively outer layer comprising breathable, odor-resistant, water-repellent fibers to further prevent fluid from passing through the garment; wherein, during use, the operatively inner layer faces the user's body, while the operatively outer layer faces away from the user's body.

[0005] U.S. Patent Application Publication No. 2020 / 0246203 discloses an underwear article comprising: a fabric layer for wearing around a person's pelvic region; a water-repellent layer coupled to a crotch portion of the fabric layer to form an inner chamber; and an inner pad disposed within the inner chamber between the water-repellent layer and the fabric layer. The inner pad is heat-resistant and includes a liquid-absorbing layer and a water-repellent layer. The liquid-absorbing layer contacts the water-repellent layer and is effective for absorbing a volume of liquid greater than 2 fluid ounces. The water-repellent layer is effective for limiting liquid from reaching the fabric layer. The crotch portion of the fabric layer and the water-repellent layer can be substantially elastic in at least one of a transverse direction and a longitudinal direction of the crotch portion. Methods of using the underwear, sets of articles for use of the underwear, and uses thereof are also disclosed.

[0006] U.S. Patent No. 7,322,966 discloses a washable, reusable garment for retaining bodily fluids when worn on the lower body of a person. The garment comprises a crotch portion and a main body portion. The crotch portion comprises an absorbent composite material and a pocket adapted to receive a removable absorbent pad. The main body portion comprises a waist opening and is seamless except for where it is attached to the crotch portion. The main body portion and the crotch portion together form a first leg opening and a second leg opening.

[0007] U.S. Patent No. 8,117,675 discloses waterproof underwear with rolled seams. The rolled seams prevent leakage of body fluids at the leg openings due to seaming and wicking. The underwear comprises an outer shell and an inner panty layer. The outer shell is formed from a continuous cut of a soft blended laminate fabric. The outer shell is liquid-resistant, breathable, hypoallergenic, stain-resistant, and elastic. The outer shell is cut to form a waist opening and two leg openings. If desired, stretchable lace or elastic side sections may be provided. The inner panty liner is a breathable, soft blended fabric and includes a front, back, and crotch section. The crotch section is double-layered for increased dryness. The inner panty layer is cut to form a complete panty design with a waist opening and two leg openings. This integrated design provides the wearer with a sense of security and safety through stylish, lightweight, comfortable, and waterproof underwear.

[0008] U.S. Patent No. 8,460,265 discloses a washable women's undergarment designed to be comfortable and leak-reducing. The undergarment comprises an outer layer of stretchable fabric, an inner layer of absorbent fabric, and a primary absorbent layer positioned between the inner and outer layers in the crotch area. These three layers are permanently secured together to form a reusable, reliable undergarment.

[0009] U.S. Patent No. 10,231,885 discloses an undergarment configured to help absorb body fluids leaked from a person suffering from mild to moderate incontinence or other conditions, the undergarment comprising a body made of a material that allows absorption of body fluids, and a crotch panel made of a material that allows absorption of body fluids covering a crotch portion of the body. The crotch panel of the undergarment may extend high enough and wide enough on the front side of the garment body to provide an adequate protection area for the user.

[0010] U.S. Patent No. 10,441,479 discloses an undergarment comprising: a main body portion having an upper edge defining a waistband, two leg openings, and a crotch region between the leg openings; an absorbent pad located inside the main body portion at least in the crotch region, the absorbent pad having an inner region and a peripheral region, wherein the thickness of the absorbent pad in the peripheral region is less than that in the inner region; and an elastic bonding film lining each of the two leg openings while covering a corresponding portion of the peripheral region of the absorbent pad, thereby bonding the absorbent pad to the main body portion. A method for manufacturing the undergarment is provided.

[0011] US Patent No. 10,555,841 discloses a protective garment comprising an inner surface or portion of an inner surface that is absorbent and stain resistant while maintaining the soft feel, breathability, and aesthetics associated with conventional "non-protective" undergarments. Also disclosed herein are fabrics and methods for constructing the garment.

[0012] International Patent Application Publication No. 2019 / 162615 discloses leak-proof underpants comprising a fabric body having a waist opening and a pair of leg openings. The underpants comprise a front portion and a rear portion, the front and rear portions being fastened together by transverse seams. The leak-proof underpants include a protective assembly in the crotch portion, the protective assembly comprising an absorbent layer and a drainage layer, which are fastened to the edge portions of each leg opening. The absorbent layer or drainage layer is fastened to the transverse seams of the front or rear portion of the fabric body, with only the absorbent layer or only the drainage layer being fastened to the rear edge or the front edge, respectively, defining the waist opening.

[0013] International Patent Application Publication No. 2020 / 121176 discloses a multi-layer liquid-absorbing and retaining textile assembly. The textile assembly includes at least a first layer, a second layer, and an intermediate layer. The intermediate layer is constructed as a warp-knitted spacer fabric having multiple sections, at least one section being adjacent to the first layer and at least another section being adjacent to the second layer. The first layer is adapted to transfer liquid from a first side of the textile assembly to the intermediate layer. The intermediate layer is adapted to receive liquid and transfer it to the second layer. The second layer is adapted to retain liquid at or near a second side of the textile assembly that faces opposite the first side.

[0014] U.S. Patent No. 11,154,431 discloses a garment comprising a main body comprising a front portion, a back portion, and a lining connecting the front portion and the back portion. The lining has a left transverse edge and a right transverse edge that partially define the respective left and right leg openings of the garment. An absorbent material layer is coupled to the inner face of the main body at least at the lining. A waterproof material layer is sandwiched between the main body and the absorbent material layer. Left and right elastic bands couple the absorbent material layer and the waterproof material layer to the main body along the respective left and right transverse edges of the lining. A method for manufacturing the absorbent garment is also provided. Summary of the Invention

[0015] This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0016] According to one example, a garment comprises a body comprising a front portion, a back portion and a lining connecting the front portion and the back portion. The lining has a left lateral edge and a right lateral edge that partially define the corresponding left leg opening and right leg opening of the body. An absorbent material is coupled to the inner face of the body at least at the lining. A waterproof material is sandwiched between the body and the absorbent material. A left elastic band and a right elastic band are coupled to the outer lateral edges of the absorbent material. The left elastic band and the right elastic band are bonded to the waterproof material, and the waterproof material is attached to the body adjacent to the corresponding left lateral edge and right lateral edge of the lining.

[0017] In one example, the left and right elastic bands are folded over around the respective left and right transverse edges of the absorbent material. Optionally, the left and right elastic bands are bonded to the absorbent material wherein the left and right elastic bands overlap the respective left and right transverse edges of the absorbent material.

[0018] In one example, the lining material is coupled to the absorbent material, thereby sandwiching the absorbent material between the lining material and the waterproof material. Optionally, the left elastic and the right elastic are folded around the respective left and right transverse edges of each of the lining material and the absorbent material, and the left elastic and the right elastic are bonded to the lining material and the absorbent material, wherein the left elastic and the right elastic overlap the respective left and right transverse edges of each of the lining material and the absorbent material.

[0019] In one example, the left and right transverse edges of the chassis material are folded inwardly at the gusset to define left and right transverse edges of the gusset, and the left and right transverse edges of the waterproof material are attached to the respective left and right transverse edges of the chassis material. Optionally, the left and right transverse edges of the waterproof material are attached to the respective left and right transverse edges of the chassis material by stitching. Optionally, the left and right elastic bands are folded around the respective left and right transverse edges of the absorbent material, and the left and right elastic bands overlap the stitching between the left and right transverse edges of the waterproof material and the respective left and right transverse edges of the chassis material, respectively. Optionally, the chassis material is bonded to itself with the left and right transverse edges of the chassis material folded over, and the chassis is substantially seamless on its outer surface, at least at the gusset.

[0020] In one example, the waterproof material comprises a fabric bonded to a waterproof membrane.

[0021] According to another example of the present disclosure, a method for making an absorbent garment includes providing a body including a front portion, a back portion, and a gusset connecting the front portion and the back portion, wherein the gusset has left and right transverse edges configured to partially define respective left and right leg openings of the body; providing an absorbent material sized and shaped to fit the gusset and having left and right transverse edges configured to extend along respective left and right transverse edges of the gusset; attaching left and right elastic bands along the respective left and right transverse edges of the absorbent material; providing a waterproof material sized and shaped to fit the gusset and having left and right transverse edges configured to extend along respective left and right transverse edges of the gusset; attaching the left and right transverse edges of the waterproof material to the main body near the respective left and right transverse edges of the gusset so that the waterproof material is located on an inner face of the main body at the gusset; and placing the attached absorbent material and left and right elastic bands on the gusset over the waterproof material, and attaching the left and right elastic bands to the waterproof material so that the waterproof material is sandwiched between the absorbent material and the main body.

[0022] In one example, the method further comprises folding the left and right elastic bands around the respective left and right transverse edges of the absorbent material. Optionally, the method further comprises bonding the left and right elastic bands to the absorbent material, wherein the left and right elastic bands overlap the respective left and right transverse edges of the absorbent material.

[0023] In one embodiment, the method further comprises folding the left and right transverse edges of the body material toward the interior of the body at the gusset to define left and right transverse edges of the gusset, and attaching the left and right transverse edges of the waterproof material to the corresponding left and right transverse edges of the body material. Optionally, the attachment of the left and right transverse edges of the waterproof material to the corresponding left and right transverse edges of the body material is accomplished by stitching. Optionally, the left and right elastic bands overlap the stitching between the left and right transverse edges of the waterproof material, respectively, and the corresponding left and right transverse edges of the body material. Optionally, the method further comprises bonding the body material to itself, wherein the left and right transverse edges of the body material are folded over, such that the body is substantially seamless on its exterior at least at the gusset.

[0024] In one example, attachment of the left and right elastic bands along the respective left and right transverse edges of the absorbent material is accomplished by bonding.

[0025] In one example, attachment of the left and right lateral edges of the waterproof material to the body adjacent the corresponding left and right lateral edges of the gusset is accomplished by stitching.

[0026] In one example, the method further includes providing a liner material sized and shaped to mate with the liner and having left and right lateral edges configured to extend along respective left and right lateral edges of the liner; attaching left and right elastic bands along respective left and right lateral edges of each of the absorbent material and the liner material; and positioning the attached liner material, absorbent material, and left and right elastic bands on the liner over the waterproof material, and attaching the left and right elastic bands to the waterproof material, thereby sandwiching the absorbent material between the liner material and the waterproof material. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Examples of garments and parts thereof are described with reference to the following drawings. Throughout the drawings, like numerals are used to denote like features and like parts.

[0028] Figure 1 is a front view of a garment according to the present disclosure.

[0029] Figure 2 This is an inside view of the lining of a garment.

[0030] Figure 3 It is along Figure 2 A schematic cross-sectional view of a panty liner taken along line 3-3 is shown in FIG.

[0031] Figure 4 It is a partial cross-sectional view of the panty lining.

[0032] Figure 5 A method of making underpants according to the present disclosure is shown. DETAILED DESCRIPTION

[0033] The present application relates to clothing, and more specifically to clothing with an absorbent and waterproof lining area that is configured to cover the wearer's crotch, although the absorbent and waterproof parts of the clothing also can extend to outside the lining area. For example, the present application relates to underwear or a swimsuit, or relates to clothing that can absorb body fluids, such as urine, menstrual fluid, vaginal discharge and / or sweat and does not allow body fluids to penetrate into the clothing outside, such as shorts, trousers or a short skirt with one-piece underwear. Underpants or a swimsuit or clothing with one-piece underwear can be any style and can have any border, and these details do not limit the scope of the present disclosure. In other examples, the clothing is a tights, a pair of pantyhose, tights or is configured to directly wear any other type of clothing on the wearer's skin.

[0034] Figure 1A front view of an example of a garment 10 is shown. Here, the garment 10 is a pair of underwear, although it is noted that the garment 10 could alternatively be a pair of swim trunks. The garment 10 has a body 12 including a front portion 14, a back portion 16, and a gusset 18 connecting the front portion 14 and the back portion 16. The gusset 18 has opposing left and right lateral edges 20 that partially define respective left and right leg openings 22 of the body 12.

[0035] Figure 2 The interior of the garment 10 is shown, wherein a portion of the lining 18 is shown in detail. It can be seen that the lining material 24 covers a large portion of the lining 18. The lining material 24 shows the extent of the absorbent assembly 11 of the garment 10 and covers the absorbent material and waterproof material, which are also coupled to the lining 18, as will be further described in this article below. Although the absorbent assembly 11 is coupled to the garment 10 at least at the lining 18, the absorbent assembly can extend to the front portion 14 and / or the back portion 16, as mentioned above. The selection of the absorbent assembly 11 for the garment 10 is described below.

[0036] In one example, Figure 3 As shown, absorbent material 26 is coupled to the inner side 13 of the main body 12 of the garment 10 at least at the lining 18. Waterproof material 28 is sandwiched between the main body 12 and the absorbent material 26. Lining material 24 is coupled to the absorbent material 26 opposite the waterproof material 28, so that the absorbent material 26 is sandwiched between the lining material 24 and the waterproof material 28. In use, the lining material 24 is configured to contact the wearer's skin when the garment 10 is worn. However, as will be described below, the lining material 24 is optional. Left and right elastic bands 30 are coupled to the outer lateral edges of the optional lining material 24, the absorbent material 26, and the waterproof material 28, as will be described in further detail below. The waterproof material 28 is attached to the main body 12 adjacent to the respective left and right lateral edges 20 of the lining 18.

[0037] In one example, the left and right elastic bands 30 are folded around the respective left and right transverse edges of each of the lining material 24 and the absorbent material 26 to form a "V" shape and then attached to the layers of the lining material 24 and the absorbent material 26 along their opposing transverse edges. For example, the left and right elastic bands 30 are bonded to the lining material 24 and the absorbent material 26, such as by a bonding film 32, where the left and right elastic bands 30 overlap the respective left and right transverse edges of each of the lining material 24 and the absorbent material 26. In some examples, the bonding film 32 provides a lining for the entire "V" of each folded elastic band 30, while in other examples, separate strips of bonding film are used on the top and bottom folds of the "V." In other examples, bonding is accomplished by spray glue or other adhesive applications. Before attaching the elastics 30, the liner material 24 can optionally be bonded to the absorbent material 26 with heat-activated tape and / or can be stitched to the absorbent material 26, as shown at stitching 31. Stitching 31 can be intermittent along the length of the liner 18 and is meant to simply hold the liner material 24 and absorbent material 26 in place relative to each other while the elastics 30 are attached thereto. If the absorbent material 26 and liner material 24 are stitched together before the elastics 30 are attached thereto, the absorbent material 26 can also optionally be stitched to the folded lower half of each of the elastics 30. The folded upper half of each elastic 30 can then be folded over and bonded to the top of the liner material 24.

[0038] In one example, the outer lateral edges of the waterproof material 28 are attached to the fabric of the main body 12 before the attached absorbent material 26, liner material 24, and elastic band 30 are assembled into the main body 12. More specifically, the left and right lateral edges 48 of the main body 12 material are folded over toward the inner side 13 of the main body 12 at the gusset 18 to define the left and right lateral edges 20 of the gusset 18. The left and right lateral edges of the waterproof material 28 are attached to the corresponding left and right lateral edges 48 of the main body 12 material. In one example, the left and right lateral edges of the waterproof material 28 are attached to the corresponding left and right lateral edges of the main body 12 material by sewing, as shown at 39, which can be a pullout overlock, cover stitch, or other known sewing. In other examples, the waterproof material 28 is bonded to the main body 12 material at each lateral edge of the material. Optionally, the body 12 material is bonded to itself, with the left and right lateral edges 48 of the body 12 material being folded over using a bonding film 37. Thus, the body 12 is substantially seamless on its outer face 15, at least at the gusset 18. However, the seams 39 connecting the waterproof material 28 to the body 12 material provide a sense of integrity to the garment 10 that is not present in prior art garments that are merely bonded.

[0039] After the lining material 24 and the absorbent material 26 are bonded and / or sewn to each other and to the elastic bands 30, the left and right elastic bands 30 are bonded to the waterproof material 28, which is optionally pre-attached to the main body 12. More specifically, the waterproof material 28 can be bonded to each of the left and right elastic bands 30 at the outer lateral edges of the waterproof material 28 using a bonding film 36. If the lining material 24 and the absorbent material 26 are sewn to the folded lower half of each elastic band 30, the bonding film 36 can be placed over the stitching, thereby sewing the left and right elastic bands 30 to the respective left and right lateral edges of each of the absorbent material 26 and the lining material 24. The lining material 24, absorbent material 26 and elastic 30 are sized and shaped so that when they are placed on the gusset 18, the left and right elastics 30 overlap the seam 39 between the left and right transverse edges of the waterproof material 28 and the corresponding left and right transverse edges 48 of the main body 12 material, thereby hiding the seam 39 from view and protecting it from contact. Figure 4This is also shown in the partial cross-sectional view provided, in which the folded edge 48 of the main body 12 material is shown sewn to the outer lateral edge of the waterproof material 28 at seam 39, with the seam 39 being covered by the elastic 30. Optionally, the elastic 30 can also be bonded to the seam 39 and / or to the folded lateral edge 48 of the main body 12, such as if the bonding film 36 extends outward on both sides of the gusset 18 to cover the seam 39 and extend to or over the main body 12 fabric.

[0040] Because the left and right elastics 30 are bonded and / or sewn to the absorbent material 26 and liner material 24, and to the waterproof material 28, the likelihood of leakage is reduced. The bonding film 32 effectively creates a "cuff" around the absorbent portions 24, 26 of the absorbent assembly 11, which, together with the waterproof material 28, prevents body fluids from penetrating the fabric of the main body 12. As described herein below, the elastics 30 can be treated with chemicals that make them waterproof or water-resistant, which can further prevent leakage from the absorbent portion of the absorbent assembly 11. Furthermore, because the waterproof material 28 is bonded to each of the left and right elastics 30 above any stitching that optionally stitches the left and right elastics 30 to each of the respective left and right transverse edges of the absorbent material 26, any liquid that might otherwise tend to leak from the absorbent portions 24, 26 of the absorbent assembly 11 is retained on the inner side of the waterproof material 28 (i.e., not on the side that contacts the fabric of the main body 12) due to such stitching 31.

[0041] Optionally, the elastic band 30 may be folded asymmetrically, such as Figure 3 As shown, there is more elastic 30 at the bottom portion of the fold than at the top portion of the fold. This provides more surface area for the waterproof material 28 to be bonded to the bottom portion of the folded elastic 30 at the bonding film 36, while providing less surface area on the upper surface of the absorbent assembly 11 that contacts the wearer's skin. The waterproof material 28 extends outward beyond the bonding film 36 to provide a free edge to be attached to the material of the main body 12. As will be described herein below, the waterproof material 28 may comprise a fabric bonded to a waterproof membrane, and either the fabric side or the membrane side may be the side bonded to the elastic 30 via the bonding film 36. In a preferred embodiment, the fabric side of the waterproof material 28 is bonded to the elastic 30 via the bonding film 36. This is because the fabric side of the waterproof material 28 has a certain water absorption capacity, thereby attracting any moisture that leaks from the elastic 30 and / or the absorbent material 26. This leakage is then ultimately stopped by the waterproof membrane side of the waterproof material 28, which faces the inner surface 13 of the main body 12.

[0042] like Figure 5, a method 500 for making an absorbent garment 10 is also disclosed. The method includes providing a chassis 12 comprising a front portion 14, a back portion 16, and a gusset 18 connecting the front portion 14 and the back portion 16, wherein the gusset 18 has opposing left and right transverse edges 20 configured to partially define respective left and right leg openings 22 of the chassis 12, as shown at 502. As shown at 504, the method includes providing an absorbent material 26 sized and shaped to mate with the gusset 18 and having left and right transverse edges configured to extend along the respective left and right transverse edges 20 of the gusset 18. Note that the absorbent material 26 can have the same (or similar) shape as the gusset 18, but be slightly smaller in the transverse direction than the gusset 18, such that the absorbent material 26 can mate with the gusset 18 and not extend beyond its transverse edges 20.

[0043] The method includes attaching left and right elastic bands 30 along the respective left and right transverse edges of the absorbent material 26, as shown at 506. For example, as shown and described above, the method includes folding the left and right elastic bands 30 around the respective left and right transverse edges of the absorbent material 26. The method may also include bonding the left and right elastic bands 30 to the absorbent material 26, wherein the left and right elastic bands 30 overlap the respective left and right transverse edges of the absorbent material 26, as shown at bonding film 32. Note that in this example of the method, a lining material 24 is not provided. This may be desirable if the lining material 18 of the finished garment 10 is to be lightweight and thin. For example, the absorbent material 26 may be the layer that contacts the wearer's skin (and thus acts as a dual "liner" / absorbent layer). As will be further described herein below, such a lining / absorbent material 26 may be a push-pull fabric. In other examples, however, the method can include providing a liner material 24 that is sized and shaped to mate with the gusset 18 and having left and right transverse edges configured to extend along the respective left and right transverse edges 20 of the gusset 18. Such a method can include attaching left and right elastic bands 30 along the respective left and right transverse edges of each of the absorbent material 26 and the liner material 24, for example, by bonding.

[0044] Continue to refer Figure 5As shown at 508, the method includes providing a flashing material 28 sized and shaped to mate with the gusset 18 and having left and right transverse edges configured to extend along the respective left and right transverse edges 20 of the gusset 18. Note that the flashing material 28 can have the same (or similar) shape as the gusset 18, but be slightly smaller in the transverse direction. In this manner, the flashing material 28 can mate with the gusset 18 without extending beyond its transverse edges 20, yet still be wide enough to attach to the folded-over transverse edges 48 of the body 12 material. To this end, the method also includes attaching the left and right transverse edges of the flashing material 28 to the body 12 adjacent to the respective left and right transverse edges 20 of the gusset 18, such that the flashing material 28 is positioned on the inner side 13 of the body 12 at the gusset 18, as shown at 510. For example, the attachment of the left and right transverse edges of the flashing material 28 to the respective left and right transverse edges 48 of the body 12 material can be accomplished by sewing. Optionally, the method includes bonding the body 12 material to itself, wherein the left and right transverse edges 48 of the body 12 material are folded over, so that the body 12 is substantially seamless on its outer face 15, at least at the gusset 18. In one specific, non-limiting example, the waterproof material 28 can be sewn to the edges 48 of the body 12 fabric in a bagged-out configuration, after which a bonding film 37 can be applied to the edges of the body 12 adjacent to the stitching 39, and the body 12 can be turned right side out. When the body 12 is turned right side out and heat treated along its edges 48, the edges 48 of the body 12 are bonded together by the bonding film 37, where they are folded over. Other methods of attaching the waterproof material 28 to the body 12 may be used.

[0045] As shown at 512, the method includes placing the attached absorbent material 26 and left and right elastics 30 on the gusset 18 over the waterproof material 28 and attaching the left and right elastics 30 to the waterproof material 28, thereby sandwiching the waterproof material 28 between the absorbent material 26 and the main body 12. As mentioned above, this portion of the method can include folding the left and right transverse edges 48 of the main body 12 material at the gusset 18 toward the inner side 13 of the main body 12 to define the left and right transverse edges 20 of the gusset 18, and attaching the left and right transverse edges of the waterproof material 28 to the corresponding left and right transverse edges 48 of the main body 12 material. Optionally, as shown at 513, the method can include folding the left and right transverse edges 48 of the main body 12 material at the gusset 18 toward the inner side 13 of the main body 12 to define the left and right transverse edges 20 of the gusset 18. Figure 3 and 4 As shown, the left and right elastic bands 30 may overlap the seams 39 between the left and right lateral edges, respectively, of the waterproof material 28 and the corresponding left and right lateral edges 48 of the main body 12 material.

[0046] In instances where a liner material 24 is present, the method can include placing the attached liner material 24, absorbent material 26, and left and right elastic bands 30 on the liner 18 over the waterproof material 28 and attaching the left and right elastic bands 30 to the waterproof material 28, thereby sandwiching the absorbent material 26 between the liner material 24 and the waterproof material 28.

[0047] In other examples, the elastic band 30, absorbent material 26, and optional liner material 24 are attached to the waterproof material 28 before the waterproof material 28 is attached to the main body 12 material. In other examples, the edges of the main body 12 are raw cut without the turned edge 48.

[0048] Although the inventors have found that the connections specifically shown and described herein are suitable for strength and waterproofing purposes, any of the above sewn connections can be formed by bonding instead, and vice versa. For example, the waterproof material 28 is sewn to the material of the main body 12 to provide a strong, washable connection that lasts longer than the prior art bonded connections along the leg openings 22. The bonded connection between the elastic 30 and the waterproof material 28 ensures that liquid absorbed by the absorbent material 26 will not leak from the absorbent portion of the garment 10, as this might occur due to the sewn connections between these sheets. The elastic 30 can be treated with a water-repellent or waterproof finish, which makes them resistant to water ingress, thereby further ensuring that liquid remains inside the absorbent portion of the garment 10. Any line used for the seams, particularly at the seams 39, can also be treated with a water-repellent or waterproof finish.

[0049] The lining material 24 can be any suitable material that absorbs liquid quickly and keeps it away from the body. In one example, the lining material 24 is a plain knit material made of, for example, cotton or a cotton-synthetic blend. In a specific example, the lining material 24 is a 91% cotton (40S), 9% spandex (40D) weft knit single jersey fabric. In another example, the lining material 24 is a terry knit. The lining material 24 can be treated to provide special functionality, such as having a soil-release finish. In one example, the lining material 24 is made of a polyester soil-release yarn, such as TOP CLEAN® from Far Eastern New Century Corporation of Taiwan, China. TM. For example, if the fabric is a terry cloth knit, the terry side can be made of a soil-release polyester yarn and the flat side can be made of a regular polyester yarn. In another example, the non-skin side of the lining material 24 is treated with a chemical that causes the fabric to remove liquid from its skin-facing surface and thereafter prevent the liquid from returning to the skin-facing side of the fabric. In another example, a push-pull action can be provided by yarn selection and fabric construction, such as if the skin-facing side of the lining material 24 is constructed of a liquid-repellent yarn and the non-skin side is constructed of a liquid-absorbent yarn. The liquid will be pushed by the liquid-repellent side to pass through to the liquid-absorbent side, which simultaneously removes water from the skin-facing liquid-repellent side of the fabric. In another example, the lining material 24 is treated with an antimicrobial finish. In one specific example, the lining material 24 can be treated with AGION®, available from Sciessent LLC of Wakefield, Massachusetts. TM AM slurry treated liner material 24. In another embodiment, the liner material 24 may be treated with Sanitized slurry from Sanitized AG, Switzerland. TM The lining material 24 is treated with a T20-19 antimicrobial finish and / or a HeiQ Fresh FFL odor control finish from HeiQ AG, Switzerland. Any of the above functionalities and / or treatments of the lining material 24 may be combined with one another.

[0050] When provided in sizes corresponding to typical panty liners, the absorbent material 26 can be any suitable material capable of absorbing a volume of liquid up to, for example, 20-50 mL. The absorbent material 26 can be cotton, polyester, or a blend thereof. Typically, the fabric will have a medium to heavy weight ranging from 250 gsm to 400 gsm. The absorbent material 26 can be a terry cloth fabric in which the non-flat side is maintained as a longer yarn loop or chopped to make fleece. In one example, the absorbent material 26 is a cotton / polyester terry cloth or fleece fabric with a water-absorbing finish, wherein the flat side faces the lining material 24 and the non-flat (e.g., fleece) side faces the waterproof material 28. In another example, the absorbent material 26 is two layers of combined terry or fleece fabric, the flat side of the absorbent material having a water-absorbing finish facing the lining material 24, and the non-flat (e.g., fleece) side of the absorbent material having a water-absorbing finish facing the waterproof material 28. In one embodiment, the absorbent material 26 is a weft-knitted terry cloth whose non-flat side has been shredded to form a fleece made from 84% cotton (30S), 16% polyester (10S) with a weight of 340 gsm, such as CO3F0024-BR01AV from Far Eastern Polytex (VN) Ltd. of Binh Duong, Vietnam. In some embodiments, the absorbent material 26 can be treated with chemicals, knitted, and / or through yarn selection and configured to provide a push-pull action, as described above with respect to the liner material 24. This can be particularly advantageous if a separate liner material 24 is not provided and the absorbent material 26 directly contacts the wearer's skin. In one embodiment, the dual-purpose liner / absorbent push-pull fabric is specifically knitted to have a surface contact angle against the skin that tends to pull moisture away from the skin in the z-direction via capillary action. The fabric is then configured so that the side located further from the skin can again disperse the moisture in the x and y directions throughout and along the distal side of the fabric by capillary action, thereby causing the moisture to be located on the distal side of the fabric rather than on the side contacting the skin. In this regard, the dual-purpose liner / absorbent push-pull fabric as a whole is considered to wick water by capillary action, even though it is knitted from yarns of a hydrophobic polymer such as polyester.

[0051] The waterproof material 28 can be any suitable material that does not allow liquid to pass through it or at least resists liquid. In one example, the waterproof material 28 includes a fabric bonded to a waterproof membrane. The fabric can be a transparent or translucent fabric knitted from nylon, spandex, polyester or a blend thereof. The waterproof membrane can be bonded, laminated, coated or otherwise integrally formed on the fabric or bonded to the fabric. The waterproof membrane can be a polyurethane membrane or a thermoplastic polyurethane (TPU) membrane, and in one example, the waterproof membrane contains coffee oil to provide odor control. In a specific example, the waterproof material 28 is a weft knitted 100% polyester coated with a polyurethane membrane, and the membrane contains coffee oil. One such fabric is KB445S from Singtex Industrial Co., Ltd. of New Taipei City, Taiwan, which is made from a material containing SCAFE TM 100% weft knitted polyester coated with polyol polyurethane film. Alternatively, the waterproof material 28 can be SCAFE from Singtex Industrial Co., Ltd. TM AIRMEM TM In another example, the waterproof material 28 is a fabric treated with a water-repellent finish that is bonded to a waterproof membrane. In another example, the waterproof material 28 is a fabric treated with a water-repellent finish that is not bonded to a waterproof membrane, for example, a nonwoven material coated with a waterproofing chemical.

[0052] The body 12 material can be any fabric suitable for maintaining a snug fit on the wearer's lower torso. For example, the body 12 fabric can be a cotton-synthetic blend (e.g., cotton-spandex), a synthetic blend (of nylon, elastane, polyester, etc.), or any other known suitable fabric. In one embodiment, the body 12 fabric is a weft-knit interlock nylon-elastane blend. In another embodiment, the body 12 fabric is a warp-knit nylon-elastane blend. The body 12 fabric of the lining 18 can be treated with or made of an odor-control material. For example, the fabric of the lining 18 can be knitted partially or entirely with a coffee-containing yarn, such as from SCAFE. TM MYLITHE TM Alternatively, the main body 12 fabric may be treated with an odor control substance, such as HeiQ Fresh FFL odor control finish from HeiQ AG, Switzerland. Additionally or alternatively, the main body 12 fabric may be treated with a wicking finish that wicks moisture away from the wearer's body to the outside of the garment 10. Regardless of the fabric used for the lining 18, any or all of the material layers 24, 26, 28 may be treated with an antimicrobial finish as described herein above for the lining material 24, and / or the threads of the fabric may include antimicrobial fibers (e.g., silver) to neutralize odors.

[0053] Reference again Figure 2 18 and / or the front and rear ends of the main body 12. Alternatively, or in addition, the front and rear ends of the lining material 24 (or absorbent material 26, if no lining material is provided) may be bonded to the fabric of the lining 18 and / or the front 14 or rear 16 of the main body 12 by heat-activated finishing tape 50. Alternatively, or in addition, the front and rear ends of the lining material 24 (or absorbent material 26) may be sewn to the main body 12. The waterproof material 28 may also be bonded to the main body 12 at these locations on its outwardly facing side. At these locations, the waterproof material 28 may be bonded to the absorbent material 26 on its inwardly facing side, which in turn is bonded to the lining material 24 (if present).

[0054] Any of the above mentioned bonds can be made by elastomeric heat activated tapes / films (e.g. TM Alternative methods of bonding include the use of spray adhesives, printed adhesives, web tapes, ultrasonic bonding, and / or liquid glues.

[0055] The elastic 30 mentioned above may be a woven, knitted or textile elastic typical for elasticizing the leg openings and / or waistband of a garment.

[0056] As mentioned, in the above, the garment may be a pair of underwear or swimming trunks. Alternatively, the garment may be a pair of underwear or swimming trunks having a plurality of underpants sewn therein. Figure 1 The chassis 12 may be a pair of shorts, a pair of pants, a skirt, a dress, etc., or a pair of underwear shown. In these examples, the chassis 12 may be sewn around its waistband or incorporated into the waistband of the shorts, pants, skirt, etc. A benefit of the seamless outer portion 15 of the chassis 12 is that when included as built-in underwear in a more fitted garment, the chassis 12 is less noticeable, or at least has a less noticeable seam line, than would otherwise be noticeable if seams were present on the outer portion 15 of the chassis 12.

[0057] In the above description, unless otherwise specified, "inner" refers to the side of a layer that faces the wearer when the garment 10 is worn, and "outer" refers to the side of a layer that faces away from the wearer when the garment 10 is worn. The terms "left" and "right" and "front" and "back" are for reference purposes and do not limit the scope of the present disclosure or the claims.

[0058] In this description, certain terms are used for brevity, clarity, and understanding. No unnecessary limitations beyond the requirements of the prior art should be implied, as these terms are used for descriptive purposes only and are intended to be interpreted broadly. The various components described herein may be used alone or in combination with other systems. Numerous equivalents, alternatives, and modifications are possible within the scope of the appended claims. The methods herein are not limited to being performed in the order described, but may be performed in any logical order.

Claims

1. An absorbent garment comprising: a chassis comprising a front portion, a back portion, and a gusset connecting the front portion and the back portion, wherein the gusset has left and right lateral edges that partially define respective left and right leg openings of the chassis; an absorbent material coupled to an inner surface of the body at least at the gusset; a waterproof material sandwiched between the main body and the absorbent material; and left and right elastic bands coupled to outer lateral edges of the absorbent material; wherein the left elastic band and the right elastic band are bonded to the waterproof material; wherein the waterproof material is attached to the body adjacent respective left and right lateral edges of the gusset; wherein the left and right elastic bands are folded around respective left and right transverse edges of the absorbent material; and wherein the waterproof material is attached to the main body between the folded respective lower halves of each of the left and right elastic bands and the inner face of the main body.

2. The garment of claim 1 , wherein the left and right elastic bands are bonded to the absorbent material, wherein the left and right elastic bands overlap respective left and right lateral edges of the absorbent material.

3. The garment of claim 1 , further comprising a lining material coupled to the absorbent material such that the absorbent material is sandwiched between the lining material and the waterproof material.

4. The garment of claim 3, wherein the left and right elastic bands are folded around respective left and right lateral edges of each of the lining material and the absorbent material; and wherein the left and right elastic bands are bonded to the liner material and the absorbent material, wherein the left and right elastic bands overlap respective left and right transverse edges of each of the liner material and the absorbent material.

5. The garment of claim 1 , wherein left and right transverse edges of the chassis material are folded toward the interior of the chassis at the gusset to define left and right transverse edges of the gusset; and wherein the left and right transverse edges of the waterproof material are attached to the corresponding left and right transverse edges of the main body material.

6. The garment of claim 5, wherein the left and right lateral edges of the waterproof material are attached to the corresponding left and right lateral edges of the body material by stitching.

7. The garment of claim 6, wherein the left and right elastics overlap the seams between the left and right lateral edges, respectively, of the waterproof material and the corresponding left and right lateral edges of the body material.

8. The garment of claim 5 wherein the chassis material is bonded to itself with left and right lateral edges of the chassis material folded over and the chassis is seamless on an exterior face of the chassis at least at the gusset.

9. The garment of claim 1 , wherein the waterproof material comprises a fabric bonded to a waterproof membrane.

10. A method for making an absorbent garment, the method comprising: providing a chassis comprising a front portion, a back portion, and a gusset connecting the front portion and the back portion, wherein the gusset has left and right lateral edges configured to partially define respective left and right leg openings of the chassis; providing an absorbent material sized and shaped to mate with the gusset and having left and right transverse edges configured to extend along respective left and right transverse edges of the gusset; folding the left and right elastic bands around the respective left and right transverse edges of the absorbent material; attaching the left and right elastic bands along respective left and right transverse edges of the absorbent material; providing a waterproof material sized and shaped to mate with the gusset and having left and right lateral edges configured to extend along respective left and right lateral edges of the gusset; attaching left and right transverse edges of the waterproof material to the body adjacent to respective left and right transverse edges of the gusset so that the waterproof material is located on an interior face of the body at the gusset; and placing the attached absorbent material and left and right elastic bands on the gusset over the waterproof material and attaching the left and right elastic bands to the waterproof material, thereby sandwiching the waterproof material between the absorbent material and the main body; wherein the waterproof material is attached to the main body between the folded respective lower halves of each of the left and right elastic bands and the inner face of the main body.

11. The method of claim 10, further comprising bonding the left and right elastic bands to the absorbent material, wherein the left and right elastic bands overlap respective left and right transverse edges of the absorbent material.

12. The method of claim 10, further comprising folding left and right transverse edges of the body material toward the inner face of the body at the gusset to define left and right transverse edges of the gusset; and Attaching the left and right transverse edges of the flashing material to the corresponding left and right transverse edges of the body material.

13. The method of claim 12, wherein the attachment of the left and right transverse edges of the waterproof material to the corresponding left and right transverse edges of the body material is accomplished by sewing.

14. The method of claim 13, wherein the left and right elastic bands overlap the stitching between the left and right transverse edges, respectively, of the waterproof material and the corresponding left and right transverse edges of the body material.

15. The method of claim 12, further comprising bonding the body material to itself, wherein left and right transverse edges of the body material are folded over so that the body is seamless on an outer face of the body at least at the gusset.

16. The method of claim 10, wherein attaching the left and right elastic bands along the respective left and right transverse edges of the absorbent material is accomplished by bonding.

17. The method of claim 10, wherein attaching the left and right lateral edges of the waterproof material to the body adjacent the corresponding left and right lateral edges of the gusset is accomplished by sewing.

18. The method according to claim 10, further comprising: providing a lining material sized and shaped to mate with the gusset and having left and right lateral edges configured to extend along respective left and right lateral edges of the gusset; attaching the left and right elastic bands along respective left and right transverse edges of each of the absorbent material and the liner material; and Over the waterproof material, place the attached lining material, absorbent material and left and right elastic bands onto the lining material and attach the left and right elastic bands to the waterproof material, sandwiching the absorbent material between the lining material and the waterproof material.

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