Underwear with hammock gusset construction that resists leaks

Abstract

Described is an absorbent garment comprising a front body portion comprising a front waistband having a front waistband length; a rear body portion comprising a rear waistband having a rear waistband length; and a gusset comprising an absorbent portion and a front elastic portion; wherein the front elastic portion comprises: a front elastic portion proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband for a first length; wherein a first ratio of the first length to the front waistband length is greater than 0.50.

Description

UNDERWEAR WITH HAMMOCK GUSSET CONSTRUCTION THAT RESISTSLEAKSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 594,740, filed on October 31, 2023, and entitled “UNDERWEAR WITH HAMMOCK GUSSET CONSTRUCTION THAT RESISTS LEAKS,” the content of which is hereby incorporated herein by reference in its entirety for all intents and purposes.FIELD OF THE INVENTION

[0002] The present disclosure relates generally to absorbent articles intended for personal wear, and more particularly to absorbent articles with hammock gusset constructions that resist leaks.BACKGROUND

[0003] Many absorbent articles intended for personal wear, such as diapers, training pants, feminine hygiene products, adult incontinence products, bandages, medical garments, and the like are designed to be sufficiently absorbent to absorb moisture from liquid body exudates including urine, menses, blood, etc., away from the wearer to reduce skin irritation caused by prolonged wetness exposure. Reusable underwear and other similar garments are typically constructed like regular underwear (or other garment), but with added layers for absorbent and barrier properties with the layers being fully sewn into the underwear (or other garment). However, this often results in leakage for boyshort-style underwear (or other garments) due to the downward curve of the gusset edges down toward the leg openings creating a path for fluid to escape as well as wicking from the sewn gusset to the surrounding fabric due to a lack of an edge barrier between the sewn gusset and the surrounding fabric. Additionally, some reusable underwear (or other garment) incorporates a hammock-style gusset that is a fixed, discreet length and does not provide an adaptive fit of the hammock-style gusset for the wearer. Such hammock-style gussets often shrink at a different rate after washing compared to the remaining material of the reusable underwear (or other garment), which results in additional fit, comfort, and leakage issues for the wearer.SUMMARY

[0004] The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0005] According to certain embodiments, and absorbent garment includes a front body portion including a front waistband having a front waistband length; a rear body portion including a rear waistband having a rear waistband length; and a gusset including an absorbent portion and a front elastic portion; where the front elastic portion includes a front elastic portion proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband for a first length; where a first ratio of the first length to the front waistband length is greater than 0.50.

[0006] According to some embodiments, an absorbent garment includes a front body portion including a front waistband; a rear body portion including a rear waistband; and a gusset including an absorbent portion, a front elastic portion, and a rear elastic portion; where the front elastic portion includes a front elastic proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband; where the rear elastic portion includes a rear elastic portion proximal end coupled to a rear end of the absorbent portion; a rear elastic portion first side and a rear elastic portion second side each coupled to the rear bodyportion; and a rear elastic portion distal end coupled to the rear waistband or another portion of the rear body portion.

[0007] According to various embodiments, an absorbent garment includes a front body portion including a front waistband; a rear body portion including a rear waistband; and a gusset including an absorbent portion and a front elastic portion; where the front elastic portion includes a front elastic proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband; where the absorbent portion includes a first side and a second side, the first side and the second side of the gusset each floating free from the front body portion and the rear body portion; and where the absorbent portion further includes a rear end that is coupled to the rear body portion.

[0008] Various implementations described in the present disclosure can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

[0010] FIG. 1A is a front outer view of an absorbent garment with a gusset according to embodiments.

[0011] FIG. IB is a rear outer view of the absorbent garment of FIG. 1 A.

[0012] FIG. 2A is a front inner view of the absorbent garment of FIG. 1A.

[0013] FIG. 2B is a rear inner view of the absorbent garment of FIG. 1A.

[0014] FIG. 3 is an inner view of an absorbent garment with a gusset according to embodiments.

[0015] FIG. 4 is a sectional view of a portion of the gusset of FIG. 1A.

[0016] FIG. 5A is a front outer view of an absorbent garment with a gusset according to embodiments.

[0017] FIG. 5B is a rear outer view of the absorbent garment of FIG. 5 A.

[0018] FIG. 6A is a front inner view of the absorbent garment of FIG. 5 A.

[0019] FIG. 6B is a rear inner view of the absorbent garment of FIG. 5 A.DETAILED DESCRIPTION

[0020] Described herein are improved gussets for absorbent garments as well as absorbent garments incorporating such gussets. In certain embodiments, the gussets described herein may provide an improved fit that minimizes and / or prevents leakage compared to traditional approaches. In some embodiments, the gussets described herein may float from the main body of the absorbent garment to minimize and / or prevent leakage based on the adaptive fit of the gusset and the ability of the gusset to stretch fit to the wearer and move with the wearer separately from portions of the main body of the absorbent garment. Additionally, the gussets described herein continue to provide an improved fit that minimized and / or prevents leakage even after washing based on the design similar shrinkage of the gusset compared to the main body of the absorbent garment. Various other benefits and advantages may be realized with the systems and methods provided herein, and the aforementioned advantages should not be considered limiting.

[0021] FIGS. 1A-2B illustrate an example of an absorbent garment 100 with a hammock gusset 102 according to certain embodiments. In FIGS. 1A-2B, the absorbent garment 100 is illustrated as reusable underwear. However, the particular reusable underwear illustrated should not be considered limiting, and in further embodiments, other types of reusable underwear and / or other types of absorbent garments 100 may be utilized with the hammock gusset 102 as desired, such as but not limited to a brief, an undergarment, a bathing suit, a pajama, a shorts, a leotard, a legging, a pants, a skort, a panty, a boy short, a bikini, a thong, an overalls, a bodysuit, a leotard, a tights, a pantyhose, a boxers, a biking shorts, and / or a compression shorts. Additionally, the absorbent garment 100 may be a non-reusable garment, a single-use garment, a throw-away garment, etc. and / or may be sized to be worn by an infant, a toddler, a child, a teen, an adult, etc.

[0022] As illustrated in FIGS. 1A-2B, the absorbent garment 100 may include a front body portion 106 that includes a front waistband 107 and a rear body portion 108 that includes a rear waistband 109. The front body portion 106 may form the entirety of the front of the absorbent garment 100 when the absorbent garment 100 is folded in half along the left and right edges, as illustrated in FIGS. 1A-1B. However, in some embodiments, the front body portion 106 forms an area of the front of the absorbent garment 100 that is less than the entirety of the front of the absorbent garment 100. The rear body portion 108 may form the entirety of the rear of the absorbent garment 100 when the absorbent garment is folded in half along the left and right edges, as illustrated in FIGS. 1A-1B. However, in some embodiments, the rear body portion 108 forms an area of the rear of the absorbent garment 100 that is less than the entirety of the rear of the absorbent garment 100.

[0023] Additionally, the front waistband 107 has a front waistband length that extends from the leftmost folded edge to the rightmost folded edge of the folded absorbent garment 100 along the front of the folded absorbent garment 100, and the rear waistband 109 has a rear waistband length that extends from the leftmost folded edge to the rightmost folded edge of the folded absorbent garment 100 along the rear of the folded absorbent garment 100. In some embodiments, the front waistband length and the rear waistband length are equal to one another and are each equal to one half of the circumference of the entire waistband.

[0024] The absorbent garment 100 may also include a hammock gusset 102 arranged at least partially between the front body portion 106 and the rear body portion 108. In certain embodiments, the hammock gusset 102 may extend from the front waistband 107 to the rear waistband 109. The hammock gusset 102 may form a portion of an interior surface of the absorbent garment 100 that faces and / or contacts a wearer when the absorbent garment 100 is worn. In some embodiments, the front body portion 106, the front waistband 107, the rear body portion 108, and the rear waistband 109 may also form portions of the interior surface of the absorbent garment 100. In further embodiments, the front body portion 106 and the rear body portion 108 form the entire exterior surface of the absorbent garment 100 that faces away from a wearer when the absorbent garment 100 is worn, and the hammock gusset 102 does not form a portion of the exterior surface of the absorbent garment 100.

[0025] The hammock gusset 102 may include an absorbent portion 104 and a front elastic portion 101. As used herein, “elastic,” “elastomeric,” and the like refer to the ability of a material or composite forming the respective portion to be elongated by at least 50 percent and upon relaxation to return to within at least 50 percent of its original length. In some embodiments, the front elastic portion 101 includes a front elastic portion proximal end 110, a front elastic portion distal end 112, a front elastic portion first side 114, and a front elastic portion second side 116. Each of the front elastic portion proximal end 110, the front elastic portion distal end 112, the front elastic portion first side 114, and the front elastic portion second side 116 may be a seamed area along a corresponding edge of the front elastic portion 101.

[0026] The front elastic portion proximal end 110 may be coupled to a front end 118 of the absorbent portion 104, and the front elastic portion distal end 112 may be coupled to a portion of the front waistband 107. The front elastic portion first side 114 may extend along an edge of the front elastic portion 101 between the front elastic portion proximal end 110 and the front elastic portion distal end 112, and the front elastic portion second side 116 may extend along an edge of the front elastic portion 101 opposite the front elastic portion first side 114 and between the front elastic portion proximal end 110 and the front elastic portion distal end 112. Additionally, the edges of the front elastic portion proximal end 110, the front elastic portion distal end 112, the front elastic portion first side 114, and / or the front elastic portion second side 116 may be linear, curved / non-linear, or a combination of linear and curved / non-linear. In certain embodiments, the front elastic portion 101 may be substantially trapezoidal-shaped.

[0027] The front elastic portion distal end 112 may be coupled to the portion of the front waistband 107 for a first length. In some embodiments, the first length is equal to the length of the entire front elastic portion distal end 112. However, in further embodiments, the first length may be less than the length of the entire front elastic portion distal end 112. A first ratio of the first length to the front waistband length may be greater than 0.50, less than 0.90, between 0.50 and 0.90 (inclusive), between 0.55 and 0.85 (inclusive), between 0.50 and 0.85 (inclusive), or between 0.55 and 0.90 (inclusive).

[0028] In some embodiments, the hammock gusset 102 may also include a rear elastic portion 120. In some embodiments, the rear elastic portion 120 includes a rear elastic portion proximalend 122, a rear elastic portion distal end 124, a rear elastic portion first side 126, and a rear elastic portion second side 128. Each of the rear elastic portion proximal end 122, the rear elastic portion distal end 124, the rear elastic portion first side 126, and the rear elastic portion second side 128 may be a seamed area along a corresponding edge of the rear elastic portion 120.

[0029] The rear elastic portion proximal end 122 may be coupled to a rear end 130 of the absorbent portion 104, and the rear elastic portion distal end 124 may be coupled to a portion of the rear waistband 109. The rear elastic portion first side 126 may extend along an edge of the rear elastic portion 120 between the rear elastic portion proximal end 122 and the rear elastic portion distal end 124, and the rear elastic portion second side 128 may extend along an edge of the rear elastic portion 120 opposite the rear elastic portion first side 126 and between the rear elastic portion proximal end 122 and the rear elastic portion distal end 124. Additionally, the edges of the rear elastic portion proximal end 122, the rear elastic portion distal end 124, the rear elastic portion first side 126, and / or the rear elastic portion second side 128 may be linear, curved / non-linear, or a combination of linear and curved / non-linear. In certain embodiments, the rear elastic portion 120 may be substantially trapezoidal-shaped.

[0030] The rear elastic portion distal end 124 may be coupled to the portion of the rear waistband 109 for a second length. In some embodiments, the second length is equal to the length of the entire rear elastic portion distal end 124. However, in further embodiments, the second length may be less than the length of the entire rear elastic portion distal end 124. A second ratio of the second length to the rear waistband length may be less than 0.35, less than 0.30, or less than 0.40. Additionally, a third ratio of the first length plus the second length to the front waistband length plus the rear waistband length may be between 0.40 and 0.60 (inclusive), between 0.35 and 0.65 (inclusive), between 0.40 and 0.65 (inclusive), or between 0.35 and 0.60 (inclusive).

[0031] The coupling of the front elastic portion distal end 112 to the front waistband 107 may couple the front elastic portion distal end 112 to the front body portion 106. However, in some embodiments, the front elastic portion distal end 112 may be coupled to the front body portion 106 along an area other than the front waistband 107, e.g., along an area of the front body portion 106 below the front waistband 107. Additionally, the coupling of the rear elastic portion distal end 124 to the rear waistband 109 may couple the rear elastic portion distal end 124 to the rear body portion108. However, in some embodiments, the rear elastic portion distal end 124 may be coupled to the rear body portion 108 along an area other than the rear waistband 109, e.g., along an area of the rear body portion 108 below the rear waistband 109. The coupling of the various areas of the hammock gusset 102 may be done via stitching, sealing tape, adhesive and / or other suitable techniques.

[0032] In some embodiments, various areas of the hammock gusset 102 may float from the corresponding front body portion 106 and / or rear body portion 108. As used herein, float may mean without a direct attachment to the front body portion 106 and / or rear body portion 108 for that portion of the hammock gusset 102. For example, the front elastic portion proximal end 110, the front elastic portion first side 114, and the front elastic portion second side 116 may each float from the front body portion 106. Thus, the front elastic portion proximal end 110, the front elastic portion first side 114, and the front elastic portion second side 116 are not directly attached to the front body portion 106. In fact, the front elastic portion 101 may only be coupled to the front body portion 106 via the coupling of the front elastic portion distal end 112 to the front waistband 107 so that the entirety of the front elastic portion 101 floats from the front body portion 106 except for the front elastic portion distal end 112. Additionally, the coupling of the front elastic portion proximal end 110 to the front end 118 of the absorbent portion 104 also floats from the front body portion 106.

[0033] This floating of the front elastic portion 101 permits the floating areas of the front elastic portion 101 to separate from and move relative to the front body portion 106 except at the front elastic portion distal end 112. This floating of the front elastic portion 101 also permits a hand or any other suitable item to be inserted between the floating areas of the front elastic portion 101 and the front body portion 106.

[0034] For the rear elastic portion 120, the rear elastic portion proximal end 122 may float from the rear body portion 108 while the rear elastic portion distal end 124 may be coupled to the rear body portion 108 via the coupling of the rear elastic portion distal end 124 to the rear waistband109, and the rear elastic portion first side 126 and the rear elastic portion second side 128 may each also be coupled to the rear body portion 108. Although the rear elastic portion 120 may be coupled to the rear body portion 108 along the rear elastic portion distal end 124, the rear elasticportion first side 126, and the rear elastic portion second side 128, the remaining areas of the rear elastic portion 120 may float from the rear body portion 108. Additionally, the coupling of the rear elastic portion proximal end 122 to the rear end 130 of the absorbent portion 104 also floats from the rear body portion 108.

[0035] This floating of the rear elastic portion 120 permits the floating areas of the rear elastic portion 120 to separate from and move relative to the rear body portion 108 except at the rear elastic portion distal end 124, the rear elastic portion first side 126, and the rear elastic portion second side 128. This floating of the rear elastic portion 120 also permits a hand or any other suitable item to be inserted between the floating areas of the rear elastic portion 120 and the rear body portion 108.

[0036] In some embodiments, the absorbent portion 104 includes a first segment 132 positioned on a first side of the absorbent portion 104 and a second segment 134 positioned on a second side of the absorbent portion 104. The first segment 132 and / or the second segment 134 may be coupled to the rear body portion 108. The first segment 132 and the second segment 134 may be a seamed area along a corresponding edge of the absorbent portion 104. The rear end 130 of the absorbent portion 104 may extend between a first end of the first segment 132 and a first end of the second segment 134.

[0037] In further embodiments, the absorbent portion 104 may also include a third segment 136 positioned on the first side of the absorbent portion 104 and a fourth segment 138 positioned on the second side of the absorbent portion 104. The third segment 136 and / or the fourth segment 138 may float from the rear body portion 108. The third segment 136 may intersect and extend from a second end of the first segment 132, and the fourth segment 138 may intersect and extend from a second end of the second segment 134. In some embodiments, the third segment 136 and the fourth segment 138 may each extend along the first side and the second side, respectively, of the absorbent portion 104 from the rear of the absorbent garment 100 to the front of the absorbent garment 100. The portions of the third segment 136 and the fourth segment 138 that extend to the front of the absorbent garment 100 may also float from the front body portion 106.

[0038] Thus, the entirety of the absorbent portion 104 may float from the front body portion 106 and the rear body portion 108 except for the first segment 132 and the second segment 134. Thisfloating of the absorbent portion 104 permits the floating areas of the absorbent portion 104 to separate from and move relative to the front body portion 106 and the rear body portion 108 except at the first segment 132 and the second segment 134. This floating of the absorbent portion 104 also permits a hand or any other suitable item to be inserted between the floating areas of the absorbent portion 104 and the respective front body portion 106 and rear body portion 108. However, in certain embodiments, the rear end 130 and the rear elastic portion distal end 124 may be coupled to the rear body portion 108.

[0039] In some embodiments, the front body portion 106 and / or the rear body portion 108 may be formed from a single layer of material. Though one skilled in the art will understand that the front body portion 106 and / or the rear body portion 108 may be formed from any suitable number of layers of material. Similarly, the front elastic portion 101 and / or the rear elastic portion 120 may be formed from a single layer of material. Though one skilled in the art will understand that the front elastic portion 101 and / or the rear elastic portion 120 may be formed from any suitable number of layers of material. Thus, the areas of the absorbent garment 100 where the front elastic portion 101 overlaps the front body portion 106 and the rear elastic portion 120 overlaps the rear body portion 108 may have at least two layers of material. As discussed below with respect to FIG. 4, the absorbent portion 104 may be formed from any suitable number of layers that increase absorbency and reduce leakage. In some embodiments, the material(s) forming the hammock gusset 102 have a maximum elongation applied in the length (or longitudinal) direction ranging from 90% to 130%, from 100% to 120%, or from 105% to 115%.

[0040] FIG. 3 illustrates another example of an absorbent garment 200 with a hammock gusset 202 according to embodiments. The absorbent garment 200 and the hammock gusset 202 are similar to the absorbent garment 100 and the hammock gusset 102 except that the hammock gusset 202 has a different shape compared to the hammock gusset 102.

[0041] Referring to FIG. 4, the absorbent portion 104 generally includes one or more functional layers 324, a barrier layer 326, and a body fabric layer 330. In the embodiment illustrated in FIG. 4, the one or more functional layers 324 includes two functional layers 324A-B. However, the number of functional layers 324 should not be considered limiting, and in other embodiments, theabsorbent portion 104 may include a single functional layer 324 and / or more than two functional layers 324 as desired.

[0042] The one or more functional layers 324 may be various absorbent materials and / or moi sture-wi eking materials as desired. As non-limiting examples, the one or more functional layers 324 may be a material including, but not limited to, fabric, natural yarn, synthetic yarn, synthetic fabric, nonwovens, wovens, microfiber terry fabrics, super absorbent fabrics, cellulose, spacer fabrics, polyurethane, wool, polypropylene, polyamide, polyester, cotton, silk, elastane, rubber, plastic, metal, merino wool, rayon, linen, bamboo, taffeta, Gore-Tex®, X-static®, Tencel™, lyocell, modal, combinations thereof, or other suitable materials as desired. In certain embodiments, a single functional layer 324 may be constructed via various techniques as desired such that the functional layer 324 provides both moisture-wicking and absorbent properties. As a non-limiting example, the functional layer 324A may be constructed from a material or combination of materials such that the functional layer 324A provides both moisture-wicking and liquid absorption. In other embodiments, the moisture-wicking material and the absorbent material may be provided as discrete layers. As non-limiting examples and referring to FIG. 4, the functional layer 324A may be a moisture-wicking layer and the functional layer 324B may be an absorbent layer, or, alternatively, the functional layer 324A may be an absorbent layer and the functional layer 324B may be a moisture-wicking layer.

[0043] The barrier layer 326 may be constructed from various materials such that the barrier layer 326 is substantially liquid-impervious to thereby prevent moisture from penetrating through the absorbent portion 104 from the one or more functional layers 324 and / or out the side edge(s) 334. Suitable materials include, but are not limited to, waterproof materials, water resistant materials, coated materials, laminated materials, nonwovens, films, combinations thereof, and / or other barrier technologies as desired. Such materials may be provided in one or more layers to form the barrier layer 326. In the embodiment illustrated in FIG. 4, the barrier layer 326 is a laminate having a barrier side 340 and a fabric side 342. In this embodiment, the fabric side 342 may be a material such as but not limited to a fabric, natural yarn, synthetic yarn, synthetic fabric, polyurethane, wool, polypropylene, polyamide, polyester, cotton, silk, elastane, rubber, plastic, metal, merino wool, rayon, linen, bamboo, taffeta, Gore-Tex®, X-static®, Tencel™, lyocell, modal, combinations thereof, or other suitable materials as desired. The barrier side 340 may be a film or coating, suchas but not limited to a polyurethane coating and / or other suitable material as desired. In these embodiments, the barrier side 340 and the fabric side 342 may be provided in various orientations or configurations relative to the one or more functional layers 324. Optionally, the barrier layer 326 may be constructed from a material that is treated to be hydrophobic and / or liquid repellant. Optionally, the material of the barrier layer 326 may be treated to be stain-resistant.

[0044] The body fabric layer 330, which may be used to form the front body portion 106 and / or the rear body portion 108, discussed above with respect to FIGS. 1 A-2B, may include any suitable material for use in a garment, including but not limited to fabric, natural yarn, synthetic yarn, synthetic fabric, polyurethane, wool, cotton, spandex, polypropylene, polyamide, polyester, combinations thereof, and / or other suitable materials as desired. Additionally, the front elastic portion 101 and / or the rear elastic portion 120 discussed above with respect to FIGS. 1A-2B may be formed from the same or similar material as the body fabric layer 330. Optionally, the body fabric layer 330 (and / or leg band coverings) may also have hydrophobic and / or liquid repellent properties. As a non-limiting example, the body fabric layer 330 may be treated with a fabric softener or other liquid repellent. Various other materials may be used as the body fabric layer 330 as desired, and the aforementioned examples should not be considered limiting.

[0045] FIG. 4 illustrates a sectional view of an example of an arrangement of the one or more functional layers 324, the barrier layer 326, and the body fabric layer 330 at the third segment 136 and / or the fourth segment 138 of the absorbent portion 104. As shown, no layer of the third segment 136 and / or the fourth segment 138 is coupled to the body fabric layer 330

[0046] As illustrated in FIG. 4, the one or more functional layers 324 include a body side surface 333 that faces the body of the wearer when the absorbent garment 100 is worn, and each of the one or more functional layers 324 includes side edge(s) 334. In FIG. 4, the functional layer 324A is a moisture-wicking layer and the functional layer 324B is an absorbent layer. However, as previously discussed, in other embodiments, a single functional layer 324 may be utilized and / or the functional layers 324 may be provided in various orders or arrangements as desired. As such, the particular functional layer 324A that defines the body side surface 333 should not be considered limiting.

[0047] The barrier layer 326 is provided on the garment side 314 of the one or more functional layers 324 and extends around the side edge(s) 334 of the one or more functional layers 324 such that the barrier layer 326 defines a side edge 344 having an external side 346. The barrier layer 326 additionally covers and / or extends over at least a portion of the body side surface 333 such that the barrier layer 326 has a topmost surface 336. In such embodiments, the barrier layer 326 may include a folded barrier layer portion 338 that is folded under the topmost surface 336. As mentioned, the barrier layer 326 is a laminate having the barrier side 340 and the fabric side 342, and in the embodiment illustrated in FIG. 4, the barrier side 340 is between the one or more functional layers 324 and the fabric side 342. However, in other embodiments, the barrier layer 326 may be a single layer and / or provided in a different arrangement as desired. As a non-limiting example, in other embodiments, the fabric side 342 may be between the barrier side 340 and the one or more functional layers 324.

[0048] FIGS. 5A-6B illustrate an example of an absorbent garment 500 with a hammock gusset 502 according to certain embodiments. In FIGS. 5A-6B, the absorbent garment 500 is illustrated as reusable underwear. However, the particular reusable underwear illustrated should not be considered limiting, and in further embodiments, other types of reusable underwear and / or other types of absorbent garments 500 may be utilized with the hammock gusset 502 as desired, such as but not limited to a brief, an undergarment, a bathing suit, a pajama, a shorts, a leotard, a legging, a pants, a skort, a panty, a boy short, a bikini, a thong, an overalls, a bodysuit, a leotard, a tights, a pantyhose, a boxers, a biking shorts, and / or a compression shorts. Additionally, the absorbent garment 100 may be a non-reusable garment, a single-use garment, a throw-away garment, etc. and / or may be sized to be worn by an infant, a toddler, a child, a teen, an adult, etc.

[0049] As illustrated in FIGS. 5A-6B, the absorbent garment 500 may include a front body portion 506 that includes a front waistband 507 and a rear body portion 508 that includes a rear waistband 509. The front body portion 506 may form the entirety of the front of the absorbent garment 500 when the absorbent garment 500 is folded in half along the left and right edges, as illustrated in FIGS. 5A-5B. However, in some embodiments, the front body portion 506 forms an area of the front of the absorbent garment 500 that is less than the entirety of the front of the absorbent garment 500. The rear body portion 508 may form the entirety of the rear of the absorbent garment 500 when the absorbent garment is folded in half along the left and right edges,as illustrated in FIGS. 5A-5B. However, in some embodiments, the rear body portion 508 forms an area of the rear of the absorbent garment 500 that is less than the entirety of the rear of the absorbent garment 500.

[0050] Additionally, the front waistband 507 has a front waistband length that extends from the leftmost folded edge to the rightmost folded edge of the folded absorbent garment 500 along the front of the folded absorbent garment 500, and the rear waistband 509 has a rear waistband length that extends from the leftmost folded edge to the rightmost folded edge of the folded absorbent garment 500 along the rear of the folded absorbent garment 500. In some embodiments, the front waistband length and the rear waistband length are equal to one another and are each equal to one half of the circumference of the entire waistband.

[0051] The absorbent garment 500 may also include a hammock gusset 502 arranged at least partially between the front body portion 506 and the rear body portion 508. In certain embodiments, the hammock gusset 502 may extend from the front waistband 507 to an area of the rear body portion 508 below the rear waistband 509. The hammock gusset 502 may form a portion of an interior surface of the absorbent garment 500 that faces and / or contacts a wearer when the absorbent garment 500 is worn. In some embodiments, the front body portion 506, the front waistband 507, the rear body portion 508, and the rear waistband 509 may also form portions of the interior surface of the absorbent garment 500. In further embodiments, the front body portion 506 and the rear body portion 508 form the entire exterior surface of the absorbent garment 500 that faces away from a wearer when the absorbent garment 500 is worn, and the hammock gusset 502 does not form a portion of the exterior surface of the absorbent garment 500.

[0052] The hammock gusset 502 may include an absorbent portion 504 and a front elastic portion 501 and may not include a rear elastic portion. In some embodiments, the front elastic portion 501 includes a front elastic portion proximal end 510, a front elastic portion distal end 512, a front elastic portion first side 514, and a front elastic portion second side 516. Each of the front elastic portion proximal end 510, the front elastic portion distal end 512, the front elastic portion first side 514, and the front elastic portion second side 516 may be a seamed area along a corresponding edge of the front elastic portion 501.

[0053] The front elastic portion proximal end 510 may be coupled to a front end 518 of the absorbent portion 504, and the front elastic portion distal end 512 may be coupled to a portion of the front waistband 507. The front elastic portion first side 514 may extend along an edge of the front elastic portion 501 between the front elastic portion proximal end 510 and the front elastic portion distal end 512, and the front elastic portion second side 516 may extend along an edge of the front elastic portion 501 opposite the front elastic portion first side 514 and between the front elastic portion proximal end 510 and the front elastic portion distal end 512. Additionally, the edges of the front elastic portion proximal end 510, the front elastic portion distal end 512, the front elastic portion first side 514, and / or the front elastic portion second side 516 may be linear, curved / non-linear, or a combination of linear and curved / non-linear. In certain embodiments, the front elastic portion 501 may be substantially trapezoidal-shaped.

[0054] The front elastic portion distal end 512 may be coupled to the portion of the front waistband 507 for a first length. In some embodiments, the first length is equal to the length of the entire front elastic portion distal end 512. However, in further embodiments, the first length may be less than the length of the entire front elastic portion distal end 512. A first ratio of the first length to the front waistband length may be greater than 0.50, less than 0.90, between 0.50 and 0.90 (inclusive), between 0.55 and 0.85 (inclusive), between 0.50 and 0.85 (inclusive), or between 0.55 and 0.90 (inclusive).

[0055] The coupling of the front elastic portion distal end 512 to the front waistband 507 may couple the front elastic portion distal end 512 to the front body portion 506. However, in some embodiments, the front elastic portion distal end 512 may be coupled to the front body portion 506 along an area other than the front waistband 507, e.g., along an area of the front body portion 506 below the front waistband 507. The coupling of the various areas of the hammock gusset 502, may be done via stitching, sealing tape, adhesive and / or other suitable techniques.

[0056] In some embodiments, various areas of the hammock gusset 502 may float from the corresponding front body portion 506 and / or rear body portion 508. As used herein, float may mean without a direct attachment to the front body portion 506 and / or rear body portion 508 for that portion of the hammock gusset 502. For example, the front elastic portion proximal end 510, the front elastic portion first side 514, and the front elastic portion second side 516 may each floatfrom the front body portion 506. Thus, the front elastic portion proximal end 510, the front elastic portion first side 514, and the front elastic portion second side 516 are not directly attached to the front body portion 506. In fact, the front elastic portion 501 may only be coupled to the front body portion 506 via the coupling of the front elastic portion distal end 512 to the front waistband 507 so that the entirety of the front elastic portion 501 floats from the front body portion 506 except for the front elastic portion distal end 512. Additionally, the coupling of the front elastic portion proximal end 510 to the front end 518 of the absorbent portion 504 also floats from the front body portion 506.

[0057] This floating of the front elastic portion 501 permits the floating areas of the front elastic portion 501 to separate from and move relative to the front body portion 506 except at the front elastic portion distal end 512. This floating of the front elastic portion 501 also permits a hand or any other suitable item to be inserted between the floating areas of the front elastic portion 501 and the front body portion 506.

[0058] The absorbent portion 504 may include a rear end 530 that may be coupled to the rear body portion 508. In some embodiments, the absorbent portion 504 may include a first segment 532 positioned on a first side of the absorbent portion 504 and a second segment 534 positioned on a second side of the absorbent portion 504. The first segment 532 and / or the second segment 534 may each extend from the front of the absorbent garment 500 to the rear of the absorbent garment 500 and may each float from the front body portion 506 and / or the rear body portion 508.

[0059] Thus, the entirety of the absorbent portion 504 may float from the front body portion 506 and the rear body portion 508 except for the rear end 530. This floating of the absorbent portion 504 permits the floating areas of the absorbent portion 504 to separate from and move relative to the front body portion 506 and the rear body portion 508 except at the rear end 530. This floating of the absorbent portion 504 also permits a hand or any other suitable item to be inserted between the floating areas of the absorbent portion 504 and the respective front body portion 506 and rear body portion 508.

[0060] In some embodiments, the front body portion 506 and / or the rear body portion 508 may be formed from a single layer of material. Though one skilled in the art will understand that the front body portion 506 and / or the rear body portion 508 may be formed from any suitable numberof layers of material. Similarly, the front elastic portion 501 may be formed from a single layer of material. Though one skilled in the art will understand that the front elastic portion 501 may be formed from any suitable number of layers of material. Thus, the areas of the absorbent garment 500 where the front elastic portion 501 overlaps the front body portion 506 may have at least two layers of material. As discussed above with respect to FIG. 4, the absorbent portion 504 may be formed from any suitable number of layers that increase absorbency and reduce leakage.

[0061] As mentioned, the gussets described herein and absorbent garments incorporating such gussets may have improved leakage control compared to traditional approaches. The gussets described herein may include one or more elastic portion(s) on either side of the absorbent portion with areas of the one or more elastic portion(s) and the absorbent portion floating from the main body of the absorbent garment to provide an adaptive fit of the gusset to the wearer. The adaptive fit of the gusset serves to reduce, minimize, and / or prevent leakage regardless of the shape and / or style of the absorbent garment. Additionally, stretch properties are incorporated into the gussets described herein to minimize shrinkage mismatch between the gusset and the absorbent garment after washing so that the improved adaptive fit features of the gusset remain present in the absorbent garment even after repeated washing of the absorbent garment. Various other benefits and advantages may be realized with the systems and methods provided herein, and the aforementioned advantages should not be considered limiting.

[0062] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as “Embodiments” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These embodiments are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example embodiments but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0063] Embodiment 1. An absorbent garment comprising: a front body portion comprising a front waistband having a front waistband length; a rear body portion comprising a rear waistband having a rear waistband length; and a gusset comprising an absorbent portion and a front elastic portion; wherein the front elastic portion comprises: a front elastic portion proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second sideeach floating from the front body portion; and a front elastic portion distal end coupled to the front waistband for a first length; wherein a first ratio of the first length to the front waistband length is greater than 0.50.

[0064] Embodiment 2. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the first ratio is less than 0.90.

[0065] Embodiment 3. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the first ratio is between 0.55 and 0.85, inclusive.

[0066] Embodiment 4. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the gusset further comprises a rear elastic portion comprising: a rear elastic portion proximal end coupled to a rear end of the absorbent portion; a rear elastic portion first side and a rear elastic portion second side each coupled to the rear body portion; and a rear elastic portion distal end coupled to the rear waistband for a second length.

[0067] Embodiment 5. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein a second ratio of the second length to the rear waistband length is less than 0.35.

[0068] Embodiment 6. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein a third ratio of the first length plus the second length to the front waistband length plus the rear waistband length is between 0.40 and 0.60, inclusive.

[0069] Embodiment 7. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the gusset has a maximum elongation applied in a longitudinal direction ranging from 90% to 130%.

[0070] Embodiment 8. An absorbent garment comprising: a front body portion comprising a front waistband; a rear body portion comprising a rear waistband; and a gusset comprising an absorbent portion, a front elastic portion, and a rear elastic portion; wherein the front elastic portion comprises: a front elastic proximal end coupled to a front end of the absorbent portion; a frontelastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband; wherein the rear elastic portion comprises: a rear elastic portion proximal end coupled to a rear end of the absorbent portion; a rear elastic portion first side and a rear elastic portion second side each coupled to the rear body portion; and a rear elastic portion distal end coupled to the rear waistband or another portion of the rear body portion.

[0071] Embodiment 9. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the absorbent portion comprises a first segment positioned on a first side of the absorbent portion and a second segment positioned on a second side of the absorbent portion and wherein each of the first segment and the second segment is coupled to the rear body portion.

[0072] Embodiment 10. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the absorbent portion further comprises a third segment positioned on the first side of the absorbent portion and a fourth segment positioned on the second side of the absorbent portion; and wherein each of the third segment and the fourth segment floats from the rear body portion.

[0073] Embodiment 11. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the gusset is only coupled to the front body portion via the front elastic portion along the front waistband.

[0074] Embodiment 12. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein each of the front elastic portion and the rear elastic portion is trapezoidal-shaped.

[0075] Embodiment 13. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein: the front waistband has a front waistband length, and the front elastic portion distal end is coupled to the front waistband for a first length; a first ratio of the first length to the front waistband length is greater than 0.50; the rear waistband has a rear waistband length, and the rear elastic portion distal end is coupled to the rear waistband for a second length; and a second ratio of the second length to the rear waistband length is less than 0.35.

[0076] Embodiment 14. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the absorbent garment is a reusable, boyshort underwear.

[0077] Embodiment 15. An absorbent garment comprising: a front body portion comprising a front waistband; a rear body portion comprising a rear waistband; and a gusset comprising an absorbent portion and a front elastic portion; wherein the front elastic portion comprises: a front elastic proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband; wherein the absorbent portion comprises a first side and a second side, the first side and the second side of the gusset each floating free from the front body portion and the rear body portion; and wherein the absorbent portion further comprises a rear end that is coupled to the rear body portion.

[0078] Embodiment 16. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the front end of the absorbent portion floats from the front body portion.

[0079] Embodiment 17. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the gusset further comprises a rear elastic portion comprising a rear elastic portion proximal end coupled to the rear end of the absorbent portion.

[0080] Embodiment 18. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the rear elastic portion is coupled to the rear body portion along each edge of the rear elastic portion.

[0081] Embodiment 19. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the absorbent portion comprises a first segment and a third segment positioned on the first side of the absorbent portion and a second segment and a fourth segment positioned on the second side of the absorbent portion; each of the first segment and the second segment is coupled to the rear body portion and each of the third segment and the fourth segment floats from the rear body portion; and the first segment ispositioned between the third segment and the rear elastic portion, and the second segment is positioned between the fourth segment and the rear elastic portion.

[0082] Embodiment 20. The absorbent garment of any of the preceding or subsequent embodiments or combination of embodiments, wherein the front waistband has a front waistband length, and the front elastic portion distal end is coupled to the front waistband for a first length; and a first ratio of the first length to the front waistband length is greater than 0.50.

[0083] The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. It should be appreciated that the various elements of concepts from the figures may be combined without departing from the spirit or scope of the invention.

[0084] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, or gradients thereof, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0085] As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, anobject that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained.

[0086] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. The invention is susceptible to various modifications and alternative constructions, and certain shown exemplary embodiments thereof are shown in the drawings and have been described above in detail. Variations of those preferred embodiments, within the spirit of the present invention, may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, it should be understood that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the abovedescribed elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

[0087] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Claims

CLAIMSThat which is claimed:

1. An absorbent garment comprising: a front body portion comprising a front waistband having a front waistband length; a rear body portion comprising a rear waistband having a rear waistband length; and a gusset comprising an absorbent portion and a front elastic portion; wherein the front elastic portion comprises: a front elastic portion proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband for a first length; wherein a first ratio of the first length to the front waistband length is greater than 0.50.

2. The absorbent garment of claim 1, wherein the first ratio is less than 0.90.

3. The absorbent garment of claim 1, wherein the first ratio is between 0.55 and 0.85, inclusive.

4. The absorbent garment of claim 1, wherein the gusset further comprises a rear elastic portion comprising: a rear elastic portion proximal end coupled to a rear end of the absorbent portion; a rear elastic portion first side and a rear elastic portion second side each coupled to the rear body portion; and a rear elastic portion distal end coupled to the rear waistband for a second length.

5. The absorbent garment of claim 4, wherein a second ratio of the second length to the rear waistband length is less than 0.35.

6. The absorbent garment of claim 5, wherein a third ratio of the first length plus the second length to the front waistband length plus the rear waistband length is between 0.40 and 0.60, inclusive.

7. The absorbent garment of claim 1, wherein the gusset has a maximum elongation applied in a longitudinal direction ranging from 90% to 130%.

8. An absorbent garment comprising: a front body portion comprising a front waistband; a rear body portion comprising a rear waistband; and a gusset comprising an absorbent portion, a front elastic portion, and a rear elastic portion; wherein the front elastic portion comprises: a front elastic proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband; wherein the rear elastic portion comprises: a rear elastic portion proximal end coupled to a rear end of the absorbent portion; a rear elastic portion first side and a rear elastic portion second side each coupled to the rear body portion; and a rear elastic portion distal end coupled to the rear waistband or another portion of the rear body portion.

9. The absorbent garment of claim 8, wherein the absorbent portion comprises a first segment positioned on a first side of the absorbent portion and a second segment positioned on a second side of the absorbent portion and wherein each of the first segment and the second segment is coupled to the rear body portion.

10. The absorbent garment of claim 9, wherein the absorbent portion further comprises a third segment positioned on the first side of the absorbent portion and a fourth segment positioned onthe second side of the absorbent portion; and wherein each of the third segment and the fourth segment floats from the rear body portion.

11. The absorbent garment of claim 8, wherein the gusset is only coupled to the front body portion via the front elastic portion along the front waistband.

12. The absorbent garment of claim 8, wherein each of the front elastic portion and the rear elastic portion is trapezoidal-shaped.

13. The absorbent garment of claim 8, wherein: the front waistband has a front waistband length, and the front elastic portion distal end is coupled to the front waistband for a first length; a first ratio of the first length to the front waistband length is greater than 0.50; the rear waistband has a rear waistband length, and the rear elastic portion distal end is coupled to the rear waistband for a second length; and a second ratio of the second length to the rear waistband length is less than 0.35.

14. The absorbent garment of claim 8, wherein the absorbent garment is a reusable, boyshort underwear.

15. An absorbent garment comprising: a front body portion comprising a front waistband; a rear body portion comprising a rear waistband; and a gusset comprising an absorbent portion and a front elastic portion; wherein the front elastic portion comprises: a front elastic proximal end coupled to a front end of the absorbent portion; a front elastic portion first side and a front elastic portion second side each floating from the front body portion; and a front elastic portion distal end coupled to the front waistband;wherein the absorbent portion comprises a first side and a second side, the first side and the second side of the gusset each floating free from the front body portion and the rear body portion; and wherein the absorbent portion further comprises a rear end that is coupled to the rear body portion.

16. The absorbent garment of claim 15, wherein the front end of the absorbent portion floats from the front body portion.

17. The absorbent garment of claim 15, wherein the gusset further comprises a rear elastic portion comprising a rear elastic portion proximal end coupled to the rear end of the absorbent portion.

18. The absorbent garment of claim 17, wherein the rear elastic portion is coupled to the rear body portion along each edge of the rear elastic portion.

19. The absorbent garment of claim 17, wherein: the absorbent portion comprises a first segment and a third segment positioned on the first side of the absorbent portion and a second segment and a fourth segment positioned on the second side of the absorbent portion; each of the first segment and the second segment is coupled to the rear body portion and each of the third segment and the fourth segment floats from the rear body portion; and the first segment is positioned between the third segment and the rear elastic portion, and the second segment is positioned between the fourth segment and the rear elastic portion.

20. The absorbent garment of claim 15, wherein: the front waistband has a front waistband length, and the front elastic portion distal end is coupled to the front waistband for a first length; and a first ratio of the first length to the front waistband length is greater than 0.50.

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