Shaped absorbent gusset

Abstract

An absorbent gusset (30) for a washable absorbent undergarment has left and right side panels (331,341) which are mirror symmetric about a sagittal plane (SP) of the gusset. Each side panel has a panel length that extends between an upper edge (335) and a lower apex (336) and a panel width that extends between inner and outer side edges (333,334). A mid-line ML extends between a respective midpoint of the upper edge (335) and the lower apex (336). The outer side edges (334) are closer to the respective midline ML than the inner side edges (333), at least along one-third (1 / 3) of the panel length, and the inner side edges (333) being joined together along the sagittal plane.

Description

SHAPED ABSORBENT GUSSETFIELD OF INVENTION

[0001] The present disclosure relates to washable absorbent undergarments, and more particularly to an absorbent gusset for integration into such washable absorbent undergarments.BACKGROUND

[0002] Absorbent underwear products have been developed to address the needs of individuals dealing with body liquid leakage. These products aim to provide protection against leakage while maintaining comfort and discretion for the wearer. T raditional disposable absorbent products have been widely used, but there is growing interest in reusable, washable alternatives due to environmental concerns and long-term cost considerations.

[0003] Washable absorbent underwear typically incorporates multiple layers of materials with different properties to manage moisture and prevent leakage. These layers may include a liquid permeable top layer, a liquid impermeable bottom layer, and one or more intermediate absorbent layers arranged between the top and bottom layers. The design and construction of these layers can significantly impact the overall performance and comfort of the product.

[0004] One challenge in designing washable absorbent underwear is achieving an effective balance between absorbency and comfort. Increasing the amount of absorbent materials will improve the absorption but may compromise the garment's flexibility and discretion. Additionally, the repeated washing and drying cycles that these products undergo can potentially affect their performance and durability over time.

[0005] For male-specific absorbent underwear, there may be unique design considerations related to the anatomical differences and typical patterns of urine release. Creating a product that provides adequate coverage and absorption in the appropriate areas while maintaining a masculine appearance and comfort can be particularly challenging.

[0006] A reusable and washable absorbent male undergarment is disclosed in W02025011764. This garment includes an absorbent front assembly having a shaped pouch construction in order to provide space for the genitals. The assembly comprises first and second side panels joined along long curved side-edges by a curved central join extending in a longitudinal direction from a top edge to a bottom of the absorbent front assembly The side panels each comprise multiple layers including a liquid impermeable layer, a liquid permeable layer and an absorbent layer. Such known assemblies offer good absorbent performance but do not always achieve an optimal fit.

[0007] Therefore, there may still exist a need to provide washable absorbent underwear that not only possess efficient fluid handling properties that are at least comparable to those of conventional disposable absorbent articles, but that also do so while improving user comfort and / or discretion. In this sense, it may be highly desirable to provide and absorbent gusset that offers increased comfort and better fit.SUMMARY

[0008] The above and further objects may be achieved with an absorbent gusset for integration in a washable absorbent undergarment in accordance with claim 1 and a washable absorbent undergarment according to claim 19. Variations of the disclosure are set out in the dependent claims and in the following description.

[0009] Accordingly, in a first aspect of the present disclosure there is provided a shaped absorbent gusset for a washable absorbent undergarment, the gusset having a length dimension in a longitudinal direction (y) and a width dimension in a transverse direction (x), measured along a plane of the gusset and further having a thickness dimension in a z-direction perpendicular to the plane of the gusset, , the gusset having a perimeter that comprises a top edge and first and second side edges, the gusset comprising a plurality of layers, including a liquid permeable layer and a liquid impermeable layer, wherein the gusset comprises left and right side panels which are mirror symmetric about a sagittal plane (SP) of the gusset, each side panel having a panel length that extends between an upper edge and a lower apex and a panel width that extends between inner and outer sides edges, a mid-line extending between a respective midpoint of the upper edge and the lower apex, wherein each panel is asymmetric, whereby the outer side edges are closer to the respective midline than the inner side edges at least along one-third (1 / 3) of the panel length, and the inner side edges being joined together along the sagittal plane to form a three dimensional cup. The outer side edges may, according to a further alternative, be closer to the respective midline than the inner side edges at least along one-half (1 / 2) of the panel length or at least two-third (2 / 3) of the panel length, or at least three / fourth (3 / 4) of the panel length. This configuration allows for a more natural and comfortable fit while maintaining adequate coverage and absorbency. The cup-shaped design may have a deeper but narrower form that improves fit and comfort for the wearer, particularly reducing chafing at the thighs and flattening of the genitalia.

[0010] As a result of the differences between the inner and outer side edges, each panel is asymmetric about its midline. In this sense, closer is intended to denote that the maximum distance to the midline is less.

[0011] According to a second aspect of the present disclosure, there is provided a shaped absorbent gusset for a washable absorbent undergarment, the gusset having a length dimension in a longitudinal direction (y) and a width dimension in a transverse direction (x), measured along a plane of the gusset and further having a thickness dimension in a z-direction perpendicular to the plane of thegusset, the gusset having a perimeter that comprises a top edge and first and second side edges, the gusset comprising a plurality of layers, including a liquid permeable layer and a liquid impermeable layer, wherein the gusset comprises left and right side panels which are mirror symmetric about a sagittal plane (SP) of the gusset, each side panel having a panel length that extends between an upper edge and a lower apex and a panel width that extends between inner and outer sides edges, a mid-line extending between a respective midpoint of the upper edge and the lower apex, wherein each panel is asymmetric, whereby an outer area between an outer side edge and the respective midline is less than an inner area between an inner side edge and the midline, preferably the outer area is less than 90% or less than 80% or less than 70% of the inner area.

[0012] According to a third aspect of the present disclosure, there is provided a shaped absorbent gusset for a washable absorbent undergarment, the gusset having a length dimension in a longitudinal direction (y) and a width dimension in a transverse direction (x), measured along a plane of the gusset and further having a thickness dimension in a z-direction perpendicular to the plane of the gusset, , the gusset having a perimeter that comprises a top edge and first and second side edges, the gusset comprising a plurality of layers, including a liquid permeable layer and a liquid impermeable layer, wherein the gusset comprises left and right side panels which are mirror symmetric about a sagittal plane (SP) of the gusset, each side panel having a panel length that extends between an upper edge and a lower apex and a panel width that extends between inner and outer sides edges, a mid-line extending between a respective midpoint of the upper edge and the lower apex, wherein each panel is asymmetric, the inner side edges are at least partially curved and have an inner radius in the lower region defined as the smallest radius of curvature of the inner side edge. The inner side edges are joined together along the sagittal plane to form a three dimensional cup. According to the present disclosure, the panels are distinguished over those of the prior art at least in that the outer radius is greater than the inner radius. This configuration allows for a more natural and comfortable fit while maintaining adequate coverage and absorbency. The cup-shaped design may have a deeper but narrower form that improves fit and comfort for the wearer, particularly reducing chafing at the thighs and flattening of the genitalia. The outer radius may be at least 90 mm. This dimension leads to relatively slight curvature of the outer contour of the gusset. The inner radius may be in a range of from 60 mm to 80 mm.

[0013] According to a fourth aspect of the present disclosure, there is provided a shaped absorbent gusset for a washable absorbent undergarment, the gusset having a length dimension in a longitudinal direction (y) and a width dimension in a transverse direction (x), measured along a plane of the gusset and further having a thickness dimension in a z-direction perpendicular to the plane of the gusset, the gusset having a perimeter that comprises a top edge and first and second side edges, the gusset comprising a plurality of layers, including a liquid permeable layer and a liquid impermeable layer, wherein the gusset comprises left and right side panels which are mirror symmetric about a sagittal plane (SP) of the gusset, each side panel having a panel length that extends between an upper edge and a lower apex and a panel width that extends between inner and outer sides edges, a mid-lineextending between a respective midpoint of the upper edge and the lower apex, wherein each panel is asymmetric, and the inner side edges are joined together along the sagittal plane to form a three dimensional cup, wherein the length dimension comprises an upper region, a lower region, and a central region arranged in between the upper and lower regions. The outer side edge and / or the inner side edge may each comprise a straight section in the upper region extending to the upper edge. The upper region of the gusset may thus be less cup-shaped and relatively flat compared to the lower region. Furthermore, the outer side edge and / or the inner side edge may in the central region transition between a straight section and a curved section. It will be understood that a straight section may transition to a curved region having a single fixed radius of curvature, whereby the transition takes place at a defined point at which the straight section is tangential to the curve. Alternatively, this transition may take place gradually with the radius of curvature decreasing from a large value to eventually arrive at the smallest value. It is also possible that the radius of curvature of the inner and / or outer side edges may increase again towards the lower apex.

[0014] In some embodiments, the upper region, the central region, and the lower region may each extend one-third (1 / 3) of the length dimension of the gusset. The main curvature is thus to be found in the lower third of each panel, in particular for the inner side edge. This leads to a cup shape in which the depth of the cup is greatest in the lower third of the gusset close to the lower apex and decreases gradually towards the top edge

[0015] According to a nonlimiting embodiment the panel length may be at least 3 times the maximum panel width, or at least 3.5 times the maximum panel width, or at least 4 times the maximum panel width. Furthermore, according to another non-limiting example, the panel length may be at least 5 times the maximum panel width.

[0016] The panel width may increase from the upper edge to the central region and decrease from the central region to the lower apex. The maximum panel width may be no greater that 110% or 120% of the width at the upper edge.

[0017] The shape of the gusset may also be distinguished over existing gussets in that an inner apex angle between an inner side edge and the midline at the apex may be greater than an outer apex angle between an outer side edge and the midline at the apex. For example, the inner apex angle may be more than 5 degrees or 7 degrees or 10 degrees greater than the outer apex angle. The inner apex angle may be between 35 degrees and 50 degrees, such as between 40 degrees and 45 degrees.

[0018] The panels may also be asymmetric at the upper edge. In particular, an outer side angle between the upper edge and the outer side edge may be greater than an inner side angle between the upper edge and the inner side edge.

[0019] In addition to the liquid permeable layer and the liquid impermeable layer, the gusset may further comprise at least one absorbent layer arranged between the liquid permeable layer and the liquid impermeable layer. Alternatively, the gusset may comprise only the liquid permeable layer andthe liquid impermeable layer, wherein the liquid permeable layer and / or the liquid impermeable layer is absorbent. The plurality of layers may be arranged as a stack. The plurality of layers may further comprise first and second absorbent layers. These absorbent layers may be coextensive in at least one of the transverse and longitudinal directions (x, y). The first absorbent layer may be a liquid transfer layer arranged between the liquid permeable layer and the second absorbent layer. The second absorbent layer may be a liquid storage layer arranged between the first absorbent layer and the liquid impermeable layer. Such layered structure helps optimize liquid management by efficiently transferring liquid away form the wearer’s skin and storing it securely within the absorbent gusset, and by extension, contributes to enhancing the physical comfort of the article during use and the user’s confidence in the same.

[0020] Various constructions may be provided for holding the layers together, including mechanical means such as stitching or stapling and adhesive means. In an embodiment, a bonding tape may be provided around some or all of the perimeter adapted to seal the plurality of layers together. This tape may enhance the integrity of the gusset structure and help prevent leakage.

[0021] The layers and panels of the gusset may be of any appropriate materials that achieve the desired functions and subject to the gusset being washable. Washable in this context should be understood as being suitable to undergo at least 10 washing cycles at a temperature of at least 30° Celsius, without disintegrating. During washing, the gusset should release any absorbed fluids, thereby regenerating the absorptive functioning, enabling the washable absorbent undergarment to be reused for the same purpose again. The gusset and the undergarment to which it is attached may thus be suitable to be subjected to an aqueous solution containing detergent without losing their structural integrity. This aqueous solution may be heated as part of the laundering process, e.g. to 30°C, 40°C or 60°C. The laundering may be performed by a machine.

[0022] In some embodiments, the gusset may be polyester based, meaning that it comprises predominantly polyester. Preferably it comprises more than 90% or more than 92% or more than 94% polyester. Each layer of the plurality of layers may comprise polyester. The absorbent gusset may include elastane in order to enhance comfort. Each layer of the plurality of layers may comprise elastane. The structure of the layers may be woven and / or knitted. In some embodiments, all of the layers are knitted e.g. weft knitted, thus improving the stretchability compared to woven fabrics.

[0023] The liquid impermeable layer may be any suitable layer that ensures that moisture cannot penetrate through the gusset to the garment beneath. The impermeable layer may be a separate layer or may be present as an impermeable coating on a supporting fabric. In an embodiment the liquid impermeable layer comprises a thermoplastic polyurethane film supported on a fabric layer, in particular a polyester based layer such as for example a polyester / elastane layer.

[0024] The inner side edges of the left and right panels may be joined together by any suitable procedure or means, including adhesive, welding, heat sealing or mechanical means. In an embodiment the panels are joined by stitching. The plurality of layers that are present in the left and right panels mayall be joined together at the inner side edges by one process. Alternatively, the individual layers of the left and right side panels may be first joined to each other before the layers are built into a stack and joined around the perimeter.

[0025] A washable absorbent undergarment incorporating the shaped absorbent gusset may also be provided. The undergarment may comprise a textile garment with a front portion, a rear portion, a crotch portion arranged between the front and rear portions, and a waistband attached to the front and rear portions. The absorbent gusset may be located at an interior of the garment and extend from within the front portion and into the crotch portion.

[0026] In embodiments, a top edge of the gusset may be directly joined to the waistband. This configuration may provide a more secure attachment of the gusset to the garment.

[0027] The first side edge and the second side edge of the gusset may additionally or alternatively be joined to the front portion of the textile garment by stitching.

[0028] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0029] The present invention will be discussed in more detail below, with reference to the attached drawings, in which:

[0030] Figure 1 shows a front view of the garment-facing side of an exemplary male-style washable absorbent underwear;

[0031] Figure 2 shows another exemplary brief-style washable absorbent underwear in planar view from the inner, wearer-facing side;

[0032] Figure 3 shows a planar view of an exemplary absorbent gusset;

[0033] Figure 4 shows a cross-section taken along the line IV of Fig. 3; and

[0034] Figure 5 shows an exemplary transverse join between the absorbent gusset and the waistband of the textile garment.

[0035] Figure 6 shows the left and right side panels of Fig 3 laid flat prior to joining.

[0036] Figure 7 shows left and right side panels of a prior art gusset.DETAILED DESCRIPTION

[0037] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0038] In the context of this disclosure, certain terms may be used interchangeably to describe different types of stitches. The terms "multithread chain stitch" and "coverstitch" may be used to refer to the same type of stitching. Similarly, the terms "overedge chain stitch" and "overlock stitch" may be used interchangeably. These stitches are defined according to international standards, such as ISO 4915. Also more generally, the terms “stitching” and “stitches” may be used interchangeably herein.

[0039] A join that is permanent means a connection between two or more components that is intended to remain intact throughout the normal use and washing of the garment. A permanent join may be achieved through various methods, including but not limited to stitching, gluing, bonding, or welding.

[0040] "Thread coverage" describes the extent to which the threads of a stitch are visible on a particular side of the fabric. Higher thread coverage indicates a greater presence of visible thread, while lower thread coverage results in a more discreet appearance.

[0041] The terms “absorbent undergarment” or, in plural, “absorbent underwear” are used interchangeably and refer to garments that are worn and intended to be placed against the skin of the wearer to absorb and contain body fluids such as urine. The absorbent undergarment is a fabric undergarment, and not a diaper. The undergarment according to the present disclosure is intended to be worn in the same manner as conventional underwear and to be laundered after use for reuse as an absorbent undergarment.

[0042] The absorbent undergarment is configured to be washable. Washable should be understood as being suitable to undergo at least 10 washing cycles at a temperature of at least 30° Celsius, without disintegrating. During the washing, the absorbent undergarment releases the absorbed fluids, thereby regenerating the absorptive functioning, enabling the washable absorbent undergarment to be reused for the same purpose again. The absorbent undergarment may thus be subjected to an aqueous solution containing detergent without losing its structural features. This aqueous solution may be heated as part of the laundering process, e.g. to 30°C, 40°C or 60°C. The laundering may be performed by a machine.

[0043] Different aspects of the present disclosure will be described more fully hereinafter with reference to the accompanying figures. The washable absorbent undergarment provided herein can, however, be realized in many different forms, such as different sizes and / or in different absorption levels. Accordingly, the washable absorbent undergarment should not be construed as being limited to the aspects set forth herein.

[0044] Figure 1 shows an exemplary washable absorbent undergarment 1 comprising a textile garment 20 including a visible elastic waistband 24, and an absorbent gusset 30. In this non-limiting example, the absorbent undergarment is in the form of a male brief, which includes the absorbent gusset 30 in the front portion. Other close fitting shapes such as slips are also possible to the extent that they are able to maintain the gusset 30 in the required position. The absorbent gusset 30 is shaped to accommodate the male genitalia.

[0045] Fig. 2 depicts the undergarment 1 of Figure 1 in opened out state viewed from the interior or wearer facing side. The undergarment 1 has an extension in a longitudinal direction (y) and in a transversal direction (x), a front portion 21, a rear portion 23, and a crotch portion 22 arranged between the front portion 21 and the rear portion 23. The waistband 24 may be designed with different visualcharacteristics. In alternative examples, the waistband 24 may be hidden or less conspicuous, blending more seamlessly with the overall design of the absorbent undergarment 1. Additionally, the width of the waistband 24 can vary, ranging from narrow to wide, depending on the specific design and intended use of the absorbent undergarment 1. Further, the absorbent gusset 30 is arranged on the wearerfacing side of the front portion.

[0046] The textile garment 20 may be constructed of any suitable fabric including naturally derived fibres and mixtures thereof selected from the group consisting of cotton, wool, silk, cellulose, regenerated cellulose, rayon, viscose, modal, lyocell, Tencel, bamboo, hemp, flax, ramie, coir or banana. Alternatively, the fabric may be constructed of synthetic fibres or mixtures thereof selected from the group consisting of polyamide, acrylic, polyester. Further, the fabric may be constructed of a blend or a mixture of naturally derived fibres and / or synthetic fibres and / or elastic fibres. The fibres may be recycled fibres. The fabric may comprise a stretchable fabric, such as elastane, so that the absorbent undergarment can provide a firm fit while simultaneously adapting to the movement(s) of the wearer, thus preventing any leakage from migrating through the leg openings and keeping the absorbent gusset 30 in place. The fabric may also be breathable to allow vapor to escape from the skin of the wearer and from the absorbent gusset 30.

[0047] As shown in Figs. 1 and 2, the absorbent gusset 30 is integrated with the absorbent undergarment 1. When assembled, the absorbent gusset 30 generally has a three-dimensional pouched shape with an extension in a longitudinal direction (y) from a top edge to a bottom edge, a width in a transverse direction (x) between first and second side edges, and a thickness in a z-direction, perpendicular to the transverse and longitudinal directions (x, y). The pouched shape is formed by providing two substantially symmetrically shaped side-panels with curved edges from each layer and stitching the edges together to form a central join. It is well known to skilled persons in many arts, including undergarment manufacture, that flexible sheet materials will deform and form three-dimensional shapes when curved edges are forced to come together by attachment means. As the pieces are sewn together, they bend and will provide a physical space along the lower ventral abdomen of the user for accommodating the genitals in a comfortable way. The pouched shape is particularly advantageous for persons with male genitalia, different in part because the penis is likely to leak urine from a place higher up the ventral abdomen, and partly in order to provide space for the genitals, i.e. , the penis and the scrotum, for comfort.

[0048] A front planar view of an exemplary absorbent gusset is shown in Figure 3. The absorbent gusset 30 generally comprises a plurality of layers arranged in a stack configuration, although only the top layer is visible in Fig. 3. In this example, the top layer is formed from left side panel 331 and right side panel 341, which are mirror symmetric about a sagittal plane (SP). The left and right side panels 331 , 341 are joined together along their inner side edges 333 by a central midseam 35 extending in the longitudinal direction (y) from the top edge 31 to the bottom edge 32. For the liquid impermeable layer and any optional absorbent layer, the midseam 35 may be preferably formed of stitches in class 500, more preferably stitch type 503, according to the international standard ISO 4915. For the liquid permeable layer, the midseam may be preferably formed of stitches in class 600, more preferably stitch type 605, according to the international standard ISO 4915.

[0049] The assembled absorbent gusset 30 itself has a U-shape with a perimeter formed by a top edge 31, bottom edge 32, first side edge 33, and second side edge 34. A bonding tape 40 is provided along the entire perimeter of the absorbent gusset 30 to join and seal the layers of the absorbent gusset 30.

[0050] As can be seen in Figure 4, which is a cross-section taken along the line IV in Fig. 3, the plurality of layers includes a liquid permeable layer 301 and a liquid impermeable layer 302. The liquid permeable layer 301 is arranged closest to the wearer-facing side of the absorbent undergarment 1. The liquid permeable layer 301 lies in direct contact with the wearer’s body and should therefore be soft and comfortable. The liquid permeable layer 301 may be constructed of any suitable fabric, including naturally derived fibers selected from any one or more of cotton, wool, silk, cellulose, regenerated cellulose, rayon, viscose, modal, lyocell, tencel, bamboo, hemp, flax, ramie, coir or banana. Alternatively, the liquid permeable layer 301 may be constructed of synthetic fibers including any one or more of polyamide, acrylic, polyester or elastane, such as a mixture of polyester and elastane. It is further conceivable that the liquid permeable layer 301 may also be constructed of a blend or a mixture of naturally derived and / or synthetic fibers. In any case, the material(s) used for construction of the liquid permeable layer 301 should be soft and non-irritating to the skin and should be readily penetrable by any body fluid(s). Further, the liquid permeable layer 301 should also be formed of material(s) that is capable of being repeatedly washed. It is also contemplated that the liquid permeable layer 301 may have some level of absorbent capacity in its own right. For example, the liquid permeable layer 301 may, in certain non-limiting embodiments, be formed of material(s) that is / are relatively thick, with a surface weight of above 80 gsm.

[0051] The liquid impermeable layer 302 is arranged closest to the garment-facing side of the absorbent undergarment 1. The liquid impermeable layer 302 is generally included as a barrier layer to prevent absorbed fluids from passing from the absorbent gusset 30 to the fabric layer of the absorbent undergarment 1 and further through into contact with either the wearer or other layers worn by the wearer. The liquid impermeable layer 302 is typically provided in the form of a polymer film, made in whole or in part of polyurethane or polyester. The polymer film is preferably breathable, letting air and water vapor pass through the film yet forming a liquid barrier.

[0052] Optionally, at least one absorbent layer 303 may be further provided in between the liquid impermeable layer 302 and the liquid permeable layer 301. The absorbent layer(s) 303 may comprise any material capable of absorbing fluid(s), such as woven or nonwoven material(s) like microfiber or polymer knits fabric formed from hydrophilic fibers, other absorbent fibers, combinations, and / or composites thereof. The optional absorbent layer(s) 303 may comprise material(s) which has / have liquid transferring or wicking properties. The optional absorbent layer(s) 303 may additionally or alternatively comprise material(s) which have liquid retaining properties.

[0053] In embodiments with additional absorbent layer(s) 303 arranged between the liquid permeable layer 301 and the liquid impermeable layer 302, it is preferable that any liquid transfer layer be arranged adjacent to the liquid permeable layer 301 and that any liquid storage layer be arranged adjacent to the liquid impermeable layer 302 for purposes of liquid management and distribution to and within the absorbent gusset.

[0054] In embodiments in which the absorbent gusset 30 comprises one or more absorbent layers 303, one or more of such absorbent layers 303 may be formed as a laminate with the liquid impermeable layer 302. For example, the liquid impermeable layer 302 may be laminated onto an outward-facing surface of an absorbent layer 303 to form an absorbent-liquid impermeable laminate.

[0055] It is further contemplated that one or more anti-microbial agents may be included in or among the material(s) used to construct the absorbent gusset and / or absorbent undergarment for the purpose of hindering growth of microorganisms supported by absorbent urine, which may cause odor.

[0056] Turning back to Fig. 4, the plurality of layers of the absorbent gusset 30 are joined and sealed along the entire perimeter of the absorbent gusset 30 by bonding tape 40. In certain non-limiting embodiments, the bonding tape 40 may be applied first to cover the entire length of the top edge 31 of the absorbent gusset 30. Thereafter, the bonding tape 40 may be applied around the remaining perimeter (e.g. , the U-shape) of the absorbent gusset 30. As can be seen in at least Fig. 4, the bonding tape 40 has a length dimension that comprises a sealing portion 410, a ridge portion 420, and an extension portion 430. The sealing portion 410 sandwiches the plurality of layers of absorbent gusset on the top and the bottom of the stack, and the free edges of the layers are bound by the ridge portion 420. The ridge portion 420 is generally perpendicular to the sealing 410 and extension 430 portions. The extension portion 430 extends from a fixed end 4301a at the ridge portion 420 to a free end edge 4301b. The provision of a bonding tape 40 with such an extension portion 430 promotes leak-proofness and a high level of security against leakage from the absorbent gusset 30. This is because this construction allows the absorbent gusset 30 to be joined with the textile garment fabric 201 in the extension portion 430 alone and without risk to the integrity of the sealed plurality of layers.

[0057] In Figure 5, the top edge 31 of the absorbent gusset 30 is shown joined to the waistband 24 of the textile garment 20. The absorbent gusset 30 is joined to the waistband 24 along the entire top edge 31 by a transverse join 500. In this particular example, the transverse join 500 is made by stitching the extension portion 430 of the top edge 31 of the absorbent gusset 30 together with the waistband 24. However, it is to be understood, that the transverse join 500 can be formed in other ways, for example, such as with one or more adhesives, one or more welds, or any combination of these with or with stitching.

[0058] When stitching is used to create the transverse join 500, it is preferable that the stitching is of a stitch-type having an interior thread coverage on the wearer-facing side that is greater than an exterior thread coverage on an outer garment-facing side because the stitching is less visible from the garment-facing side of the absorbent undergarment. For at least this reason, the transverse join 500 may, in certain non-limiting exemplary embodiments, be stitching of a multithread chain stitch in class 400 according to the international standard ISO 4915. The stitching may even be preferably selected from any one of stitch types 402, 403, 406, 407, and 410 according to the international standard ISO 4915. Further, any suitable thread, such as spun thread and / or soft multifilament thread may be used to form the multithread chain stitches herein.

[0059] As mentioned above, the absorbent gusset 30 is stitched to the waistband 24 in the extension portion 430. In line with this construction, the ridge portion is spaced a distance from the transverse join, as this spacing contributes to ensuring leak-proofness of the absorbent gusset. In someexemplary non-limiting embodiments, it may be preferred that the ridge portion 420 is spaced at least 1 mm from the transverse join 500.

[0060] In some non-limiting embodiments, the top edge 31 of the absorbent gusset 30 may be pre-stitched, for example, with an overedge chain stitch, before being joined with the waistband 24. Having an overedge stitch along the entire top edge 31 of the absorbent gusset 30 helps to soften the bonding tape 40 where it will be joined with the waistband 24. This further helps to minimize, if not avoid, the chance that the bonding tape 40 pierces through the transverse join 500, which is undesirable, as it can cause chaffing and / or other discomfort. Also, the overedge chain stitch will be obscured by the transverse join 500 (e.g. , the multithread chain stitch) when the absorbent gusset 30 and waistband 24 are attached together. The overedge chain stitch may, in certain non-limiting exemplary embodiments, be stitching of an overedge chain stitch in class 500, preferably stitch type 514, according to the international standard ISO 4915. Further, any suitable thread, such as soft multifilament thread may be used to form the overedge chain stitches herein.

[0061] Turning back to Fig. 5, the remainder of the perimeter of the absorbent gusset 30 (i.e., not the top edge 31 ) is joined with the textile garment fabric 201 to secure the absorbent gusset 30 in place. This is done by single stitching 510 of the extension portion of the first side edge 33, the bottom edge 32, and the second side edge 34 to the textile garment fabric 201. In certain non-limiting exemplary embodiments, it may be preferred that the single stitching is spaced a distance of 1 mm from the free end edge of the extension portion 430.

[0062] Figure 6 shows the left side panel 331 and the right side panel 341 laid flat prior to joining. The right side panel 341 will further be described, with the understanding that the left side panel 331 is identical but a mirror image. The right side panel 341 has an inner side edge 333 and an outer side edge 334 that corresponds to the second side edge 34 of the gusset 30. The right side panel 341 further has an upper edge 335 and an apex 336. A mid-line ML joins a midpoint of the upper edge 335 with the apex 336.

[0063] Both the inner side edge 333 and the outer side edge 334 are curved in their lower region. The respective curvatures vary along these edges and each has a minimum radius of curvature. The inner side edge 333 has an inner radius IR defined as the smallest radius of curvature of the inner side edge 333. The outer side edge 334 has an outer radius OR defined as the smallest radius of curvature of the outer side edge 334. The outer radius OR is greater than the inner radius IR. In the illustrated embodiment, the outer radius OR is about 90 mm and the inner radius IR is about 70 mm.

[0064] As can be seen, as a result of the difference in radius of curvature the inner side edge 333 and the outer side edge 334 meet at the apex 336 with a different angle with respect to the mid-line ML. The inner apex angle IA is larger than the outer apex angle OA. Additionally the area of the right side panel 341 between the mid-line ML and the inner side edge 333 is greater than the area between the mid-line ML and outer side edge 334.

[0065] At the upper edge 335, the outer side angle OS between the upper edge 335 and the outer side edge 334 is larger than the inner side angle IS between the upper edge 335 and the inner side edge 333. In the illustrated example the inner side angle IS is about 90 degrees and the outer side angle OS is about 100 degrees.

[0066] Figure 7 shows a comparable gusset 30’ of a prior art in a laid out view corresponding to Figure 6. Like elements are denoted by the same reference numerals with a As can be seen in Figure 7, the gusset 30’ comprises left and right side panels 331’, 341’. Each of the side panels 331’, 341’ is symmetrical about its mid-line ML’. The respective inner apex angle I A’ and outer apex angle OA’ are also equal.

[0067] While the invention has been described herein by reference to certain embodiments, it is to be understood that modifications in addition to those described herein may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, they are examples only and are not limiting upon the scope of the invention.

[0068] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

CLAIMS1. A shaped absorbent gusset (30) for a washable absorbent undergarment, the absorbent gusset (30) having a length dimension in a longitudinal direction (y) and a width dimension in a transverse direction (x), measured along a plane of the absorbent gusset (30) and further having a thickness dimension in az-direction perpendicular to the plane of the absorbent gusset (30), the absorbent gusset (30) having a perimeter that comprises a top edge (31 ) and first and second side edges (33,34), the gusset comprising a plurality of layers, including a liquid permeable layer (301 ) and a liquid impermeable layer (302), wherein the absorbent gusset (30) comprises left and right side panels (331, 341) which are mirror symmetric about a sagittal plane (SP) of the absorbent gusset (30), each side panel (331, 341) having a panel length that extends between an upper edge (335) and a lower apex (336) and a panel width that extends between inner and outer sides edges (333, 334), a mid-line (ML) extending between a respective midpoint of the upper edge (335) and the lower apex (336), wherein each side panel (331, 341) is asymmetric, whereby the outer side edges (334) are closer to the respective midline (ML) than the inner side edges (333) at least along one-third (1 / 3) of the panel length, and the inner side edges (333) of the panels being joined together along the sagittal plane.

2. The gusset according to claim 1 , whereby an outer area between an outer side edge (334) and the respective midline (ML) is less than an inner area between an inner side edge (333) and the midline (ML), preferably the outer area is less than 90% or less than 80% or less than 70% of the inner area.

3. The gusset according to claim 1 or 2, wherein the inner side edges (333) are at least partially curved and have an inner radius (IR) in the lower region defined as the smallest radius of curvature of the inner side edge (333) and wherein the outer side edges (334) are at least partially curved and have an outer radius (OR) in the lower region defined as the smallest radius of curvature of the outer side edge (334) and wherein the outer radius (OR) is greater than the inner radius (IR).

4. The gusset according to any of preceding claims, wherein the length dimension comprises an upper region, a lower region, and a central region arranged in between the upper and lower regions.

5. The gusset according to claim 4, wherein the outer side edge (334) and / or the inner side edge (333) each comprise a straight section in the upper region extending to the upper edge (335).

6. The gusset according to claim 4 or 5, wherein the outer side edge (334) and / or the inner side edge (333) in the central region transition between a straight section and a curved section.

7. The gusset according to any of claims 4-6, wherein the upper region, the central region, and the lower region each extend one-third (1 / 3) of the length dimension of the gusset.

8. The gusset according to any of claims 3-7, wherein the outer radius is at least 90 mm.

9. The gusset according to any of claims 3-8, wherein the inner radius is in a range of from 60 mm to 80 mm.

10. The gusset according to any of claims 4-7, wherein the panel width increases from the upper edge (335) to the central region and decreases from the central region to the lower apex (336).

11. The gusset according to any preceding claim, wherein the panel length is at least 3 times the maximum panel width, or at least 3.5 times the maximum panel width, or at least 4 times the maximum panel width.

12. The gusset according to any preceding claim, further comprising at least one absorbent layer (303) arranged between the liquid permeable layer (301) and the liquid impermeable layer (302), preferably wherein the plurality of layers are arranged in a stack configuration.

13. The gusset according to any preceding claim, wherein the plurality of layers comprises first and second absorbent layers that are preferably coextensive in at least one of the transverse and longitudinal directions (x, y).

14. The gusset according to any preceding claim, further comprising a bonding tape (40) provided along the perimeter adapted to seal the plurality of layers together.

15. The gusset according to any preceding claim, wherein the liquid impermeable layer (302) comprises a thermoplastic polyurethane film.

16. The gusset according to any preceding claim, wherein each layer of the plurality of layers comprises elastane.

17. The gusset according to any preceding claim, wherein the inner side edges (333) of the left and right panels (331, 341) are joined together by stitching.

18. The gusset according to any preceding claim, wherein the plurality of layers are present in the left and right panels (331, 341) and each of the plurality of layers are joined together at the inner side edges (333).

19. A washable absorbent undergarment (1) comprising:a. a textile garment (20) comprising a front portion (21), a rear portion (23), a crotch portion (22) arranged between the front and rear portions, and a waistband (24) attached to the front and rear portions; andb. an absorbent gusset according to any one of the preceding claims located at an interior of the textile garment, extending from within the front portion (21) and into the crotch portion (22).

20. The washable absorbent undergarment according to claim 19, wherein a top edge (31) of the gusset is directly joined to the waistband.

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