WO2004069093A2

WO2004069093A2 - Protective undergarment having pocketed sling for absorbent pad

Info

Publication number: WO2004069093A2
Application number: PCT/US2004/001913
Authority: WO
Inventors: Frederica Coates
Original assignee: Tailored Technologies, Inc.
Priority date: 2003-01-27
Filing date: 2004-01-26
Publication date: 2004-08-19
Also published as: JP2006515793A; EP1648257A2; WO2004069093A3; CN1753631A; EP1648257A4; CN100482119C

Abstract

A fastener tab assembly for an undergarment (14), comprising a tab (19) formed from a generally trapezoidal piece of material in which opposite edges (26) thereof are folded inwardly and joined together so as to present unseamed enclosed sides (26), hence tending to avoid irritation when in contact with the body of a wearer. A piece of filamentary fastener material (34) on a surface of the tab (19) is adapted to couple with a complementary piece of filamentary fastener material (24) on the undergarment (14).

Description

50014-057

PROTECTIVE UNDERGARMENT HAVING POCKETED SLING FOR ABSORBENT PAD

Field of the Invention

[01] The subject matter of this invention relates generally to protective undergarments, and more particularly to improvements to reusable underwear deemed important to the industry such as structures that prevent leakage and improve containment, innovations that enhance fastening of the garment to the body, and adaptations of reusable underwear for the newborn baby and their healing umbilical cords.

Background of the Invention

[02] To enhance the fluid and fecal containment properties of protective underwear, U.S. Patent Nos. 5,137,526 and 5,409,476, issued to Fredrica Coates, describe protective underwear having a wateφroof or water-resistant sling with its front and rear ends adjoined through connecting pieces to an outer shell. This sling isolates body fluids from spreading to the outer region of the shell by implementing elastic on the outer perimeter edge of the sling or wateφroof gussets mounted on opposite sides of the sling. The elasticized and gusseted sling design is effective, although there remained a need for greater containment of fluid. [03] As an improvement, in U.S. Patent No. 5,722,127, issued to Fredrica Coates, the sling is enhanced to form a deeper pocket and implement fasteners of greater adjustability to retain the garment to the wearer. However, even with improved fit and a deeper inner pocketed sling, there still remained a need for a greater circumferential area for fluid and fecal matter containment. Hence, further disclosed in the '127 patent is a pocketed sling for retaining fluid absorbent pads, and Coates Application Serial No. 08/792,735, filed on January 31, 1997, discloses a frontal hidden pocket added to a connecting frontal piece for enhanced circumferential area and hence fluid absoφtion.

[04] A further improvement disclosed in Coates application Serial No. 09/791,773, filed on February 26, 2001, implements an S-shaped sling folded in its longitudinal direction, providing three-plies of material, and establishing a pocket for retaining one end of a fluid absorbent pad again this design enhanced more circumferential for fluid absoφtion. [05] Although considered to be dramatic improvements in the diaper industry, with many variations used in various undergarments as structures for retaining body fluids and fecal matter, the "S -sling" has a tendency to tangle in the wash, particularly during tumble drying. The longitudinal ends of the S-sling, attached near the waist of the frontal and rear portions of the garment, were attached only at the frontal and rear portions. Hence the remaining portion of the S-sling then "floated." This floating action tended to have too much room between the S-sling and its outer shell, and the product would twist inside out during tumble- drying. Another characteristic of the S-sling is in the tendency of the frontal portion of the garment at the waist to buckle slightly under the weight of the S- sling with an absorbent pad contained therein. This buckle, at the front of the garment, presented a somewhat unkempt appearance both when the garment is worn and when it is being handled for inspection. [06] A further aspect of the Coates technology is in the implementation of filamentary hook and loop fasteners for releasably securing the garment to a wearer without using pins. In Coates U.S. Patent No. 4,537,591, one in a series of patents on fastener technology, a filamentary type fastener is constructed as a tab in such a manner as to face a cover strip of complimentary filamentary material. During washing, the tab and cover structure advantageously displays a self-closing tendency such that the complimentary cover protects the tab from accumulation of lint. Coates U.S. Patent No. 4,680,030 and 4, 681,581 are examples of other self-closing fasteners in accord with the Coates contributions. U.S. Patent No. 5,137,526 and 5,409,476 describe variations in which the tab and cover are not self- closing, but have constructional attributes that make the assemblies easier and more economical to manufacture. There still remains a need for a tab construction of yet more economical and soft appearance for its wearer because in reusable underwear there is always a need to improve fit by making it closer to the body, less bulky and as soft as possible. An additional feature seen in Coates Patents is adaptations for garments accommodating a newborn's umbilical cord. First seen in U.S. Patent No. 5,707,364 is an elasticized concave portion, a frontal portion of underwear adapting to fit the newborn umbilical cord. In U.S. Patent No. 6.254,583 there appears a more tailored version of a cut-out notch for the umbilical cord.

[07] Again in U.S. Patent No. D452, 3155 a gathered opening for an umbilicus is shown, enhancing tailored fit. This technology lacked an economical way to both elasticize the opening for the newborn' s umbilical cord and remain affordable to the manufacturer of the garment. The new assembly of pieces of material both enhances performance of the delicate and tiny structure for the newborn' s healing umbilical cord, and also reduces the assembly time to produce this garment at a lower cost.

[08] Advantages of the current disclosure are in improving the floating sling structure, so that tangling during the washing is eliminated, as well as enhancing the appearance of the garment. The appearance is improved by eliminating waφage or wrinkling at the waist. Another advantage is in a self-closing garment fastener that is easily and economically produced. Another advantage is improving fit and performance of the umbilical cord opening while reducing the cost of the manufacturing procedures. A further improvement appears in satisfying the need for softness applied to a closure for reusable underwear.

Brief Description of the Drawings

[09] Fig. 1 is a perspective view of a diaper, in accordance with one embodiment, showing an improved sling and garment construction, and novel self-closing fastener tab and cover.

[10] Fig 2 shows the embodiment from top view to expose the inner surface of the garment and sling.

[11] Figs. 3 A - 3F show steps of manufacturing a fastener cover as depicted in Figs. 1 and

2.

[12] Fig. 4 shows another embodiment of the garment, with modified fastener.

[13] Fig. 5 is a view showing the inside surface of the garment and sling of Fig. 4.

[14] Figs. 6A-6F show steps of manufacturing the fastener depicted in Fig. 5.

[15] Fig. 7 shows a variation having an umbilical opening in the diaper for a newborn.

Detailed Description of Embodiments [16] Fig. 1 depicts an exemplary garment, in this example a diaper, 10, that is constructed of a diaper shell 14, that may be of fluid absorbent or resistant material sized and shaped to conform to the buttocks and waist of a wearer, and a correspondingly shaped inner liner. The liner is composed of a frontal section 48 joined at seam line 52 of a middle section liner 56. Liner 56 is then joined to a rear section of the garment at 50, which connects to a terminal back piece 46. The liner is then connected to the outer shell 14 at the rear elastic 66. An S- pocket sling 62 is centered at 56(rear section) and sealed at joining line 50 to the terminal end piece 46. S-sling 62 has a novel attachment of elastic, a stitched U-shaped elastic 61, which surrounds the opening of the inner cavity of S-sling. The U-shaped elastic 61, as it finishes, is enclosed in seam 50, hence sealed at 50. The U-shaped attachment of elastic more clearly fits the pubis of the wearer. Elastic 60 on opposite leg holes of shell 14 serves to encase both the liner 56 with the outer shell 14. Liner 56 is preferably a soft material such as a 100% brushed polyester, which will come directly in contact with the wearer's skin. The backside of this material may have the option of being wateφroof.

[17] Within the S-sling 62 is arranged an absorbent pad (not shown) held tight to the body by the pull of S-pocket sling 62 that is joined at its opposite ends to the inner liner along lines of stitching 50 and 52, at least one of which is displaced from the end or ends of the shell 14. The pocketed S-sling itself is similar in construction to one or more or those disclosed in my U.S. Patent Nos. 5,409,476, 5,137,526, 5,725,518 and co-pending applications serial no. 09/512,085, filed Feb. 24, 2000, and serial no. 09/791,773, filed Feb. 26, 2001, incoφorated herein by reference, with S-shaped pocket constructed in accord therewith and connected at the frontal and rear ends of the diaper. This current construction differs from what has been disclosed previously in that the displacement of the ends of the sling from the terminal ends of the waist, at lines 50 and 52, establishes a sling of effectively shorter length compared to the length of the garment than those in the foregoing patents and applications. [18] Securing the ends of the S-sling to the insert lines of attachment 50 (rear) and 52 (frontal) has two beneficial effects. First, the sling shown in Fig. 1 tends to be retained within the diaper and does not swing laterally or invert with respect to the remainder of the diaper as was the tendency in the prior designs in which the sling is connected to the diaper at the terminal ends of the waist. Thus, during washing and tumbling, the sling will remain seated within the diaper. Second, because the load bearing region at the contact line between the sling and liner is displaced from the waist, any pulling of the liner by the weight of the S- sling will not translate into waφing or wrinkling of the waistband. This presents a cleaner appearance to the diaper both when it is worn and handled.

[19] The frontal portion of the shell 14 is provided with a strip of filamentary material 44 that receives filamentary hook material 34 on fastener tabs 19 at the corners of the rear portion of the diaper. These strips of filamentary hook material couple to frontal strip 44, which is of loop material, when the diaper is worn, as described in my previous patents and application. In accord with an aspect of the embodiment of Fig. 1, each fastener tab 19 has a side edge 26 and a terminal end 38. Each tab 19 is constructed of a trapezoidal piece of fabric, with its base attached to and extending from a corner of the diaper. A corresponding trapezoidal piece of loop 24 type filamentary material, functioning as a cover, is stitched inwardly on the inner layer or liner 56, as shown, with its base facing and in contact with the base of the tab 19. Of particular note is that the base of tab 19 is joined to the diaper at seam 30, of diaper shell 14. This seam 30 is arcuate, as depicted, causing the tab to have a tendency to bias inward by force created by the arcuate configuration of the seam, particularly when tumbled in a dryer, so as to make contact with cover piece 24. With hook type strip 34 and cover 24 in contact with each other, the tab and its filamentary hook material 34 are protected from lint and other material contamination.

[20] Fig. 2 shows the diaper 10, with tab 19 self-closed to the protective cover 24 underneath as will occur naturally as a result of the seam 30 being arcuate as described. Fig. 2 also shows another view of liner 56 attached at line 52 along with S-sling 62 elastic 61 shown in the U-shape manufacturing procedure. Leg elastic 60 is seen at leg holes. Filamentary loop 44 is depicted on the front of the garment 14 (garment surface). The rear of the garment is finished with elastic 66 as it connects to liner 46 joining line 50 at the seam supporting S-sling 61 in the center most portion of garment 10.

[21] Figs. 3A-3F show how the tab is constructed. In Fig.3A, an approximately trapezoidal piece of material 19, with a outer edge portion at 36 bowed outward and the top of trapezoidal piece being linear at 32 forms tab 19. In Fig. 3b, tab 19 is first folded in half at notch 28, and the common edge 44 will co-extend and be joined in over-lock stitch 22, and common edge 44 is then covered by an over-lock stitch 22. The trapezoidal piece in Fig. 3b is next folded at 26 and over-lock edge 22 is rolled inward, centered at notch 28, forming tab 19 as shown in Fig. 3c. The top edge 32 is folded downward finished outer edge 38 shown in Fig. 3d. Next per Fig. 3e a strip of hook filamentary material 34 is applied covering the end of 32 and part of seam 22, shown in Fig. 3c. The counteφart loop type cover 24 of Fig. 3f is formed separately, but with a size and shape that conforms to the tab 19. Of particularly interest is the shape of base 25, which will match to base 36 of tab 19. [22] The base 25 of the cover 24 has an arcuate shape and is complimentary to that of tab 19 (viewed from the backside of the tab shown in Fig. 3E). When the tab and cover are brought together, with bases 25 and 36 adjoining, the two components abut each other along the common arcuate joining 30 shown in Fig.l.

[23] Figs. 4 and 5 correspond to Figs. 1 and 2, except that the tab and cover has a configuration, which has a linear, rather than arcuate base. Diaper 12 of Figs. 4 and 5 is constructed of a diaper shell 16, that may be of fluid absorbent or resistant material conformed to the buttocks and waist of a wearer, and a corresponding shaped liner 106, joined at its periphery to the periphery of the shell. Within the liner 106 is a S-sling 162 that is joined at its opposite ends to the inner liner along the attachment lines 150 (rear of garment) and 152 (frontal portion of garment). The S-sling is the same as depicted in Figs. 1 and 2 as the difference in these two garments is found in the tab construction. Tab 90 carries hook strip 64. This tab is configured to close onto cover 67 of loop material, just as the configuration of tab structure of Figs. 1 and 2, but the joining line 65 is straight. In Fig. 4 and 5 diaper 12 has all the same properties as seen in diaper 10, a liner, a mid-section liner 106 joined at 150 in the rear to terminal liner piece 96 and covered by elastic 166 in Fig. 5. Tab 90, when folded shut in Fig. 5, has a straight edge as produced by attachment of straight edges as in 65. The tab 90 has a terminal end 68 folded sides at 88, leg elastic at 160 on outer shell, S-pocket sling at 162. In the front of garment we see loop 44 mounted to outside of shell fabric 16. In Fig. 4 the over-lock seam of tab 19 is seen as 82. [24] Figs. 6A, 6F show steps of manufacturing tab 90 and cover 67 shown in Figs. 4 and 5, with trapezoidal piece 90 having lower linear edge at 70 and outer top edge 92, and opposite sides of the trapezoidal piece shown at 84. In Fig. 6B, notch 89 serves as a reference point for a folding line of trapezoidal overlapping edges 84 and covered by over-lock stitch 82. In Fig. 6C over-lock edge 82 is rolled inward and centered at notch 89 forming the straight edge 70. Folded sides 88 extend to terminal 92, which is folded at 68 to form a finished terminal end of tab. In Fig. 6D, the unfinished end 92 now folded inward is ready to be covered as shown in Fig. 6E. In Fig. 6E, hook strip 64 is placed over edge 92 and centered on seam 82 hiding most of seam 82. The sides of 88 are of soft fabric. Linear base 70 in Fig. 6F is now ready to join liner base 65 of loop piece 67. Referring back at Fig.4, loop piece 67 is finished with a stitch line 69 that helps tab 90 close. Hence the stitching at 69 helps the non-arcuate edge to self-close.

[25] Fig. 7 is a variant of protective underwear with construction incoφorating a novel opening in the front of the garment to accommodate the umbilical cord of a newborn baby. Garment 200 has an opening at 92, that when positioned on a baby, circumscribes the healing navel but does not touch it. The cutaway 92 is arcuate and recessed deep enough so that the umbilical cord of the newborn has enough room to allow circulation of air for healing but not too much to allow leakage from the central cavity of garment 200. Overlock stitched edge 96 gives a neat and low cost finish to the terminal front edge of the garment, but the most important feature is the removal of the ends of elastic 98, or trim with elastic or stretch property. Elasticized material enhances the bowing inward of the garment only where needed, at opening 92. It is important there are no raw edges of elastic to irritate the baby's abdomen, and hence, it is necessary that the elastic be removed by the over-lock cut-and- stitch process, 96. Over-lock stitch 96 should be a soft wooly nylon thread. Loop strip 94 angles to help conform to the tiny shape of a newborn baby when tabs 19 engage. The frontal strip 94 corresponding to strip 44 in Figure 1 is now divided and inclined as shown to yield to the umbilical opening 92. Leg elastic 108 corresponds to leg elastic 60 of Fig. 1.

Claims

What is Claimed Is:

1. A fastener tab assembly for an undergarment, comprising: a tab including a generally trapezoidal piece of material in which opposite edges thereof are folded inwardly and joined, so as to present unseamed enclosed sides tending to avoid irritation when in contact with the body of a wearer; and a piece of filamentary fastener material on a surface of the tab, adapted to couple with a complementary piece of filamentary fastener material on the undergarment.

2. The fastener tab assembly of claim 1 , in which the piece of filamentary fastener material is located on the surface of the tab so as at least to partially cover the joined side edges thereof.

3. The fastener tab assembly of claim 1, in which an apex of the folded trapezoidal piece of material is folded downwardly to present an unseamed, enclosed top edge.

4. The fastener tab assembly of claim 3, in which the piece of filamentary fastener material is located on the surface of the tab so as at least to partially cover the unseamed top and joined side edges thereof.

5. The fastener tab assembly of claim 1, in which the joined edges are joined by overlock stitching.

6. The fastener tab assembly of claim 1, including the generally trapezoidal piece of complementary filamentary fastener material for attachment to the undergarment, and having the base of the piece of complementary filamentary fastener material secured to the base of the tab.

7. The fastener tab assembly of claim 6, in which the bases of the tab and piece of complementary filamentary fastener material are stitched together with the tab and piece of complementary filamentary fastener material generally congruent, so that the tab and piece of filamentary fastener material will have a tendency to self-close to each other.

8. A method of making a fastener tab assembly for an undergarment, comprising: inwardly folding opposite sides of a generally trapezoid piece of material to form a tab, so as to present unseamed enclosed sides tending to avoid irritation when in contact with the body of a wearer; joining the inwardly folded sides at a surface of the material; and covering at least a portion of the joined sides with a piece of filamentary fastener material.

9. The method of claim 8, including the step of: downwardly folding an apex of the trapezoidal piece of material, in which piece of filamentary fastener material is position to cover at least a portion of the joined sides and downwardly folded apex of the trapezoidal piece of material.

10. The method of claim 8, in which bases of the trapezoidal piece or material and a generally trapezoidal piece of complementary filamentary fastener material are stitched together with the two pieces generally congruent, so that two pieces will have a tendency to self-close to each other.