An absorbent re-usable patient underpad is formed of five layers of fabric consisting from top to bottom of: an absorbent rayon-polyester blend, non-woven polyester; vinyl; and polyester, a synthetic taffeta. The third, fourth and fifth layers are bonded together as are, generally, the first and second layers.

BACKGROUND OF THE INVENTION 
The present invention relates to a re-usable absorbent pad for use in 
hospitals and nursing homes beneath patients who are incontinent or who 
might otherwise have the need for an absorbent and protective component of 
their bedding. 
The problem of incontinence in seriously ill or elderly patients at home, 
in hospitals, and in nursing homes is well recognized by health care 
professionals. Many products have been developed and marketed for use in 
protecting patients' bedding from damage caused by absorption of urine and 
other fluids. Minimizing patient irritation and discomfort caused by 
prolonged exposure to absorbed fluids is also a concern of those caring 
for the patient. 
Disposable underpads are currently used by many institutions but are 
relatively expensive and do not provide optimum comfort and absorption 
because of the types of materials that must be used. Re-usable underpads 
previously known in the industry suffer from a number of drawbacks. The 
most significant problem in re-usable pads currently available is 
durability, that is, ability to withstand exposure to the soap, bleach, 
and high temperatures of wash and dry cycles. Currently available pads 
will suffer significant breakdown after one hundred (100) washings or 
less. Wrinkling of the pads over time is also a problem. The pad disclosed 
by the present invention will successfully stand up to three hundred (300) 
washings or more. Similarly, the various combinations of materials and 
bonding techniques used in the prior art have not resulted in optimum 
texture on both the top and bottom external surfaces. This provides less 
comfort to the patient and makes it more difficult in turning the patient 
because the bottom surface does not allow the pad to slide easily on the 
bedding. 
SUMMARY OF THE INVENTION 
According to one embodiment of the present invention, a washable and 
re-usable patient underpad is formed of five (5) separate layers of 
fabric: a top layer (patient-contact) of woven polyester or polyester 
tricot mesh; a second layer (bonded to the first) of a rayon-polyester 
needle-punch blend; a third layer of non-woven polyester; a fourth layer, 
bonded to the third, of waterproof vinyl; and a fifth and bottom layer, 
bonded to the fourth, of nylon or polyester taffeta. All five (5) layers 
are then stitched together around the top and bottom outside edges. This 
novel combination of fabrics and bonding overcomes the disadvantages and 
problems of the prior art. 
The top layer of woven polyester or polyester tricot mesh, when glued to 
the second layer of fabric is smoother and more comfortable to the patient 
than quilted fabrics now commonly used and withstands dryer heat and 
bleach better than cotton or nylon. A synthetic sheepskin of 
polyester-acrylic blend, not bonded to the second layer, is also suitable. 
The second layer of rayon-polyester needle-punch blend is the "soaker" or 
primary fluid absorbent layer. Rayon is an excellent absorbent material. 
The polyester acts as a stabilizer for the rayon which will not hold up as 
well if unblended. By bonding this layer to the top layer of fabric, 
wrinkling of the pad is minimized. It is also a faster drying fabric 
combination than many "soaker" fabrics used in the prior art. 
The third layer of non-woven polyester adds strength to the pad for 
durability in repeated washings and, by bonding this layer to the vinyl 
below it, the vinyl is protected from bonding to itself when exposed to 
the high temperature of commercial dryers. It also holds up to heat and 
bleach better than nylon. 
The fourth layer of PVC vinyl serves as a liquid barrier between the soaker 
layer and the bedding. It will last longer and is easier to work with 
during manufacturing than rubber and similar fabrics. 
The bottom layer of polyester or nylon taffeta is so closely wound it is 
almost waterproof. This minimizes the effects of the detergent on the 
vinyl layer. It is also smoother than fabrics now commonly used as the 
bottom layer for underpads. This makes it easier to slide the pad on the 
bedding when moving or turning the patient. For even greater durability 
with a slightly coarser surface, warp-knit polyester can be used. 
The principle object of the present invention, then, is to provide a 
re-usable patient underpad which is suitable for use in nursing homes, 
hospitals, and other institutions in the care of incontinent patients. 
A further object of the invention is to provide a reusable underpad which 
can withstand numerous wash and dry cycles with a minimum of damage to and 
wrinkling of the pad. 
Another object of the present invention is to provide a re-usable underpad 
which can be washed and dried commercially at least two to three hundred 
times before it must be replaced. 
Another object of the present invention is to provide a underpad which will 
absorb and hold larger amounts of fluid while minimizing discomfort to the 
patient and while protecting the surrounding environment from damage. 
Another object of the present invention is to provide an absorbent underpad 
which will dry quickly after washing. 
A further object of the present invention is to provide smooth top and 
bottom surfaces for patient comfort and for ease in moving the patient on 
the bed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
While the size and thickness of the pad can vary according to the precise 
needs of the user, the preferred embodiment shown in the drawings 
demonstrate the novel combination of fabrics and bonding which give the 
present invention its advantages in durability, comfort, and ease of use. 
As shown if FIGS. 1 and 2, the underpad is formed of a top layer 1 of woven 
polyester or polyester tricot mesh or polyester-acrylic sheepskin, to 
provide a smooth and comfortable surface for the patient. A second layer 2 
of rayon-polyester needle-punch blend is glued to layer 1 across their 
entire top and bottom surfaces respectively, unless sheepskin is used. The 
thickness of fabric layer 2 is chosen to accomodate the desired absorption 
needs of the pad. 
Beneath layer 2 is fabric layer 3 of non-woven polyester which is not 
bonded to layer 2. Bonded across the lower surface of layer 3, by heat or 
glue, is the water barrier layer 4 of PVC vinyl or similar material. The 
bottom layer 5 is bonded by glue or heat across the bottom surface of 
layer 4. The bottom layer 5, which in use contacts the bedding, is made of 
nylon or polyester taffeta to provide a smooth slideable surface for ease 
of moving or turning the patient while on the underpad. 
All five fabric layers are bound together by stitching 6 around the top and 
bottom outside edges.