Patent Description:
<CIT> discloses an undergarment including a multilayer leak-proof pad to wick moisture, impede bacteria, prevent leaks, and resist stain.

<CIT> discloses a liquid absorbing pad for use in clothing, comprising: a liquid permeable layer; a functional layer over the liquid impermeable layer; and a liquid impermeable barrier material, wherein the functional layer is capable of acquiring and distributing liquid and/or absorbing liquid and the liquid impermeable barrier material is bonded to at least the liquid impermeable layer and the functional layer around the periphery of said layers by a bonding means, provided that the bonding means is not stitching. The liquid absorbable pad may form part of a garment.

<CIT> discloses a protective insert operatively attachable to an inner, body-facing layer of a garment. The protective insert generally comprises, a first, operatively inner layer comprising a moisture-wicking, odor resistance, fluid absorbent fiber with or without a waterproof laminate-film; and a second, operatively outer layer comprising a breathable, odor resistant, water repellent fiber to further prevent fluid passage through the garment; wherein the operatively inner layer faces the body of a user while the operatively outer layer faces away from the body of a user, in use.

<CIT> discloses an undergarment article having a fabric layer for wearing about a pelvic region of a person, a water-repellent layer coupled to a crotch portion of the fabric layer to form an inner chamber, and an inner pad disposed within the inner chamber between the water-repellent layer and the fabric layer. The inner pad is resistant to heat and includes a liquid-absorbent layer and a waterproof layer. The liquid-absorbent layer contacts the water-repellent layer and is effective for absorbing a volume of liquid greater than <NUM> fluid <NUM>. 15m1 (<NUM> ounces). The waterproof layer is effective for restricting liquid from reaching the fabric layer. The crotch portion of the fabric layer and the water-repellent layer can be substantially elastic in at least one of a lateral direction and a longitudinal direction of the crotch portion. Methods for using the undergarment, kits and uses of the undergarment are also disclosed.

<CIT> discloses a washable, reusable garment for retention of body fluids when worn on a person's lower body part. The garment has a crotch portion and a body portion. The crotch portion has an absorbent composite, and a pocket adapted for receiving a removable absorbent pad. The body portion has a waist opening and is seamless except where attached to the crotch portion. The body portion and the crotch portion together form first and second leg openings.

<CIT> discloses a waterproof panty that has rolled over welded seams. The rolled over welded seam will inhibit the leaking of bodily fluids at the leg openings caused by stitching and wicking. The panty has an outer shell and an inner panty layer. The outer shell a continuous cut formed of a soft blend laminated fabric. It is liquid proof, breathable, hypoallergenic, stain resistant, and elastic. It is cut to form a waist opening and two leg openings. If desired stretchable lace or elastic side portions can be provided. The inner panty lining is a breathable soft blend fabric and includes a front portion, back portion and a crotch portion. The crotch portion is double layered for added dryness. The inner panty layer is cut to the full design of the panty having a waist opening and two leg openings. This overall design provides the user peace of mind and security with a stylish, lightweight, comfortable, waterproof panty.

<CIT> discloses a washable female undergarment designed for comfort and for alleviating leakage. The undergarment comprises an outer layer of a stretchable fabric, an inner layer of an absorbent fabric, and a main absorbent layer positioned between the inner and outer layers in the crotch area. The three layers are permanently secured together to form a reusable reliant undergarment.

<CIT> discloses an undergarment configured to help absorb leaks of bodily fluids from a person suffering from mild to moderate incontinence or other conditions including a main body made of a material that allows the absorption of bodily fluids and a crotch piece made of a material that allows the absorption of bodily fluids that overlays the crotch portion of the main body. The crotch piece of the undergarment can extend high enough and be wide enough on the front side of the garment's main body so as to offer an adequate area of protection to the user.

<CIT> discloses an undergarment including a body portion having an upper edge defining a waistband, two leg openings and a crotch region between the leg openings; an absorbent pad on the inside of the body portion within at least the crotch region, the absorbent pad having an inner region and a peripheral region, wherein the thickness of the absorbent pad in the peripheral region is less than the thickness of the absorbent pad in the inner region; and elastic bonding film lining each of the two leg openings while overlying respective portions of the peripheral region of the absorbent pad thereby to bond the absorbent pad and the body portion. A method of manufacturing an undergarment is provided.

<CIT> discloses protective garments comprising an inner surface or portion of an inner surface with both absorbent and stain resistant properties while maintaining the soft feel, breathability and aesthetic properties associated with traditional "non protective" intimate apparel. The fabrics and methods of constructing the garments are also disclosed herein.

International Patent Application Publication No.<CIT> discloses leaktight underpants comprising a fabric body with a waist opening and a pair of leg openings. They comprise a front part and a rear part, the front and rear parts being fastened together by lateral seams. The leaktight underpants comprise, in the crotch part, a protective assembly, the protective assembly comprising an absorbent layer and a draining layer, which are fastened to the edge portion of each leg opening. The absorbent layer or the draining layer is fastened to the lateral seams of the front or rear parts of the fabric body, only the absorbent layer, or only the draining layer, being fastened to the rear edge or to the front edge, respectively, delimiting the waist opening.

International Patent Application Publication No. <CIT> discloses a multi-layer liquid absorbing and retaining textile assembly. The textile assembly comprises at least a first layer, a second layer and an intermediate layer. The intermediate layer is constructed as a warp knitted spacer fabric having a plurality of sections with at least one section being proximal to the first layer and at least another section being proximal to the second layer. The first layer is adapted to transfer liquid from a first side of the textile assembly to the intermediate layer. The intermediate layer is adapted to receive and transfer liquid to the second layer. The second layer is adapted to retain the liquid at or proximal to a second side of the textile assembly that is oppositely facing to the first side.

<CIT> discloses a garment comprising a moisture management incontinence pad adapted for use within the garment, wherein the pad comprises: (a) at least one sheet of a liquid absorbent material; (b) a first and a second inside sheet of a liquid impermeable material, positioned at the opposite first and second opposite end sides of the pad; (c) at least one third sheet of a liquid impermeable material, which extends in longitudinal direction of the pad and is positioned on a side of the liquid absorbent material proximal to the garment ; (d) a fourth outside sheet of a liquid impermeable material, which is positioned on an outside face of the first, second and third sheet of liquid impermeable material which is provided to face the garment.

The document <CIT> discloses a garment with an absorbing pad in the crotch area.

According to one example of the present disclosure, a garment comprises a main body including a front portion, a back portion, and a gusset connecting the front portion and the back portion. The gusset has left and right lateral edges partially defining respective left and right leg openings of the garment. A layer of absorbent material is coupled to an inner face of the main body at least at the gusset. A layer of waterproof material is sandwiched between the main body and the layer of absorbent material. Left and right elastic bands couple the layer of absorbent material and the layer of waterproof material to the main body along the respective left and right lateral edges of the gusset.

According to another example, a method for manufacturing an absorbent garment comprises providing a main body including a front portion, a back portion, and a gusset connecting the front portion and the back portion, wherein the gusset has left and right lateral edges configured to partially define respective left and right leg openings of the garment. A layer of absorbent material is provided, which is sized and shaped to fit on the gusset and has left and right lateral edges configured to extend alongside the respective left and right lateral edges of the gusset. The method includes attaching left and right elastic bands along the respective left and right lateral edges of the layer of absorbent material. A layer of waterproof material is provided, which is sized and shaped to fit on the gusset and has left and right lateral edges configured to extend alongside the respective left and right lateral edges of the gusset. The left and right lateral edges of the layer of waterproof material are attached to the respective left and right elastic bands. The method includes attaching the left and right elastic bands to the respective left and right lateral edges of the gusset to couple the layer of absorbent material and the layer of waterproof material to the main body.

Examples of garments and portions thereof are described with reference to the following Figures. The same numbers are used throughout the Figures to reference like features and like components.

The present application relates to garments, and more specifically to garments having an absorbent gusset area configured to cover a wearer's crotch, although the absorbent portions of the garment could extend beyond the gusset area as well. For example, the present application relates to panties or swimwear capable of absorbing bodily fluids such as urine, menstrual fluid, vaginal discharges, and/or sweat. The panties or swimwear can be any style and can have any trim, which details are not limiting on the scope of the present disclosure. In other examples, the garment is a pair of tights, a pair of pantyhose, a bodysuit, or any other type of garment that is configured to be worn directly against a wearer's skin.

<FIG> shows a front view of one example of the garment <NUM>. Here, the garment <NUM> is a pair of panties, although note the garment <NUM> could instead be a pair of swim bottoms. The garment <NUM> has a main body <NUM> including a front portion <NUM>, a back portion <NUM>, and a gusset <NUM> connecting the front portion <NUM> and the back portion <NUM>. The gusset <NUM> has opposite left and right lateral edges <NUM> partially defining respective left and right leg openings <NUM> of the garment <NUM>. <FIG> shows the interior of the garment <NUM> with the hip portions of the garment <NUM> disconnected to show the extent of the gusset <NUM>. A layer of liner material <NUM> can be seen covering a majority of the gusset <NUM>. The layer of liner material <NUM> shows the extent of an absorbent assembly <NUM> of the garment <NUM> and covers a layer of absorbent material and a layer of waterproof material, which are also coupled to the gusset <NUM> as will be described further herein below. While the absorbent assembly <NUM> is coupled to the garment <NUM> at least at the gusset <NUM>, it could extend into the front portion <NUM> or back portion <NUM>, as noted hereinabove. Options for the absorbent assembly <NUM> of the garment <NUM> are described below.

In one example, as shown in <FIG>, a layer of absorbent material <NUM> is coupled to an inner face <NUM> of the main body <NUM> of the garment <NUM> at least at the gusset <NUM>. A layer of waterproof material <NUM> is sandwiched between the main body <NUM> and the layer of absorbent material <NUM>. The layer of liner material <NUM> is coupled to the layer of absorbent material <NUM> opposite the layer of waterproof material <NUM>, such that the layer of absorbent material <NUM> is sandwiched between the layer of liner material <NUM> and the layer of waterproof material <NUM>. In use, the layer of liner material <NUM> is configured to touch the wearer's skin while the garment <NUM> is worn. However, as will be described herein below, the layer of liner material <NUM> is optional. Left and right elastic bands <NUM> couple the optional layer of liner material <NUM>, the layer of absorbent material <NUM>, and the layer of waterproof material <NUM> to the main body <NUM> along the respective left and right lateral edges <NUM> of the gusset <NUM>.

In one example, the left and right elastic bands <NUM> are folded around respective left and right lateral edges of each of the layer of liner material <NUM> and the layer of absorbent material <NUM> and then attached to the layers of liner material <NUM> and absorbent material <NUM> along the opposite lateral edges thereof. For example, the left and right elastic bands <NUM> are stitched to the layer of liner material <NUM> and the layer of absorbent material <NUM> where the left and right elastic bands <NUM> overlap the respective left and right lateral edges of each of the layer of liner material <NUM> and the layer of absorbent material <NUM>, such as at stitch lines <NUM>. Before this is done, the layer of liner material <NUM> can optionally be bonded to the layer of absorbent material <NUM> by way of heat-activated adhesive tape <NUM>, such that the layer of liner material <NUM> is also bonded to the layer of absorbent material <NUM> laterally inwardly of where the left and right elastic bands <NUM> overlap and are stitched to the respective left and right lateral edges of each of the layer of liner material <NUM> and the layer of absorbent material <NUM>. After the layers of liner material <NUM> and absorbent material <NUM> are stitched to the elastic bands <NUM>, the layer of waterproof material <NUM> is attached to the elastic bands <NUM>. More specifically, the layer of waterproof material <NUM> can be bonded to each of the left and right elastic bands <NUM> over stitches (at stitch lines <NUM>) by which the left and right elastic bands <NUM> are stitched to the respective left and right lateral edges of each of the layer of absorbent material <NUM> and the layer of liner material <NUM>, again such as by way of heat-activated adhesive tape <NUM>.

The elastic bands <NUM> are folded around the opposite lateral edges of each of the layer of liner material <NUM> and the layer of absorbent material <NUM> in such a way that a laterally outer portion <NUM> of each folded elastic band <NUM> does not enclose the layer of liner material <NUM> or the layer of absorbent material <NUM> therein. The elastic bands <NUM> are stitched to the main body <NUM> along the opposite lateral edges <NUM> of the gusset <NUM> in a manner such that the stitching does not extend through the layer of liner material <NUM> and the layer of absorbent material <NUM>, such as by stitching at these laterally outer portions <NUM> of the folded elastic bands <NUM> (see stitch lines <NUM>). Although stitch lines <NUM> are shown as a single stitch, this may be a two-needle cover stitch, a zig-zag stitch, or any other known appropriate stitch.

In the example shown in <FIG>, the folded elastic bands <NUM> are "Y-folded" elastic bands. The laterally inner portions <NUM> of the Y-folded elastic bands <NUM> form "V"-shaped folds, which enclose the respective outer lateral edges of the layer of liner material <NUM> and the layer of absorbent material <NUM>. The outer lateral edges <NUM> of the gusset <NUM> fabric are folded around the "tail" of each "Y" at the laterally outer portions <NUM>, and the outer lateral edges <NUM> of the gusset <NUM> fabric are then sewn to the laterally outer portions <NUM> of the elastic bands <NUM> through the tail of the elastic bands <NUM> and the fabric of the gusset <NUM>, as shown by the stitch lines <NUM>. In another example, the elastic bands <NUM> are sewn only to the upper folded-over portion of the fabric of the gusset <NUM>. Because the main body <NUM> is folded over the left and right elastic bands <NUM> and attached to the left and right elastic bands <NUM> at the respective left and right lateral edges <NUM> of the gusset <NUM>, this provides a clean, finished look to the leg openings <NUM> and presents comfortable, finished edges of the leg openings <NUM> that reduce the likelihood of chafing against a wearer's skin.

<FIG> illustrates a second example of a cross-section of an absorbent portion of an garment. The absorbent portion of the garment includes the same front portion <NUM>, back portion <NUM>, gusset <NUM> and other layers and connections noted herein above, which are labeled with like reference numbers and will not be described further herein. The elastic bands <NUM> are "Y-fold" elastic bands that each have the laterally inner portion <NUM> and the laterally outer portion <NUM>. The laterally inner portions <NUM> are in the shape of a "V" and open inwardly such that the laterally outer edges of the layer of liner material <NUM> and the layer of absorbent material <NUM> can be inserted therein. As in the example of <FIG>, the laterally outer portions <NUM> are the portions then stitched to the outer lateral edges <NUM> of the gusset <NUM> fabric, such as shown at stitch lines <NUM>. Optional trim <NUM> (such as lace) can be sewn to the outer lateral edges <NUM> of the gusset <NUM> and to the laterally outer portions <NUM> of the elastic bands <NUM> at the same time. The layer of waterproof material <NUM> is shown as being bonded to the bottom of the laterally inner portions <NUM> of the elastic bands <NUM>, but could alternatively or additionally be bonded to the laterally outer portions <NUM>. In another example, the trim <NUM> and/or outer lateral edges <NUM> of the gusset <NUM> are folded over the laterally outer portions <NUM> of the elastic bands <NUM> and sewn thereto, along stitch lines <NUM>.

<FIG> illustrates a third example of a cross-section of an absorbent portion of an garment. The absorbent portion of the garment includes the same front portion <NUM>, back portion <NUM>, gusset <NUM> and other layers and connections noted herein above, which are labeled with like reference numbers and will not be described further herein. However, in contrast to the examples in <FIG> and <FIG>, the folded elastic bands <NUM> are folded in the shape of a "V. " The outer lateral edges <NUM> of the gusset <NUM> fabric are folded around the base of each "V", and the outer edges <NUM> of the gusset <NUM> fabric are then sewn to the laterally outer portions <NUM> of the elastic bands <NUM> through both folded-over layers of the elastic bands <NUM> and the fabric of the gusset <NUM>, as shown by the stitch lines <NUM>. In another example, the elastic bands <NUM> are sewn only to the upper folded-over portion of the fabric of the gusset <NUM>. In some examples, each laterally outer portion <NUM> of each elastic band <NUM> can be sewn, adhered, or otherwise attached to itself laterally outwardly of where it overlaps the layer of liner material <NUM> and the layer of absorbent material <NUM>, to form a sort of "faux" Y-fold elastic.

Because the left and right elastic bands <NUM>, <NUM> are stitched to the main body <NUM> along the respective left and right lateral edges <NUM> of the gusset <NUM> laterally outwardly of where the left and right elastic bands <NUM>, <NUM> overlap the respective left and right lateral edges of the layer of absorbent material <NUM> and the optional layer of liner material <NUM>, the stitching at stitch lines <NUM>, <NUM> does not extend through the liquid-absorbing portion(s) of the absorbent assembly <NUM>, lessening the likelihood of leaks. Further lessening the likelihood of leaks, each of the left and right elastic bands <NUM>, <NUM> can be stitched to itself laterally outwardly of and adjacent to where the left and right elastic bands <NUM>, <NUM> overlap and are stitched to the respective left and right lateral edges of the layer of absorbent material <NUM> and the optional layer of liner material <NUM>, as shown at stitch lines <NUM> in <FIG>. Such stitching at stitch lines <NUM> effectively creates a "cuff" around the absorbent portion(s) of the absorbent assembly <NUM>, and if the elastic bands <NUM>, <NUM> are treated with chemicals that make them waterproof or water resistant, as described herein below, this "cuff" can further prevent leaks from the absorbent portion(s) of the absorbent assembly <NUM>. Furthermore, because the layer of waterproof material <NUM> is bonded to each of the left and right elastic bands <NUM>, <NUM> over stitches (at stitch lines <NUM>) by which the left and right elastic bands <NUM>, <NUM> are stitched to each of the respective left and right lateral edges of the layer of absorbent material <NUM> and the layer of liner material <NUM>, any liquid that might otherwise tend to leak from the absorbent portion(s) of the absorbent assembly <NUM> due to such stitch lines <NUM> is maintained on the inner face of the layer of waterproof material <NUM> (i.e., not on the face that contacts the main body <NUM> fabric).

As shown in <FIG>, a method <NUM> for manufacturing an absorbent garment <NUM> is also disclosed. The method comprises providing a main body <NUM> including a front portion <NUM>, a back portion <NUM>, and a gusset <NUM> connecting the front portion <NUM> and the back portion <NUM>, wherein the gusset <NUM> has opposite left and right lateral edges <NUM> configured to partially define respective left and right leg openings <NUM> of the garment <NUM>, as shown at <NUM>. As shown at <NUM>, the method includes providing a layer of absorbent material <NUM> sized and shaped to fit on the gusset <NUM> and having left and right lateral edges configured to extend alongside the respective left and right lateral edges <NUM> of the gusset <NUM>. Note that the layer of absorbent material <NUM> can have the exact same (or similar) shape as the gusset <NUM>, but is slightly smaller in the lateral direction than the gusset <NUM>, such that the layer of absorbent material <NUM> can fit on the gusset <NUM> without hanging over the lateral edges <NUM> thereof.

The method includes attaching left and right elastic bands <NUM>, <NUM> along the respective left and right lateral edges of the layer of absorbent material <NUM>, as shown at <NUM>. For example, as shown and described with respect to <FIG>, the method includes folding the left and right elastic bands <NUM>, <NUM> around the respective left and right lateral edges of the layer of absorbent material <NUM>. Note that in this example of the method, no layer of liner material <NUM> is provided. This may be desirable if the finished garment <NUM> is to be lightweight and thin in the gusset <NUM>. For example, as shown in <FIG>, the layer of absorbent material <NUM> could be the layer that touches the wearer's skin (and thus acts as a dual "liner"/absorbent layer). As will be described further herein below, this layer of liner/absorbent material <NUM> can be a push-pull fabric.

<FIG> shows the absorbent assembly <NUM> from an inner face (i.e., the face that is intended to touch the wearer's skin once the absorbent assembly <NUM> is attached to the gusset <NUM> of the main body <NUM>) as it would appear at this point in the method of construction (i.e., after step <NUM>). It can be seen that the elastic bands <NUM>, <NUM> are sewn to themselves along stitch lines <NUM> at folded over portions, and are sewn at stitch lines <NUM> to the layer of absorbent material <NUM>. In this particular example, the attaching of the left and right elastic bands <NUM>, <NUM> along the respective left and right lateral edges of the layer of absorbent material <NUM> is done by stitching, but it could instead be done by bonding, such as with adhesive and/or ultrasonic waves.

Returning to <FIG>, as shown at <NUM>, the method includes providing a layer of waterproof material <NUM> sized and shaped to fit on the gusset <NUM> and having left and right lateral edges configured to extend alongside the respective left and right lateral edges <NUM> of the gusset <NUM>. Note that the layer of waterproof material <NUM> can have the exact same (or similar) shape as the gusset <NUM>, but is slightly smaller in the lateral direction than the gusset <NUM> and larger in the lateral direction than the layer of absorbent material <NUM>. This way, the layer of waterproof material <NUM> can fit on the gusset <NUM> without hanging over the lateral edges <NUM> thereof, but can also extend over the stitch lines <NUM> connecting the elastic bands <NUM>, <NUM> to the layer of absorbent material <NUM>. To that end, the method also includes attaching the left and right lateral edges of the layer of waterproof material <NUM> to the respective left and right elastic bands <NUM>, <NUM>, as shown at <NUM>. Referring briefly to <FIG>, which shows a view of the outer face of the absorbent assembly <NUM> before it is assembled onto the gusset <NUM>, the method may include bonding (using for example adhesive tape <NUM>, <FIG>) the left and right lateral edges of the layer of waterproof material <NUM> to the respective left and right elastic bands <NUM>, <NUM> over stitches (shown in part at <NUM>) by which the left and right elastic bands <NUM>, <NUM> are stitched to the respective left and right lateral edges of the layer of absorbent material <NUM>. As noted above, this waterproofs the seam at stitch lines <NUM>. The layer of waterproof material <NUM> may also be bonded to the respective left and right elastic bands <NUM>, <NUM> over the stitch lines <NUM> where the elastic bands <NUM>, <NUM> are stitched to themselves, thus further waterproofing the "cuff" formed by the folded-over elastic bands <NUM>, <NUM>. Thus, while the left and right elastic bands <NUM>, <NUM> may be stitched to the layer of absorbent material <NUM>, they are bonded to the layer of waterproof material <NUM> to improve waterproof performance.

Returning to <FIG>, as shown at <NUM>, the method includes attaching the left and right elastic bands <NUM>, <NUM> to the respective left and right lateral edges <NUM> of the gusset <NUM> to couple the layer of absorbent material <NUM> and the layer of waterproof material <NUM> to the main body <NUM>. As shown in <FIG>, which shows a view of the inner face of the absorbent assembly <NUM> after it has been coupled to the gusset <NUM>, this may include attaching the left and right elastic bands <NUM>, <NUM> to the main body <NUM> along the respective left and right lateral edges <NUM> of the gusset <NUM> laterally outwardly of where the left and right elastic bands <NUM>, <NUM> overlap the respective left and right lateral edges of the layer of absorbent material <NUM>. Compare stitch lines <NUM>, <NUM> where the elastic bands <NUM>, <NUM> are attached to the main body <NUM>, to stitch lines <NUM>, where the layer of absorbent material <NUM> is attached to the elastic bands <NUM>, <NUM>. As noted hereinabove with respect to <FIG>, this step may include folding the fabric of the main body <NUM> over the left and right elastic bands <NUM>, <NUM> and attaching the main body <NUM> to the left and right elastic bands <NUM>, <NUM> at the respective left and right lateral edges <NUM> of the gusset <NUM>. Thin, flat elastic bands <NUM> (<FIG>) may be sewn to the main body <NUM> at the respective left and right lateral edges <NUM> of the gusset <NUM> and along the remainder of the leg openings <NUM> before the main body <NUM> is folded over and attached to the absorbent assembly <NUM> and to itself. (Note that these elastic bands <NUM> could be used in the same places in the construction of <FIG> as well, although not shown therein.

<FIG> illustrates another method <NUM> for manufacturing an absorbent garment <NUM> according to the present disclosure. The method <NUM> comprises providing a main body <NUM> including a front portion <NUM>, a back portion <NUM>, and a gusset <NUM> connecting the front portion <NUM> and the back portion <NUM>, wherein the gusset <NUM> has opposite left and right lateral edges <NUM> configured to partially define respective left and right leg openings <NUM> of the garment <NUM>, as shown at <NUM>. As shown at <NUM>, the method includes providing a layer of absorbent material <NUM> sized and shaped to fit on the gusset <NUM> and having left and right lateral edges configured to extend alongside the respective left and right lateral edges <NUM> of the gusset <NUM>. As shown at <NUM>, the method includes providing a layer of liner material <NUM> sized and shaped to fit on the gusset <NUM> and having left and right lateral edges configured to extend alongside the respective left and right lateral edges <NUM> of the gusset <NUM>. Note that the layer of absorbent material <NUM> and the layer of liner material <NUM> can have the exact same (or similar) shape as the gusset <NUM>, but are slightly smaller in the lateral direction than the gusset <NUM>, such that the layer of absorbent material <NUM> and the layer of liner material <NUM> can fit on the gusset <NUM> without hanging over the lateral edges <NUM> thereof.

As shown at <NUM>, the method includes attaching the left and right elastic bands <NUM>, <NUM> along the respective left and right lateral edges of each of the layer of absorbent material <NUM> and the layer of liner material <NUM>. This includes folding the left and right elastic bands <NUM>, <NUM> around the respective left and right lateral edges of each of the layer of absorbent material <NUM> and the layer of liner material <NUM> and stitching the left and right elastic bands <NUM>, <NUM> to the layer of absorbent material <NUM> and the layer of liner material <NUM> where the left and right elastic bands <NUM>, <NUM> overlap the respective left and right lateral edges of each of the layer of absorbent material <NUM> and the layer of liner material <NUM>. The layer of liner material <NUM> can also be bonded to the layer of absorbent material <NUM> (see adhesive tape <NUM>, <FIG>) laterally inwardly of where the left and right elastic bands <NUM>, <NUM> overlap and are stitched to the respective left and right lateral edges of each of the layer of absorbent material <NUM> and the layer of liner material <NUM>. If this bonding is done before the left and right elastic bands <NUM>, <NUM> are stitched to the layer of liner material <NUM> and the layer of absorbent material <NUM>, it can help hold the layer of liner material <NUM> in place on the layer of absorbent material <NUM> while the two are stitched together along stitch lines <NUM>. Such bonding with adhesive tape <NUM> also prevents excessive shifting of the layer of liner material <NUM> with respect to the layer of absorbent material <NUM> in the finished assembly. All of this is done before attaching the layer of waterproof material <NUM> to the left and right elastic bands <NUM>, <NUM>.

As shown at <NUM>, the method includes providing a layer of waterproof material <NUM> sized and shaped to fit on the gusset <NUM> and having left and right lateral edges configured to extend alongside the respective left and right lateral edges <NUM> of the gusset <NUM>. Note that the layer of waterproof material <NUM> can have the exact same (or similar) shape as the gusset <NUM>, but is slightly smaller in the lateral direction than the gusset <NUM> and larger in the lateral direction than the layer of absorbent material <NUM> and the layer of liner material <NUM>. This way, the layer of waterproof material <NUM> can fit on the gusset <NUM> without hanging over the lateral edges <NUM> thereof, but can also extend over the stitch lines <NUM> connecting the elastic bands <NUM>, <NUM> to the layer of absorbent material <NUM> and the layer of liner material <NUM>. As shown at <NUM>, the method may include attaching the left and right lateral edges of the layer of waterproof material <NUM> to the respective left and right elastic bands <NUM>, <NUM> adjacent the layer of absorbent material <NUM>, such that the layer of absorbent material <NUM> is sandwiched between the layer of liner material <NUM> and the layer of waterproof material <NUM> (see <FIG>). While the attaching of the left and right elastic bands <NUM>, <NUM> along the respective left and right lateral edges of each of the layer of absorbent material <NUM> and the layer of liner material <NUM> is done by stitching, the attaching of the left and right lateral edges of the layer of waterproof material <NUM> to the respective left and right elastic bands <NUM>, <NUM> is done by bonding (see adhesive tape <NUM>, <FIG>) so as to waterproof the stitch lines <NUM>.

As shown at <NUM>, the method then includes placing the attached layer of liner material <NUM>, layer of absorbent material <NUM>, layer of waterproof material <NUM>, and left and right elastic bands <NUM>, <NUM> (together making up the absorbent assembly <NUM>) on the gusset <NUM> on an inner face <NUM> of the main body <NUM> with the layer of waterproof material <NUM> adjacent the inner face <NUM> of the main body <NUM>. The method includes subsequently attaching the left and right elastic bands <NUM>, <NUM> to the respective left and right lateral edges <NUM> of the gusset <NUM> to couple the layer of liner material <NUM>, the layer of absorbent material <NUM>, and the layer of waterproof material <NUM> to the main body <NUM>, as shown at <NUM>. Options for this step <NUM> are discussed hereinabove with respect to step <NUM> of method <NUM>.

Any of the above stitched connections could instead be made by bonding, and vice versa, although the present inventors have found that the connections specifically shown and described herein are suitable for strength and waterproofing purposes. For instance, the elastic bands <NUM>, <NUM> are sewn to the fabric of the gusset <NUM> to provide a strong, washable connection that lasts longer than prior art bonded connections along the leg openings <NUM>. The bonded connections between the elastic bands <NUM>, <NUM> and the layer of waterproof material <NUM> ensure that liquid absorbed by the layer of absorbent material <NUM> does not leak out of the absorbent portion(s) of the garment <NUM>, as might otherwise occur with a stitched connection between these pieces. The elastic bands <NUM>, <NUM> can be treated with a water-repellant or waterproof finish that makes them resistant to water intrusion, thereby further ensuring that liquid stays inside the absorbent portion(s) of the garment <NUM>. In one particular example, the elastic bands are SF7167/<NUM>/I/WP Y-folded elastic available from New Horizon Elastic Fabric Co. of Dongguan, Guangdong Province, China. The thread used for stitching, especially at stitch lines <NUM>, can also be treated with a water-repellant or waterproof finish.

The layer of liner material <NUM> can be any appropriate material that quickly absorbs liquid and pulls it away from the body. In one example, the layer of liner material <NUM> is a jersey knit material made of, for example, cotton or a cotton-synthetic blend. In one particular example, the layer of liner material <NUM> is a <NUM>% cotton (<NUM>), <NUM>% elastane (40D) weft knit single jersey fabric. In another example, the layer of liner material <NUM> is a French terry knit. The layer of liner material <NUM> may be treated to provide special functionality, such as with a stain-release finish. In one example, the layer of liner material <NUM> is manufactured from polyester stain-release yarn, such as TOP CLEAN™ from Far Eastern New Century Corporation of Taiwan. For example, if the fabric is French terry knit, the terry side can be made of stain-release polyester yarn and the flat side can be made of regular polyester yarn. In another example, the layer of liner material <NUM> is treated on the non-skin side with a chemical that causes the fabric to pull liquid away from its skin-facing surface, and thereafter prevents the liquid from returning to the skin-facing side of the fabric. In still another example, a push-pull effect can be provided by yarn choice and fabric construction, such as if the skin-facing side of the layer of liner material <NUM> is constructed of yarn which is liquid-repellant, and the non-skin side is constructed of yarn that is liquid-absorbent. The liquid will be pushed by the liquid-repellant side to go through to the water-absorbent side, which simultaneously pulls the water away from the skin-facing, liquid-repellant side of the fabric. In still another example, the layer of liner material <NUM> is treated with an anti-microbial finish. In one particular example, the layer of liner material <NUM> can be treated with AGION™ AM Slurry available from Sciessent LLC of Wakefield, Massachusetts. In another particular example, the layer of liner material <NUM> can be treated with Microban™ AEGIS™ AEM <NUM>, available from Microban International of Huntersville, North Carolina. Any of the above-noted functionalities and/or treatments of the layer of liner material <NUM> can be combined with one another.

The layer of absorbent material <NUM> can be any appropriate material that is capable of absorbing a volume of liquid up to, for example, <NUM>-<NUM> when provided in a size corresponding to a typical panty gusset. The layer of absorbent material <NUM> can be cotton, polyester, or blends thereof. Typically, the fabric will have a medium to heavy weight, ranging from 250gsm-400gsm. The layer of absorbent material <NUM> can be French terry fabric, with the non-flat side being maintained as longer loops of yarn or being shredded to create fleece. In one example, the layer of absorbent material <NUM> is a cotton/polyester French terry or fleece fabric with a water-absorbent finish, with the flat side facing the layer of liner material <NUM> and the non-flat (e.g., fleece) side facing the layer of waterproof material <NUM>. In another example, the layer of absorbent material <NUM> is a two-layer bonded terry or fleece fabric, the flat side of which has a water-absorbent finish facing the layer of liner material <NUM> and the non-flat (e.g., fleece) side of which has a waterabsorbent finish facing the layer of waterproof material <NUM>. In one particular example, the layer of absorbent material <NUM> is weft-knit French terry, the non-flat side of which has been shredded to form fleece, made of <NUM>% cotton (<NUM>), <NUM>% polyester (<NUM>) having a weight of 340gsm, such as CO3F0024-BR01AV available from Far Eastern Polytex (VN) Ltd. of Binh Duong, Vietnam. In some examples, the layer of absorbent material <NUM> can be treated with a chemical, knit, and/or by way of yarn choice be constructed to provide a push-pull effect as was described herein above with respect to the layer of liner material <NUM>. This may be particularly advantageous if no separate layer of liner material <NUM> is provided and the layer of absorbent material <NUM> directly touches the wearer's skin, as shown in <FIG>. In one particular example, the dual-purpose liner/absorbent push-pull fabric is knit specifically to have a surface contact angle against the skin that tends to pull moisture away from the skin in the z-direction by capillary action. The side of the fabric that is configured to be located further from the skin may then spread the moisture throughout and along the far side of the fabric in the x-and y-directions, again by capillary action, such that the moisture is located on the far side of the fabric instead of the side that contacts the skin. In this regard, the dual-purpose liner/absorbent push-pull fabric as a whole is considered to absorb water by capillary action, even if it is knit from yarns of a hydrophobic polymer, such as, for example, polyester.

The layer of waterproof material <NUM> can be any suitable material that does not allow liquid to pass therethrough, or at least is resistant to liquid. In one example, the layer of waterproof material <NUM> comprises a fabric 28a bonded to a waterproof membrane 28b (see <FIG>). The fabric 28a can be a sheer or semi-sheer fabric knitted from nylon, spandex, polyester, or blends thereof. The waterproof membrane 28b can be adhered, laminated, coated, or otherwise integrally formed on or bonded to the fabric 28a. The waterproof membrane 28b can be a polyurethane membrane or a thermoplastic polyurethane (TPU) membrane, which in one example comprises coffee oil to provide odor control. In one particular example, the layer of waterproof material <NUM> is weft-knit <NUM>% polyester coated with a polyurethane membrane, and the membrane includes coffee oil. One such fabric is KB445S from Singtex Industrial Co. of New Taipei City, Taiwan, which is <NUM>% weft-knit polyester coated with a polyurethane membrane that comprises SCAFE™ Polyol. Alternatively, the layer of waterproof material <NUM> can be SCAFE™ AIRMEM™ from Singtex Industrial Co. In another example, the layer of waterproof material <NUM> is a non-woven material coated with a waterproofing chemical.

The main body <NUM> fabric can be any fabric suitable for maintaining a close-to-body feel on the wearer's lower torso. For example, the main body <NUM> fabric can be a cotton-synthetic blend, a synthetic blend (of nylon, elastane, polyester, etc.), or any other known suitable fabric. In one particular example, the main body <NUM> fabric is a weft knit interlock nylon-elastane blend. In another particular example, the main body <NUM> fabric is a warp knit tricot nylon-elastane blend. The main body <NUM> fabric of the gusset <NUM> can be treated with or made from an odor-controlling material. For example, the fabric of the gusset <NUM> can be knitted partially or wholly with coffee-containing yarn, such as MYLITHE™ yarn from SCAFE™. Alternatively, the main body <NUM> fabric can be treated with an odor-controlling substance. Additionally or alternatively, the main body <NUM> fabric can be treated with a wicking finish that wicks moisture from the wearer's body to the outer face of the garment <NUM>. Regardless of the fabric used for the gusset <NUM>, any or all of the layers of material <NUM>, <NUM>, <NUM> can be treated with an antimicrobial finish as described herein above with respect to the layer of liner material <NUM> and/or the threads of the fabric can include an antimicrobial fiber, such as silver, to neutralize odors.

Referring back to <FIG>, the front and back ends <NUM>, <NUM> of the layer of liner material <NUM> (or the layer of absorbent material <NUM> if liner material is not provided) can be bonded to the fabric of the gusset <NUM> and/or front portion <NUM> or back portion <NUM> of the main body <NUM> by way of heat-activated adhesive finishing tape <NUM>. Alternatively or additionally, the front and back ends <NUM>, <NUM> of the layer of liner material <NUM> (or layer of absorbent material <NUM>) can be sewn to the main body <NUM>. The layer of waterproof material <NUM> can be bonded on its outer-facing side to the main body <NUM> at these locations as well. At these locations, the layer of waterproof material <NUM> can be bonded on its inner-facing side to the layer of absorbent material <NUM>, which in turn can be bonded to the layer of liner material <NUM> (if present).

Any bonding noted hereinabove can be done by way of elastomeric heat-activated adhesive tape/film, such as that available from BEMIS™. Alternative methods of bonding include using spray adhesive, printed adhesive, mesh adhesive tape, ultrasonic bonding, and/or liquid glue.

The elastic bands <NUM>, <NUM>, <NUM> noted herein above can be braided, knitted, or woven elastic bands typically available for elasticizing the leg openings and/or waistband of garments.

In the above description, unless otherwise noted, "inner" refers to a face of a layer that faces the wearer when the garment is worn <NUM>, while "outer" refers to a face of a layer that faces away from the wearer while the garment <NUM> is worn. The terms "left" and "right" and "front" and "back" are for reference purposes and are not limiting on the scope of the present disclosure or claims.

Claim 1:
A garment (<NUM>) comprising:
a main body (<NUM>) including a front portion (<NUM>), a back portion (<NUM>), and a gusset (<NUM>) connecting the front portion (<NUM>) and the back portion (<NUM>), wherein the gusset (<NUM>) has left and right lateral edges (<NUM>) partially defining respective left and right leg openings (<NUM>) of the garment (<NUM>);
a layer of absorbent material (<NUM>) coupled to an inner face (<NUM>) of the main body (<NUM>) at least at the gusset (<NUM>); and
a layer of waterproof material (<NUM>) sandwiched between the main body (<NUM>) and the layer of absorbent material (<NUM>);
characterised by left and right elastic bands (<NUM>, <NUM>) coupling the layer of absorbent material (<NUM>) and the layer of waterproof material (<NUM>) to the main body (<NUM>) along the respective left and right lateral edges (<NUM>) of the gusset (<NUM>).