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 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 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. A method for manufacturing the absorbent garment is also provided.

<CIT> discloses an absorbent pad for use in a garment. The absorbent pad includes: a liquid impermeable barrier layer; a functional layer attached to the barrier layer, the functional layer comprising a liquid absorbent component; a liquid impermeable peripheral sealing element bonded to peripheries of the functional layer and barrier layer; and a peripheral attaching element having a first portion and a second portion, the first portion bonded to the peripheral sealing element. The second portion of the peripheral attaching element is detached from the peripheral sealing element and is arranged to be attached to a fabric body of the garment, thereby attaching the absorbent pad to the garment.

According to one example, 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 main body. An absorbent material is coupled to an inner face of the main body at least at the gusset. A waterproof material is sandwiched between the main body and the absorbent material. Left and right elastic bands are coupled to outer lateral edges of the absorbent material. The left and right elastic bands are bonded to the waterproof material and the waterproof material is attached to the main body proximate the respective left and right lateral edges of the gusset. The left and right elastic bands are folded around respective left and right lateral edges of the absorbent material. The waterproof material is attached to the main body between respective bottom halves of the folds of each of the left and right elastic bands and the inner face of the main body.

Optionally, the waterproof material is bonded to each of the left and right elastic bands at laterally outer edges of the waterproof material using bonding film, and the waterproof material extends outwardly beyond the bonding film to provide free edges that are attached to the main body.

Optionally, the left and right elastic bands are bonded to the absorbent material where the left and right elastic bands overlap the respective left and right lateral edges of the absorbent material.

In one example, a liner material is coupled to the absorbent material such that the absorbent material is sandwiched between the liner material and the waterproof material. Optionally, the left and right elastic bands are folded around respective left and right lateral edges of each of the liner material and the absorbent material and the left and right elastic bands are bonded to the liner material and the absorbent material where the left and right elastic bands overlap the respective left and right lateral edges of each of the liner material and the absorbent material.

In one example, left and right lateral edges of a material of the main body are folded over toward the inner face of the main body at the gusset to define the left and right lateral edges of the gusset, and left and right lateral edges of the waterproof material are attached to the respective left and right lateral edges of the main body material. Optionally, the left and right lateral edges of the waterproof material are attached to the respective left and right lateral edges of the main body material by stitching. Optionally, the left and right elastic bands are folded around respective left and right lateral edges of the absorbent material and the left and right elastic bands respectively overlap the stitching between the left and right lateral edges of the waterproof material and the respective left and right lateral edges of the main body material. Optionally, the main body material is bonded to itself where the left and right lateral edges of the main body material are folded over, and the main body is substantially seamless on an outer face thereof at least at the gusset.

In one example, the waterproof material comprises a fabric bonded to a waterproof membrane.

According to another example of the present disclosure, 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 main body; providing an absorbent material sized and shaped to fit on the gusset and having left and right lateral edges configured to extend alongside the respective left and right lateral edges of the gusset; attaching left and right elastic bands along the respective left and right lateral edges of the absorbent material; providing a waterproof material sized and shaped to fit on the gusset and having left and right lateral edges configured to extend alongside the respective left and right lateral edges of the gusset; attaching the left and right lateral edges of the waterproof material to the main body proximate the respective left and right lateral edges of the gusset such that the waterproof material is located on an inner face of the main body at the gusset; and placing the attached absorbent material and left and right elastic bands on the gusset over the waterproof material and attaching the left and right elastic bands to the waterproof material such that the waterproof material is sandwiched between the absorbent material and the main body.

In one example, the method further comprises folding the left and right elastic bands around the respective left and right lateral edges of the absorbent material. Optionally, the method further comprises bonding the left and right elastic bands to the absorbent material where the left and right elastic bands overlap the respective left and right lateral edges of the absorbent material.

In one example, the method further comprises folding left and right lateral edges of a material of the main body over toward an inner face of the main body at the gusset to define the left and right lateral edges of the gusset, and attaching the left and right lateral edges of the waterproof material to the respective left and right lateral edges of the main body material. Optionally, the attaching of the left and right lateral edges of the waterproof material to the respective left and right lateral edges of the main body material is done by stitching. Optionally, the left and right elastic bands respectively overlap the stitching between the left and right lateral edges of the waterproof material and the respective left and right lateral edges of the main body material. Optionally, the method further comprises bonding the main body material to itself where the left and right lateral edges of the main body material are folded over such that the main body is substantially seamless on an outer face thereof at least at the gusset.

In one example, the attaching of the left and right elastic bands along the respective left and right lateral edges of the absorbent material is done by bonding.

In one example, the attaching of the left and right lateral edges of the waterproof material to the main body proximate the respective left and right lateral edges of the gusset is done by stitching.

In one example, the method further comprises providing a liner material sized and shaped to fit on the gusset and having left and right lateral edges configured to extend alongside the respective left and right lateral edges of the gusset; attaching the left and right elastic bands along the respective left and right lateral edges of each of the absorbent material and the liner material; and placing the attached liner material, absorbent material, and left and right elastic bands on the gusset over the waterproof material and attaching the left and right elastic bands to the waterproof material such that the absorbent material is sandwiched between the liner material and the waterproof material.

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 and waterproof gusset area configured to cover a wearer's crotch, although the absorbent and waterproof portions of the garment could extend beyond the gusset area as well. For example, the present application relates to panties or swimwear, or to garments such as shorts, pants, or skirts having an integral panty, capable of absorbing bodily fluids such as urine, menstrual fluid, vaginal discharges, and/or sweat without allowing the bodily fluid to seep through to an outer face of the garment. The panties, swimwear, or garment having an integral panty 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 a 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 main body <NUM>.

<FIG> shows the interior of the garment <NUM>, with a portion of the gusset <NUM> shown in detail. A liner material <NUM> can be seen covering a majority of the gusset <NUM>. The liner material <NUM> shows the extent of an absorbent assembly <NUM> of the garment <NUM> and covers an absorbent material and a 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> and/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>, an 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 waterproof material <NUM> is sandwiched between the main body <NUM> and the absorbent material <NUM>. The liner material <NUM> is coupled to the absorbent material <NUM> opposite the waterproof material <NUM>, such that the absorbent material <NUM> is sandwiched between the liner material <NUM> and the waterproof material <NUM>. In use, the 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 liner material <NUM> is optional. Left and right elastic bands <NUM> are coupled to the outer lateral edges of the optional liner material <NUM>, the absorbent material <NUM>, and the waterproof material <NUM>, as will be described in further detail below. The waterproof material <NUM> is attached to the main body <NUM> proximate 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 liner material <NUM> and the absorbent material <NUM> to form a "V" shape 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 bonded to the liner material <NUM> and the absorbent material <NUM> where the left and right elastic bands <NUM> overlap the respective left and right lateral edges of each of the liner material <NUM> and the absorbent material <NUM>, such as by way of bonding film <NUM>. In some examples, the bonding film <NUM> lines the entire "V" of each folded elastic band <NUM>, but in other examples separated strips of bonding film are used on the top and bottom folds of the "V. " In other examples, the bonding is done by way of spray glue or other adhesive application. Before the elastic bands <NUM> are attached, the liner material <NUM> can optionally be bonded to the absorbent material <NUM> by way of heat-activated adhesive tape and/or can be stitched to the absorbent material <NUM> as shown at stitching <NUM>. Stitching <NUM> can be intermittent along the length of the gusset <NUM>, and meant simply to hold the liner material <NUM> and absorbent material <NUM> in place with respect to each other while the elastic bands <NUM> are attached thereto. If the absorbent material <NUM> and the liner material <NUM> are stitched together before the elastic bands <NUM> are attached thereto, the absorbent material <NUM> can optionally also be stitched to the bottom half of the fold of each of the elastic bands <NUM>. The top half of the fold of each elastic band <NUM> could then be folded over and bonded to the top of the liner material <NUM>.

In one example, before the attached absorbent material <NUM>, liner material <NUM>, and elastic bands <NUM> are assembled to the main body <NUM>, the outer lateral edges of the waterproof material <NUM> are attached to the fabric of the main body <NUM>. More specifically, left and right lateral edges <NUM> of the material of the main body <NUM> are folded over toward the inner face <NUM> of the main body <NUM> at the gusset <NUM> to define the left and right lateral edges <NUM> of the gusset <NUM>. Left and right lateral edges of the waterproof material <NUM> are attached to the respective left and right lateral edges <NUM> of the main body <NUM> material. In one example, the left and right lateral edges of the waterproof material <NUM> are attached to the respective left and right lateral edges of the main body <NUM> material by stitching, as shown at <NUM>, which can be pullout overlock, cover stitch, or other known stitching. In other examples, the waterproof material <NUM> is bonded to the main body <NUM> material at the lateral edges of each material. Optionally, the main body <NUM> material is bonded to itself where the left and right lateral edges <NUM> of the main body <NUM> material are folded over using bonding film <NUM>. Thus, the main body <NUM> is substantially seamless on an outer face <NUM> thereof at least at the gusset <NUM>. However, the stitching <NUM> attaching the waterproof material <NUM> to the material of the main body <NUM> provide integrity to the garment <NUM> that is not present in prior art garments that are only bonded.

After the liner material <NUM> and absorbent material <NUM> are bonded and/or stitched to each other and to the elastic bands <NUM>, the left and right elastic bands <NUM> are bonded to the waterproof material <NUM>, which has optionally been pre-attached to the main body <NUM>. More specifically, the waterproof material <NUM> can be bonded to each of the left and right elastic bands <NUM> at laterally outer edges of the waterproof material <NUM> using bonding film <NUM>. If the liner material <NUM> and the absorbent material <NUM> are stitched to the bottom half of the fold of each elastic band <NUM>, the bonding film <NUM> can be placed over stitches by which the left and right elastic bands <NUM> are stitched to the respective left and right lateral edges of each of the absorbent material <NUM> and the liner material <NUM>. The liner material <NUM>, absorbent material <NUM>, and elastic bands <NUM> are sized and shaped such that when they are placed on the gusset <NUM>, the left and right elastic bands <NUM> respectively overlap the stitching <NUM> between the left and right lateral edges of the waterproof material <NUM> and the respective left and right lateral edges <NUM> of the main body <NUM> material to hide the stitching <NUM> from view and protect it from contact. This is also shown in the partial cutaway view provided in <FIG>, in which the folded-over edge <NUM> of the material of the main body <NUM> is shown as being stitched to the outer lateral edge of the waterproof material <NUM> at stitching <NUM>, which is covered by elastic band <NUM>. Optionally, the elastic bands <NUM> can also be bonded to the stitching <NUM> and/or to the folded-over lateral edges <NUM> of the main body <NUM>, such as if the bonding film <NUM> is extended outwardly on both sides of the gusset <NUM> to cover over the stitching <NUM> and extend to or over the main body <NUM> fabric.

Because the left and right elastic bands <NUM> are bonded and/or stitched to the absorbent material <NUM> and the liner material <NUM> and bonded to the waterproof material <NUM>, this lessens the likelihood of leaks. The bonding film <NUM> effectively creates a "cuff' around the absorbent portion(s) <NUM>, <NUM> of the absorbent assembly <NUM>, which cuff together with the waterproof material <NUM> prevents bodily fluids from seeping to the fabric of the main body <NUM>. The elastic bands <NUM> may be treated with chemicals that make them waterproof or water resistant, as described herein below, which can further prevent leaks from the absorbent portion(s) of the absorbent assembly <NUM>. Furthermore, because the waterproof material <NUM> is bonded to each of the left and right elastic bands <NUM> over any stitches by which the left and right elastic bands <NUM> are optionally stitched to each of the respective left and right lateral edges of the absorbent material <NUM>, any liquid that might otherwise tend to leak from the absorbent portion(s) <NUM>, <NUM> of the absorbent assembly <NUM> due to such stitching <NUM> is maintained on the inner face of the waterproof material <NUM> (i.e., not on the face that contacts the main body <NUM> fabric).

The elastic bands <NUM> can optionally be asymmetrically folded, as shown in <FIG>, such that more of the elastic band <NUM> is on the bottom part of the fold than on the top part of the fold. This provides more surface area for the waterproof material <NUM> to be bonded to the bottom part of the folded elastic band <NUM> at bonding film <NUM>, while providing less surface area that contacts the wearer's skin on the upper surface of the absorbent assembly <NUM>. The waterproof material <NUM> extends outwardly beyond the bonding film <NUM> to provide the free edges that are be attached to the material of the main body <NUM>. As will be described herein below, the waterproof material <NUM> can include a fabric bonded to a waterproof membrane, and either the fabric side or the membrane side can be the side that is bonded to the elastic bands <NUM> via the bonding film <NUM>. In a preferred example, the fabric side of the waterproof material <NUM> is bonded to the elastic bands <NUM> via the bonding film <NUM>. This is because the fabric side of the waterproof material <NUM> has some ability to absorb moisture, thereby attracting any moisture that leaks from the elastic bands <NUM> and/or from the absorbent material <NUM>. Such leaks are then eventually stopped by the waterproof membrane side of the waterproof material <NUM>, which faces the inner face <NUM> of the main body <NUM>.

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 main body <NUM>, as shown at <NUM>. As shown at <NUM>, the method includes providing an 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 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 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> along the respective left and right lateral edges of the absorbent material <NUM>, as shown at <NUM>. For example, as shown and described above, the method includes folding the left and right elastic bands <NUM> around the respective left and right lateral edges of the absorbent material <NUM>. The method may further include bonding the left and right elastic bands <NUM> to the absorbent material <NUM> where the left and right elastic bands <NUM> overlap the respective left and right lateral edges of the absorbent material <NUM>, as shown at bonding film <NUM>. Note that in this example of the method, no 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, the 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 liner/absorbent material <NUM> can be a push-pull fabric. In other examples, however, the method may include providing a 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>. Such a method may include attaching the left and right elastic bands <NUM> along the respective left and right lateral edges of each of the absorbent material <NUM> and the liner material <NUM>, for example by bonding.

Continuing with <FIG>, as shown at <NUM>, the method includes providing a 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 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>. This way, the waterproof material <NUM> can fit on the gusset <NUM> without hanging over the lateral edges <NUM> thereof, but is still wide enough to attach to the folded over lateral edges <NUM> of the main body <NUM> material. To that end, the method also includes attaching the left and right lateral edges of the waterproof material <NUM> to the main body <NUM> proximate the respective left and right lateral edges <NUM> of the gusset <NUM> such that the waterproof material <NUM> is located on an inner face <NUM> of the main body <NUM> at the gusset <NUM>, as shown at <NUM>. For example, the attaching of the left and right lateral edges of the waterproof material <NUM> to the respective left and right lateral edges <NUM> of the main body <NUM> material may be done by stitching. Optionally, the method includes bonding the main body <NUM> material to itself where the left and right lateral edges <NUM> of the main body <NUM> material are folded over such that the main body <NUM> is substantially seamless on an outer face thereof <NUM> at least at the gusset <NUM>. In one particular, non-limiting example, the waterproof material <NUM> may be stitched to the edges <NUM> of the main body <NUM> fabric in a bagged-out configuration, after which the bonding film <NUM> can be applied to the edges of the main body <NUM> adjacent the stitching <NUM>, and the main body <NUM> can be turned right-side-out. When the main body <NUM> is turned right-side-out and heat-treated along the edges <NUM> thereof, the edges <NUM> of the main body <NUM> are bonded together by the bonding film <NUM> where they are folded over. Other methods for attaching the waterproof material <NUM> to the main body <NUM> may be used.

As shown at <NUM>, the method includes placing the attached absorbent material <NUM> and left and right elastic bands <NUM> on the gusset <NUM> over the waterproof material <NUM> and attaching the left and right elastic bands <NUM> to the waterproof material <NUM> such that the waterproof material <NUM> is sandwiched between the absorbent material <NUM> and the main body <NUM>. As noted hereinabove, this portion of the method may include folding left and right lateral edges <NUM> of the material of the main body <NUM> over toward the inner face <NUM> of the main body <NUM> at the gusset <NUM> to define the left and right lateral edges <NUM> of the gusset <NUM>, and attaching the left and right lateral edges of the waterproof material <NUM> to the respective left and right lateral edges <NUM> of the main body <NUM> material. Optionally, as shown in <FIG> and <FIG>, the left and right elastic bands <NUM> may respectively overlap the stitching <NUM> between the left and right lateral edges of the waterproof material <NUM> and the respective left and right lateral edges <NUM> of the main body <NUM> material.

In examples in which a liner material <NUM> is present, the method may include placing the attached liner material <NUM>, absorbent material <NUM>, and left and right elastic bands <NUM> on the gusset <NUM> over the waterproof material <NUM> and attaching the left and right elastic bands <NUM> to the waterproof material <NUM> such that the absorbent material <NUM> is sandwiched between the liner material <NUM> and the waterproof material <NUM>.

In other examples, the elastic bands <NUM>, absorbent material <NUM>, and optional liner material <NUM> are attached to the waterproof material <NUM> before the waterproof material <NUM> is attached to the material of the main body <NUM>. In other examples, instead of having folded-over edges <NUM>, the edges of the main body <NUM> are raw cut.

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 waterproof material <NUM> is sewn to the material of the main body <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> and the waterproof material <NUM> ensure that liquid absorbed by the 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> 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>. Any thread used for stitching, especially at stitching <NUM>, can also be treated with a water-repellant or waterproof finish.

The liner material <NUM> can be any appropriate material that quickly absorbs liquid and pulls it away from the body. In one example, the liner material <NUM> is a jersey knit material made of, for example, cotton or a cotton-synthetic blend. In one particular example, the liner material <NUM> is a <NUM>% cotton (<NUM>), <NUM>% elastane (40D) weft knit single jersey fabric. In another example, the liner material <NUM> is a French terry knit. The liner material <NUM> may be treated to provide special functionality, such as with a stain-release finish. In one example, the 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 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 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 liner material <NUM> is treated with an anti-microbial finish. In one particular example, the liner material <NUM> can be treated with AGION™ AM Slurry available from Sciessent LLC of Wakefield, Massachusetts. In another particular example, the liner material <NUM> can be treated with Sanitized™ T20-<NUM> anti-microbial finish from Sanitized AG of Switzerland and/or HeiQ Fresh FFL odor control finish from HeiQ AG of Switzerland. Any of the above-noted functionalities and/or treatments of the liner material <NUM> can be combined with one another.

The 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 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 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 absorbent material <NUM> is a cotton/polyester French terry or fleece fabric with a water-absorbent finish, with the flat side facing the liner material <NUM> and the non-flat (e.g., fleece) side facing the waterproof material <NUM>. In another example, the absorbent material <NUM> is a two-layer bonded terry or fleece fabric, the flat side of which has a water-absorbent finish facing the liner material <NUM> and the non-flat (e.g., fleece) side of which has a water absorbent finish facing the waterproof material <NUM>. In one particular example, the 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 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 liner material <NUM>. This may be particularly advantageous if no separate liner material <NUM> is provided and the absorbent material <NUM> directly touches the wearer's skin. 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 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 waterproof material <NUM> comprises a fabric bonded to a waterproof membrane. The fabric can be a sheer or semi-sheer fabric knitted from nylon, spandex, polyester, or blends thereof. The waterproof membrane can be adhered, laminated, coated, or otherwise integrally formed on or bonded to the fabric. The waterproof membrane 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 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 waterproof material <NUM> can be SCAFE™ AIRMEM™ from Singtex Industrial Co. In another example, the waterproof material <NUM> is fabric treated with a water repellent finish, which is bonded to a waterproof membrane. In another example, the waterproof material <NUM> is a fabric treated with a water repellent finish, which is not bonded to a waterproof membrane, for example, a non-woven material coated with a waterproofing chemical.

The main body <NUM> material 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 (e.g., cotton-spandex), 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, such as HeiQ Fresh FFL odor control finish, from HeiQ AG of Switzerland. 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 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 liner material <NUM> (or the 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 of the liner material <NUM> (or the absorbent material <NUM>) can be sewn to the main body <NUM>. The 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 waterproof material <NUM> can be bonded on its inner-facing side to the absorbent material <NUM>, which in turn can be bonded to the 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> noted herein above can be braided, knitted, or woven elastic bands typically available for elasticizing the leg openings and/or waistband of garments.

As noted hereinabove, the garment can be a pair of panties or a swimsuit bottom. Alternatively, the garment can be a pair of shorts, a pair of pants, a skirt, a dress, or the like into which a pair of panties as shown in <FIG> is sewn. The main body <NUM> in such instances can be stitched or bonded about the waistband thereof into the waistband of the shorts, pants, skirt, etc. A benefit of the seamless outer face <NUM> of the main body <NUM> is that when included as a built-in panty in tighter fitting garment, the main body <NUM> is not visible or at least has less visible seam lines than might otherwise be apparent if there was stitching on the outer face <NUM> of the main body <NUM>.

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 main body (<NUM>);
an absorbent material (<NUM>) coupled to an inner face (<NUM>) of the main body (<NUM>) at least at the gusset (<NUM>);
a waterproof material (<NUM>) sandwiched between the main body (<NUM>) and the absorbent material (<NUM>); and
left and right elastic bands (<NUM>) coupled to outer lateral edges of the absorbent material (<NUM>);
wherein the left and right elastic bands (<NUM>) are bonded to the waterproof material (<NUM>); and
wherein the waterproof material (<NUM>) is attached to the main body (<NUM>) proximate the respective left and right lateral edges (<NUM>) of the gusset (<NUM>);
characterized in that
the left and right elastic bands (<NUM>) are folded around respective left and right lateral edges of the absorbent material (<NUM>); and
the waterproof material (<NUM>) is attached to the main body (<NUM>) between respective bottom halves of the folds of each of the left and right elastic bands (<NUM>) and the inner face (<NUM>) of the main body (<NUM>).