Abstract: An infant bunting formed from a single blank of multi-layer fabric material in which a thermal insulation core layer is sandwiched between inner and outer facing layers, the periphery of the blank being ultrasonically welded to create a continuous hem. The blank is contoured to define a rectangular main section provided with a lower extension forming a closure section and an upper extension whose corners are folded in and joined to form a triangular hood section for receiving the head of an infant. The opposing sides of the main section are foldable to overlap the infant's body, arms and legs to form a pouch which is held together by Velcro fasteners. The closure extension is foldable over the pouch and held thereto by a Velcro fastener to lock in the feet of the infant.

Abstract: A disposable, double-breasted gown for medical patients fabricated of non-woven synthetic plastic sheeting. The gown body is formed from a rectangular blank whose straight upper long edge is die cut to provide chamfered corners, an off-center neck indentation and isosceles triangular arm-hole indentations on the left and right sides of the arcuate indentation, the resulting straight edge shoulder segments formed between the corners and the indentations all having the same length. The peaks of the triangular indentations are aligned with parallel left and right transverse fold lines that define a rear gown section on one side of which is a relatively narrow left-front gown section, and on the other side of which is a broad right-front gown section.

Abstract: A motorless Velcro tape feed and cut assembly acting as a slave unit which cooperates with the horn of an ultrasonic welding machine. When the horn is brought down to carry out a welding action, it then depresses the spring-biased operating block of the assembly, causing it to shift downwardly from its normally raised position above a base plate to a final position adjacent to the base plate, the block returning to its raised position when the horn is retracted. Anchored on the base plate and projecting thereabove is an anvil which telescopes within an open-ended anvil channel in the block, the length of the anvil being such that in the final position of the block its head is then in operative relation to the horn to effect welding of a Velcro component onto a fabric lying on the upper face of the block.

Abstract: Disposable apparel shorts fabricated from a single blank of non-woven textile sheeting, the blank having opposing isosceles triangular indentations therein whose vertices lie at the opposite ends of a transverse center line. When the blank is folded on this line to form identical superposed sections, these constitute the front and rear sections of the shorts in which the upper margins of the sections define the waist, and the folded-over triangular indentations define the leg openings. The side margins of the front section are folded in and the corresponding side margins of the rear section are folded over the folded-in margins to define side vents in the leg openings to provide additional space, should it be required by the wearer. An elastic band is bonded in its stretched state to the inner surface of the upper margins of the sections to create a shirred circular waist which is expandable to conform to the waist of the wearer.

Abstract: A fitted sheet for covering a standard crib or bed mattress. The fitted sheet is developed from a single rectangular blank of non-woven fabric material, the sides of which are folded in along parallel longitudinal fold lines to form a folded-in sheet whose width corresponds to that of the mattress for which it is intended and whose length exceeds that of the mattress to an extent necessary to define the ends of the fitted sheet. Each corner of the folded-in sheet is seamed along a diagonal line to form a triangular flap which when the sides of the folded-in sheet are folded over the sides of the mattress, then defines a right angle corner that fits against the corresponding corner of the mattress. Each end of the fitted sheet is rendered stretchable by an elastic strip whereby the fitted sheet conforms snugly to the mattress.

Abstract: A fitted sheet for covering a standard crib or bed mattress, the sheet being made of synthetic plastic material having an absorbent top layer laminated to a liquid-impermeable backing film whereby when a crib or bed occupant wets the sheet, the liquid is absorbed thereby, yet the underlying mattress is maintained in a dry, sanitary condition. The fitted sheet is created from a single rectangular blank whose sides are folded in on longitudinal fold lines and whose ends are folded in on transverse fold lines, the corners of the blank being folded in on diagonal fold lines to form triangular folds that are ultrasonically sealed to the folded-in ends, thereby defining a box-like fitted sheet having reinforced right angle corners and sides and ends coextensive with those of the mattress. Each end of the fitted sheet is creased to form puckers that are joined to an elastic strip to render the end stretchable whereby the fitted sheet conforms snugly to the mattress.

Abstract: A disposable protective gown useable in a medical environment, the gown being fabricated of a single blank of non-woven synthetic fabric sheeting having a generally rectangular form. Cut into the short ends of the blanks in opposing relation are elongated triangular notches whose lower edges extend along an intermediate longitudinal axis which divides the blank into upper and lower sections. The free ends of the lower section are folded in on vertical fold lines to define a pair of rear flaps. The upper section is provided with a central neck opening having a slit therein to admit the head of the wearer, the upper section being folded down along a horizontal fold line extending through the diameter of this opening to define a rear fold. The margin of the rear fold is ultrasonically seamed to the upper edges of the notches to create outstretched sleeves and to the upper edges of the rear flaps to form the rear panel of a gown which can be slipped over the head of the wearer.

Abstract: A standardized, expandable cap for a newborn infant to reduce heat losses from the skull during the hours immediately following birth. The cap is fabricated by die cutting a sheet of non-woven, spunlaced, synthetic fiber material to create blanks having an arched shape, each blank including an arcuate margin and a straight base, the grain of the non-woven material being normal to the base to render it laterally stretchable. A pair of such blanks are superposed and ultrasonically seamed along a line conforming to the arcuate margin to create the dome of the cap. The cap is completed by puckering the lower rear section thereof to create a shirred zone and ultrasonically welding an elastomeric tape thereacross to provide an expandable cap which when worn adjusts itself to the head of the wearer regardless of head size.

Abstract: A basic garment suitable for use as a medical examination gown or for other purposes calling for apparel which may be quickly opened to fully expose the body of the wearer. The garment is fabricated from a single blank of non-woven polyester sheet material contoured to define front and rear sections having complementary sleeve portions, with a transverse fold line therebetween in the center of which is a neck opening. The front section is slit into a pair of panels that separate at the neck opening whereby when the front section is folded over the rear section and the two sections are ultrasonically seamed together at their opposing side margins, a garment is created having the desired characteristics. The front panels are releasably held together by hook and loop nylon fabric fasteners whose male components are ultrasonically-bonded to the margin of one panel and whose female components are ultrasonically-bonded to the margin of the other panel.

Abstract: A technique for converting flexible sheeting formed of non-woven thermoplastic material into disposal apparel shorts. The sheeting is die cut to yield identical blanks of generally rectangular form whose lower section has a pair of crotch tabs extending therefrom in opposite directions. The side margins of two superposed blanks are ultrasonically welded together to define a tube whose upper margin constitutes the waist of the shorts. Then the tabs of each blank are ultrasonically welded together at their ends to complete the crotch and define a pair of leg openings. Finally, an elastic band of thermoplastic material is ultrasonically welded in its stretched state to the inner circle of the waist to create a puckered waist which is expandable to conform to the waist size of the wearer.