Disposable front opening garment with selected pad shapes and locations

Abstract

A disposable front opening garment made with two superposed overlapped half width segments and pads of different shape located between segments. Other embodiments have pads of different shapes on both segments positioned for different requirements. Pads inside segment assemblies are enclosed with impervious substrates to contain body fluids. Elastic on segment margins form cuffs. Expandable materials, elastic side tapes, and elastic front closaure tape provide girth adjustment. Segment assemblies with enclosed pads are overlapped and bonded together in central areas of the rear panel and not sealed together in the front panel area for a front opening. Embodiments includes cooperating half width pads with wings on each segment, cooperating pads and a pad supporting panel, and a garment for use with a catheter. All embodiments include side margin tapes and a front recloseable tape. The garment is applied by using side closures or as step-in adult garment by using side and front closure tapes for girth adjustment.

Description

This application is a continuation-in-part of U.S. patent application Ser. No. 10/303,215 filed Nov. 25, 2002 which application is a continuation-in-part of U.S. patent application Ser. No. 09/286,355 filed Apr. 5, 1999 now U.S. Pat. No. 6,540,730 which is a continuation-in-part of U.S. application Ser. No. 09/240,900 filed Jan. 29, 1999 now U.S. Pat. No. 6,092,242 which is a continuation of U.S. patent application Ser. No. 08/889,461 filed Jul. 8, 1997 now U.S. Pat. No. 5,864,890.

FIELD OF THE INVENTION

This invention relates to a disposable garment made from two half width segments bonded together in the rear panel and not bonded in the front panel for a front opening. The garment is put on by stepping through the leg openings, pulling up, and attaching the front closure tape to define a receptacle for pads of different shape between segments alone, or in combination with cooperating pads located on the inside segment, and other locations to define different embodiments for use as diapers, training pants for children, adult incontinent products, and for feminine hygienic use and undergarments.

BACKGROUND OF THE INVENTION

Present disposable diapers can be applied in a prone position by folding the front portion around the user's crotch and connecting front and rear garment panels with side tapes. Older children can leave one side tape attached, step into the one completed leg opening, pull the diaper up around the other leg, and attach the other side tape to complete the waist and second leg opening, a procedure not easily accomplished by children or adults using oversized diapers for incontinence.

Training pants include larger sizes, higher absorbency pads, side fastening means, and a monolithic absorbent pad enclosed between a pervious upper sustrate and an impervious lower substrate.

There are two general types; garments where side fasteners remain attached and the garment expands around the waist when applied, and, garments with some expandable waist members and side fastening means such as elasticized tapes or hook and loop connecting tapes.

Some training pants have extensible materials for the garment waist so that side fasteners stay connected while the user steps through one leg openings and, balancing on one leg while the second leg is placed through its leg opening, the garment is pulled up over the torso. A typical garment is described in U.S. Pat. No. 6,358,077 B1.

Other training pants are put on by stepping through one of the leg openings, pulled up, and front and rear portions are connected by attaching the other side fastening member as described by U.S. Pat. No. 6,727,404 B2.

The instant garment including well known elements can be applied in a prone position like a diaper or, with sides connected, put on by stepping through both leg openings before attaching the front closure tape to complete the waist opening with the degree of waist snugness found most comfortable by the user. With elastonmeric substrates for the garment structure, elasic side fastening means, and elastic front closure tape, a wide range of waist adjustment is achieved.

The front opening differs from current diapers, training pants and adult care products by allowing frontal inspection of pads, a front opening for male urination, for front opening of the garment to pull down for male or female toilet use, and a thinner appearance and bulk than current adult incontinent products by using one or more thin pads having super absorbent agents for pads selectively shaped and located for the intended use.

The instant garment is preferably made with two bio-degradeable segments and a separable “self contained” leakproof pad with a plastic bottom enclosure for separation and disposal of non-degradeable and bio-degradeable materials. Because absorbent pads are enclosed within liner and the outer cover sheet, current diapers, training pants, and adult incontinent garments are not separable and the entire garment with integral pad is discarded, exascerbating landfill problems.

Some current adult undergarment products have multiple elastic strands aligned transversely and bonded at spaced intervals for expansion and shirred contraction of the waistband. Expanded over the waist, tension is not adjustable and can exert excessive pressure around the waist.

The instant garment avoids the complication of applying multiple elastic strands by providing elastomeric materials and three elastic tapes for adjustment of the waist opening to the degree of preferred tighness and to avoid complex manufacturing manipulations.

In addition to the pad or cooperating pads described below, the front opening permits use of a supplemental front panel pad for insertion between segments for overnight or occasional heavy fluid incontinent use.

The supplemental pad is only used between segments in the front panel area and can be lightly adhered to one of the surfaces between segments for easy removal and replacement without taking the garment off the user.

Five embodiments for combinations of differemt pad shapes and ;pcations are described below in the summary and description of the invention.

SUMMARY OF THE INVENTION

The front opening disposable garment is constructed from two similarly shaped half width overlapped segments selectively bonded between segments in the rear to form a unitary rear panel, and not bonded between segments in the front panel to define a front opening. Segments of all embodiments have elastic strands along side margins to shirr and form leg cuffs when the garment is folded. Substrates used for the segments can be nonwovens and/or paper composites.

Within the context of the two segment assembly, substrates can be extensible, one ply, or a two ply laminate depending on the intended use as disposable diapers, training pants, or for adult and feminine use.

As an assembly of two segments, one of which is reinforced along a linear margin, the garment is used a receptacle for enclosed pads of different shapes, locations, and embodiments of the specifications.

The central overlap area between segments is used for pads of different shapes, and adding a coacting pad inside the garment results in two layer absorbency in the central area.

In current products, extra central absorbency requires thicker machine formed absorbent pads versus the addition of separately processed air laid absorbent pads in two separate layers of the instant front opening garment.

Other shaped pads located between segments include a pad with “wings” on the innermost segment cooperating with a pad with “wings” and attached to the overlapped outermost segment to define a combination full width absorbent pad with “wings” in the front and rear panel areas.

In a first embodiment, a first pad assembly is attached to the inside of the outermost segment in the front panel area. The absorbent pad is enclosed between pervious top and impervious bottom substrates sealed around the pad margins to form a leakproof pad assembly. The pad assembly is a discreet ‘fluid recepticle’ and attached in the front panel area without affecting the front opening.

In a second embodiment, the pad assembly is longitudinally extended an sealed around the periphery. The pad plus end seals are proximate the ends of the garment to provide absorbency in the overlap area of both front and rear panels. The pad assembly is bonded to both segments in the rear panel only, and left unbonded in the front panel area.

In a third embodiment, a pad assembly is extended toward the curvilinear margin and attached to the inside of the outermost segment, forming one half of a garment with full width absorbency. A similar pad assembly on the innermost segment is superposed in mirror-image relationship to the other segment, thus forming the other half of a garment with full width absorbency, including two layer absorbency in the central overlap area.. The front opening remains unbonded and functional.

In a fourth embodiment, pads of the above-embodiment are used in conjunction with a third pad attached to a support panel bonded to the innermost segment at the panel ends and having elastic strands at side margins. When the garment is folded the support panel forms a shirred contoured receptacle for supporting absorbent pads or body parts.

This embodiment results in absorbency of the support panel pad plus double fluid absorbency in the central overlap area and full width fecal absorbency in the two overlapped cooperating pads of embodiment 3.

In embodiment 5, a support panel with stretched elastic strands along side margins and a width substantially equal to the overlap width is attached to the innermost segment near both end margins.

When folded for use, side margins of the support panel shirr to form a contoured receptacle for genetalia and the catheter.

A catheter tube advances through an aperture in the support panel and through an aperture in the central overlap area of the inner segment near the front end margin. The catheter tube advances over an absorbent pad attached to the front panel and passes through a centrally located aperture in the crotch region of the outermost segment. The pad absorbes fluid leakage that passes through the support panel.

These and other objectives will be understood from the detailed description when read in conjunction with other embodiments of the drawings.

DEFINITIONS

Within the context of the specification, the definition of terms listed below include the following meaning:

“Garment” refers to the assembled partially overlapped mirror- image first and second segment assemblies.

“Segment assembly” refers to an assembled segment, a V-folded reinforcing strip (s), leg elastic strands, side and front closure, and fastening means. When a segment assembly includes a pad assembly

rhe pad assembly is between to a segment and a liner. When a V-folded str is used along a linear margin of the segment, the liner is bonded to the inside surface of the strip.

“Pad assembly” refers to the assembled absorbent pad and pad enclosing substrates. When a pad assembly is enclosed between a segment and a liner, it becomes part of a segment assembly.

“Extensible” refers to a substrate material that can be elongated by at least 25% of its relaxed length and with release of the applied force will recover at least 50% of its elongation.

“Elastic” or “stretchable” refers to the property of a material or composite by which it tends to recover its original size and shape when an elongating force is removed. The term is used for side tapes and a front closure tape.

“Refastenable” refers to side and front closure fastening means and the ability to detach these means from a cooperating element to which they are attached. Refastenable includes attachment to a release coated area, or other detachable means such as well known hook and loop systems.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 of embodiment 1 is a plan view of a garment illustrating an innermost segment assembly superposed and overlapped with an outermost segnment assembly. Portions of the inner liner are cutaway from both segment assemblies and a portion of the liner on the innermost segment is cutaway to show the V-folded strip.

FIG. 2 is a plan view illustrating a segment, elastic strands, and a side tape of the innermost segment assembly. The inside liner sheet is omitted.

FIG. 3 is a plan view ilustrating a segment with elastic strands, a V-folded reinforcing strip, an absorbent pad assembly, a side tape, a front closure tape of the outermost segment assembly, and a bonding area to attach rear panels between segments. The liner sheet is omitted.

FIG. 4 is a side elevation viewed from 4-4 of FIG. 1 illustrating bonding of the pad assembly between the outermost segment and liner sheet, and bonding between the outermost and innermost segment assemblies in the rear panel area.

FIG. 5 of embodiment 1 is an end view from 5-5 of FIG. 4 illustrating the unbonded facing surfaces of the front panel to define a front opening and the outermost segment assembly with an enclosed pad assembly.

FIG. 6 is an end view from 6-6 of FIG. 4 illustrating bonding of the outermost and innermost segment assemblies in the rear panel area.

FIG. 7 of embodiment 1 is a top side perspective view of the pad assembly of FIG. 1 with a portion of the perforated upper surface cutaway to show the upper substrate of an absorbent pad assembly.

FIG. 8 of embodiment 2 is a front perspective view of a garment folded along F-F of FIG. 9 including a full length pad assembly enclosed within the outermost segment assembly.

FIG. 9 of embodiment 2 is a plan view illustrating a garment with superposed segment assemblies, with portions of the inner assembly cutaway to show the top surface of an underlying full length pad assembly. Liner sheets on both segment assemblies are partially cutaway.

FIG. 10 is a side elevation viewed from 10-10 of FIG. 9 illustrating bonding of the segment, full length pad assembly, and liner of the outermost segment, bonding of the segment and liner of the innermost segment assembly, and bonding segment assemblies together in the rear panel area only.

FIG. 11 is a simplified end view from 11-11 of FIG. 10, illustrating the unbonded front panel between innermost and outermost segment assemblies to define a front opening of the garment.

FIG. 12 is a simplified end view from 12-12 of FIG. 10 illustrating a rear panel overlap area bonded between outermost and innermost segment assemblied to define a unitary rear panel.

FIG. 13A of embodiment 3 is a top perspective view of the innermost segment assembly with an enclosed pad assembly having side wing extensions. A portion of the segment assembly liner sheet is cutaway.

FIG. 13B is a top perspective view of the outermost segment assembly with an enclosed pad assembly having side wing extensions. Bonding adhesive is applied to the upper surface in rear panel area for attachment of the innermost segment assembly. Portions of the outermost segment assembly liner sheet are cutaway.

FIG. 13C of embodiment 3 is a top perspective view of the innermost and outermost segment assemblies superposed and overlapped to form a garment having full width cooperating enclosed pad assemblies. Portions of the innermost liner sheet are cutaway.

FIG. 14 of embodiment 3 is a plan view of the overlapped super-posed innermost and outermost cooperating segment assemblies, each containing a pad assembly with enclosed pads having front and rear wing extensions. Liner sheets on each segment assembly are partially cutaway.

FIG. 15 is an end elevation along line 15-15 of FIG. 14 illustrating the overlapped superposed innermost and outermost segment assemblies with pervious portions of upper and lower substrates for the innermost enclosed pad, a pervious portion of the upper substrate, and an impervious lower substrate for the outermost enclosed pad.

FIG. 16 of embodiment 4 is a perspective plan view of the overlapped superposed segment assemblies of embodiment 3 in combination with a support panel for an absorbent pad spaced from the surface of the innermost segment assembly when the garment is folded for use. Portions of the support panel and the inside segment assembly are cutaway.

FIG. 17 of embodiment 4 is a cross sectional side elevation of the garment viewed along 17-17 of FIG. 16 illustrating shirred cuffs on both sides of the support panel and shirred leg cuffs on side margins of the segment assemblies when the garment is folded about a plane containing F-F.

FIG. 18 of embodiment 4 is a perspective frontal view of a garment illustrating use of a supplemental pad inserted in the front opening between innermost and outermost segment assemblies.

FIG. 19 is a front plan view of a folded garment illustrating location of a supplemental pad inserted for use. The garment and components are shown dashed.

FIG. 20A of embodiment 5 is a top perspective view from the side of the innermost segment having a support panel with a frontal aperture and attached to the innermost segment.

FIG. 20B is a perspective view of the innermost segment with an aperture in the front panel area.

FIG. 20C is a perspective view of the outermost segment illustrating a catheter path over an aborbent pad in the front panel area and an aperture in the rear panel area of the segment. The rear panel has an area of adhesive for bonding innermost and outermost segments together. The pad can be secured along one margin for a catheter path under the pad ( adhesive dots are under the pad but shown solid).

FIG. 20D is a perspective view of the innermost and outermost segment assemblies bonded together and having elastic strands for leg cuffs and for cuffs on side margins of the support panel.

FIG. 21 is a cross section side elevation viewed along 21-21 of FIG. 20 D when the garment folded about a plane containimg F-F, illustrating location of a pad, an aperture in the support panel and in each segment to define a catheter path.

DETAILED DESCRIPTION OF THE INVENTION

In FIG. 1 of embodiment 1, garment 1 is an assembly of components including two overlapped half width segment assemblies 5′, 6; bonded together only in the central overlap area 9 of rear panel 2, and unbonded on facing surfaces 13 (shown in FIG. 4) between segments in the overlap area 9 of front panel 3.

Segment assemblies 5′, 6′ include half width segments 5, 6, with elastic strands 18, 18′ adjacent curvilinear margins, a V-folded strip 26 folded over the linear margin 11 of at least one segment, an absorbent pad assembly 115 with internal pad 115′ between segment assemblies attached to the first outermost segment 5, and cutaway liner sheets 21, 22.

In FIG. 1, each segment 5, 6, has a stretchable elastic side margin fastening means 19,19′ and outermost segment 5 has a stretchable elastic central fastening means 20 to define leg openings and a front closure respectively

In FIG. 1 of embodiment 1, segments widths W5, W6 are substantially equal to half the width W of the garment plus half the width of the overlap and an amount to add side elastic strands adjacent margins formed by cutouts 10-10′. Elastic strands are applied in stretched condition and attached at spaced intervals along cutout margins 34, 35.

The unfolded garment and segment assemblies have a rear panel 2, front panel 3, an intermediate crotch region 4, and extend from rear end margin 7 to front end margin 8.

For use, the garment is folded transversely about line F-F before the free ends R of side fastening means 19,19′ and front closure fastening means 20 are attached to release coated landing areas R1, R2 (shown dashed at the bottom of FIG. 1) define the leg, waist, and closure for the front panel opening 14 (see FIGS. 4,5).

With one or both side fastening means attached, the folded garment is worn by “stepping into” the leg openings, pulling the garment over the torso, and fastening the front closure means, all of which are refastenable.

In FIG. 1, segment assembly 5′ includes elastomeric pervious segment 5 with elastic strands 18′ attached adjacent cutout margin 35, pad assembly 115 with enclosed absorbent pad 115′ (see FIGS. 4 and 7), V-folded reinforcing strip 26 along the linear margin 11, and liner sheet 21 bonded along the periphery 25′ to segment 5 and over the surface of strip 26 (see FIGS. 5 and 6). Portions of segment 6 and liner 21 are cutaway to show strip 26 with adhesive 25′ for periphery bonding to segment 5.

In FIG. 1, segment assembly 6′ includes elastomeric pervious segment 6 with elastic strands 18 attached along cutout margin 34 and liner sheet 22 which faces the user's body. Portions of liner 22 are cutaway and sealed to the periphery of segment 6 with adhesive 25.

In FIG. 1, underlying pad assembly 115 includes internal absorbent pad 115′. A portion of the front panel in segment 6 is cutaway to show the top of perforated area 23′ having a small cutaway portion to expose the top of pad 115 (see FIGS. 4-7 for detail of the pad assembly).

In FIG. 1, end seal 27′ of pad assembly 115 extends from near the garment front end margin 8 with end seal 27 near fold line F-F.

Side seals 28, 28′ are within overlap area 9 when both segment assemblies are overlapped.

In FIG. 1, the periphery of the absorbent pad 115′ includes ends 16, 16′ and side margins 17, 17′.

In FIG. 1, selected lines or areas of adhesive are applied to the overlap area 9 of outermost segment 5 within the peripheral boundaries 12, 12′ and spaced from linear side margin 11′ of superposed segment assembly 6′.

In FIG. 1, front panel linear side dimension 36 is the maximum length of side margin tapes 19, 19′.

In FIG. 2 of embodiment 1, segment assembly 6′ liner sheet 22 is not shown.

Adhesive area 25 along the periphery of innermost segment 6 bonds liner 22 (not shown) to segment 6 and covers elastic strands 18 to form segment assembly 6′. Stretched elastic strands 18 are applied in stretched condition and attached to segment 6 at spaced intervals along cutout margin 34.

Side margin tape 19 with refastenable free end R is attached to release coatee landing area R1 (shown dashed) on the outer surface of the front panel when the garment is folded for use.

Underlying pad assembly 115 attached to overlap area 9 of segment 5 is shown dashed.

In FIG. 2, an area of adhesive bounded by 12, 12′ and applied to underlying segment 5 is shown dashed.

In FIG. 3 of embodiment 1, V-folded reinforcing strip 26, elastic strands 18′ applied in stretched condition and attached at spaced intervals, and pad assembly 115 are bonded to outermost segment 5, and liner 25 attached along periphery 25′ to complete segment assembly 5′.

A selected adhesive pattern is applied along and between 12, 12′ in the rear panel overlap area 12, 12′ for joining segment assemblies 5′ and 6′ together and form unitary rear panel 2.

Pad assembly 115 has end seals 27 and side seals 28 enclosing internal pad 115′.

In FIG. 3, perforations 23′ in the top substrate of pad assembly 115 are not shown (see FIGS. 1, 4, 7).

In FIG. 3, adhesive 25 along the periphery of segment 5 and on the surface of strip 26 bonds the liner sheet 21 (not shown) to segment 5 and with inside pad assembly 115 forms segment assembly 5′.

In FIG. 3, a refastenable free end R of side margin elastic tape 19′ is attached to release coated landing area R1 on the outside surface of segment 5 in the front panel segment 5.

In FIG. 3, a refastenable free end R of elastic front closure tape 20 is attached to release coated landing area R2 on the outside surface of segment 6 in the front panel area. (shown in FIG. 1) to complete the front panel closure.

In FIG. 4 of embodiment 1, outermost segment 5 with elastic strands 18′ and a reinforcing V-folded strip 26 along the linear margin, a pad assembly 115, and liner 21 are bonded together to form segment assembly 5′.

Innermost segment 6, (see upper part of FIG. 4), elastic strands 18, and liner sheet 22 are bonded together as segment assembly 6.

In FIG. 4, segment assemblies 5′, 6′ are bonded together in the overlap area the of rear panel with a selected adhesive pattern within an area bounded by 12,12′ (see FIG. 3). Facing surfaces 13 of innermost segment 6 and liner sheet 21 of segment assembly 5′ are not bonded and define the front panel opening 14.

In FIG. 4, components and attachments (moving upward) include; bonding 29—outermost segment 5 to lower substrate 24, bonding 30—lower substrate 24 to pad 115′, bonding 31—top of pad to upper substrate 23, bonding 32—substrate 23 to substrate 24, bonding 33—liner 21 to upper substrate 23, segment periphery bonding 25′—liner 21 to outermost segment 5 for segment assembly 5′, segment periphery bonding 25—liner 22 to innermost segment 6 for segment assembly 6′ and bonding—12, 12′ between segment assemblies 5′, 6′ in the rear panel. The absence of bonding between facing surfaces 13 of segment assemblies 5′, 6′ defines the front opening 14.

Pad assembly 115 includes upper impervious substrate 23 with perforations in area 23′ to make it pervious, and an impervious substrate 24 below pad 115′ to provide a leakproof container with end seals 27 and side seals 28 (not shown).

For side seals see FIGS. 5, 6. In FIG. 4, top substrate 23 and bottom substrate 24 are bonded together at 32 to complete end seals 27, 27.′

At the bottom of FIG. 4, distal edges of V-folded strip 26 enclose segment 5.

In FIG. 4, side tape 19 is attached to segment 6, and side tape 19; is attached to segment 5. Front closure tape 20 is attached to the front panel of outermost segment 5 and connects the segments together by attachment to landing area R2 on segment 6 (see FIG. 1)

In FIG. 5 of embodiment 1, side seals 28, 28′ and end seals 27, 27′ (see FIG. 4) complete pad assembly 115 including pad 115′ with a portion of upper substrate 23 having a pervious portion 23″.

Elastic strands 18′ are attached to segment 5 adjacent a cutout margin, Elastic strands 18 are also attached to segment 6 (see upper left).

In FIG. 5, Segment assembly 5′ includes segment 5, V-folded strip 26, pad assembly 115, and liner 21. Segment assembly 6′ includes segment 6 and liner 22.

In FIG. 5, the absence of bonding between overlapped segment assemblies in the front panel defines front opening 14.

In FIG. 5, components and bonding 29-33 secure substrates 23, 24 to pad 115′, pad assembly 115 to segment 5, elastic strands 18′, V-folded strip 26, and edge bond 25′ for liner 21 to segment 5 to complete assembly 5′.

In FIG. 5, upper assembly 6′, bonding includes elastic strands 18, and bonding 25 for liner 22 to segment 6. Liners 22 is pervious and bonded to segment 6 along 25.

In FIG. 5 side margin tape 19 on segment 6 and 19′ on segment 5 have protruding free ends with refastenable adhesive R (not shown) Front closure tape 20 has a protruding free end with refastenable adhesive R.

FIG. 6 of embodiment 1 is like FIG. 5 without the pad, substrates, V-folded strip and bonding for the pad assembly.

In FIG. 6, Innermost segment assembly 6′ is the same as 6′ in FIG. 5. In FIG. 6, with no pad between segments in the rear panel, assemblies 5′, 6′ are bonded together with adhesive in the area bounded by 12, 12′.

In FIG. 7 of embodiment 1, pad assembly 115 includes impervious lower substrate 24 and impervious upper substrate 23 sealed along end margine 27, 27′ and side margins 28, 28′ to enclose pad 115′.

Upper impervious substrate 23 has a perforated pervious area 23′ partially cutaway to show internal pad 115′. Area 23′ is spaced from end margins 16,16′ and side margin 17,17′ to prevent leakage at pad margins.

Embodiment 2 described in FIGS. 8-12 below has the same components, bonding, etc. as embodiment 1 of FIGS. 1-7. Differences relate to length of pad and segment to segment bonding in the rear panel.

In FIG. 8 of embodiment 2, segment assemblies 5′, 6′ are bonded together in the overlap area of rear panel 2. No bonding between segments in front area 3 creates front opening 14.

In FIG. 8 a full length reinforcing strip 26 encloses the linear margin of outermost segment 5 in front and rear and is visible on the outermost segment assembly.

Pad assembly 215 is between segments and attached to the inside of segment 5.

In FIG. 8, side margin tapes 19, 19′ with free ends are attached to release coated landing areas described above. Front closure tape 20 has a protruding free end with refastenable adhesive R for attachment to release coated landing area R2 on the front of segment 6.

In FIG. 9 of embodiment 2, portions of liner sheets 21, 22 are cutaway.

Innermost segment 6 is cutaway in two areas. The upper cutaway shows a portion of the top perforated portion 23′ of pad assembly 215. The The lower cutaway of 23′ shows the top surface of internal pad 215′.

Elastic strands 18 are adjacent the crotch area of cutout margin 34 of segment 6. Elastic strands 18′ are adjacent the crotch area of cutout margin 35 of segment 5.

In FIG. 9, duplicate elements described in FIG. 1 above include segments 5, 6, elastic strands 18, 18′, V-folded strip 26, liners 21, 22, segment assemblies 5′, 6′ and a pad asembly 215 located between segments and attached to outermost segment 5.

Elastic side margin tapes 19, 19′ are attached to rear panel 2 of segments 6,5 respectively, and have adhesive coated free ends R for attachment to release coated landing areas R1, R1′ on the front panel.

In FIG. 9, an elastic central front closure tape 20 on segment 5 has a refastenable free end R (not shown) for attachment to release coated landing area R2 on the front panel of segment 6 to complete the front closure and waist opening.

In FIG. 9, end seal areas 27, 27′ of pad assembly 215 are spaced from garment end margins 7, 8, to permit direct sealing of liners 21, 22 along peripheral margins 25, 25′ of segments 6, 5.

Side seals 28, 28′ are located in the central overlap area 9.

Pad assembly 215 has internal pad 215′ enclosed by lower impervious substrate 24 and upper imperevious substrate 23 having a pervious perforated area 23′ in the central area. Perforated area 23′ is spaced from pad ends 16,16′ and sides 17, 17′ to provide a leakproof “pouch” around the perimeter of pad 215′.(similar to FIG. 7)

In the rear panel overlap area 9 of FIG. 9, the upper the surface of liner 21 is bonded in area 12, 12′ to the rear panel area of segment 6 to form a unitary rear panel. (see FIG. 10).

FIG. 10 of embodiment 2 is a side elevation with details like FIG. 4 except that pad 115′ is replaced by full length pad 215′.

In FIG. 10, duplicate components described in FIGS. 1,4 and 9 include segnents 5, 6, elastic strands 18, 18′, V-folded strip 26 on margin 11, liner sheets 21, 22 and the enclosed full length pad assembly 215 with an internal pad 215′ located between segments and attached to outermost segment 5.

In FIG. 10, bonding between components is described in FIG. 4 including adhesives 29-33, liner to segments 25, 25; and the rear panel bonding in the overlap area bounded by 12,12′. Segments are not bonded on facing surfaces 13 of the front panel to define opening 14.

Liners are bonded to segment peripheries at 25, 25′ as described above.

In FIG. 10, bottom substrate 24 and top substrate 23 with pervious portion 23′ extend toward and are spaced from pad end margins 16,16′ (see FIG. 9) to enclose pad 215′. End seals 27, 27′ extend from rear end margin 7 to front end margin 8.

Pad 215′ is attached to segment 5 and enclosed by liner 21 to define segment assembly 5′. Segment assembly 6′ includes segment 6, elastic strands 18, and liner 22.

In FIG. 10, after folding for use, side margin tape 19′ connects segment 5 front and rear panels at the side. Tape 19 connects front and rear panels of segment 6 together at the side.

Front closure tape 20 attached to segment 5 protrudes and attaches to the front of segment 6 to close the front opening 14.

FIG. 11 of embodiment 2 is a simplified end view of the garment of FIG. 9 (see similar end view of FIG. 5 for detail) The lower assembly includes segment 5, pad 215′ attached as at 29 to segment 5 forming assembly 5′ (liner 21, V-folded strip 26, and elastics omitted). Side tape 19′ connects front and rear panels together at the side margin and front closure tape 20 attached to segment 5 connects to segment 6 to close the front opening 14.

In FIG. 11, the upper assembly includes segment 6 and tape 19 to form assembly 6′ (liner 22 and elastic strands omitted) As described above, bonding between segment assemblies defines front opening 14.

In FIG. 12 of embodiment 2, details are as described for FIG. 6.

In FIG. 12, basic components for the lower assembly 5′ incude segment 5, pad 215′ attached at 29, and side tape 19′ (liner and elastic strands omitted). The upper assembly 6′ includes side tape 19 (liner and elastic strands omitted). Tape 20 is not shown in the rear panel view of FIG. 12.

In FIG. 12, assemblies 5′, 6′ are bonded together in the rear panel overlap area as at at 12′ to form a unitary rear panel with a full length pad 215′ attached to segment 5 and between segments 5′, 6′.

In FIG. 13A of embodiment 3, pad assembly 316 (shown dashed) is attached to innermost segment 6 with liner 22 superposed on top and bonded along peripheral margin 25 (see FIG. 14) to form segment assembly 6′.

Pad assembly 316 end seals 27, 27′ and side seals 28, 28′ are spaced a distance 25 from rear margin 7 and front margin 6 and from segment side margins 34, 35.

A cutaway of inside liner 22 shows the perforated pervious portion 623′ of top substrate 623 in pas assembly 316.

Stretched elastic strands 18, are attached at spaced intervals adjacent cutout margins 34.

In FIG. 13B pad assembly 315 (shown dashed) is attached to outermost segment 5 with liner 21 superposed on top and bonded along margin 25′ (see FIG. 14) to form segment assembly 5′.

Pad assembly 315 end seals 27, 27′ and side seals 28,28; are spaced a distance 25 from rear margin 7, front margin 8, and from side margins 11 and 35.

A cutaway of liner 21 shows pervious area 523′ in the central overlap area but extends into selected “wing” areas 39 as shown in FIG. 14. Substrate perforations 523′ are spaced from pad end 16,16′ and side 17,17′ margins to provide impervious upper and lower substrates inward from pad margins.

Stretched elastic strands 18′ are attached at spaced intervals along crotch margin 35.

In FIG. 13B, the V-folded strip 26 along margin 11′ is not shown.

In the overlap area of the rear panel, segments 5′, 6′ are bonded within area 12, 12′ (see FIG. 14) for a unitary rear panel. Adhesive on peripheral area 25 bonds liner 21 to segment 5.

In FIG. 13C of embodiment 3, stretched elastic strands 18, 18′ adjacent cutout margins 34, 35 in the crotch area are attached at spaced intervals to segments 5, 6.

In FIG. 13C, pad wing extensions 39 increase the width of cooperating pad assemblies 315, 316, segments 5, 6, and width of the assembled garment.

Adhesive within area 12, 12′ (see FIG. 14) bonds the segment assemblies 5′, 6′ together in the rear panel without affecting the front opening 14.

In FIG. 13C of embodiment 3, outermost pad assembly 315 on segment 5 is partially overlapped an amount 9 and covered by pad assembly 316 on segment 6.

Margin seals 28′, 28′, end seals 27, 27′ and seals adjacent linear margins 11, 11′ (see FIG. 14) of pad asemblies 315, 316 are spaced a distance 25 from segment cutout margins 34, 35, and linear side margins and end margins 7, 8.

Space 25 on 6 and 25′ on segment 5 are adhesively bonded to liners 21, 22.

In FIG. 14 of embodiment 3, liner 22 is partially cutaway to show a portion of the perforated pervious upper substrate 623′ which extends toward and is spaced from pad end margins 16,16′ and side margins 17, 17′ including selected portions of wing areas 39, 39′ of assembly 316.

Impervious portions of upper substrate 623 and underlying portions of impervious substrate 624 surround margins of three pads to provide a perimeter With two superposed pads, prefix 6 is added for pad substrates in 316, prefix 5 is added for pad assembly 315.

Non-perforated areas of upper substrate 623 are impervious and are bonded together with lower substrate 624 in end seals 27, 27′ and side seals 28, 28′ to form C-shaped impervious margin around pad 316′. The perforated portions extend into selected areas of wings 39.

See FIG. 15 for detail of upper superposed pad 316′ includes a pervious portion in lower subsrtrate 614 for fluid transmission to the lower pad 315′. The upper substrate in pad assembly 315 has a pervious area 523′ and an impervious lower substrate to prevent leakage from the bottom.

Returning to FIG. 14, side tapes 19, 19′ have free ends R for attachment at landing areas R1. Front closure tape 20 has free end R for landing area R2.

Stretched elastic strands 18, 18′ are attached adjacent margins 34, 35 of segments 5, 6. Segment assemblies 5′, 6′ are bonded together in the rear panel overlap area by adhesive 12, 12′ (see FIG. 15) In FIG. 14, segment cutout margins 34, 35 have margin adhesive 25 for attaching liners 21, 22. The outline of pad end and side seals for pad assemblies 315, 316 are spaced from the segment cutout margins 34, 35, end margin 7, linear margins 11,11′ to provide space for peripheral adhesive 25.

In FIG. 14 with a linear margin of segment assembly 6′ partially cutaway, the linear adhesive space 25, pad side seal 28 and upper substrate of pad assembly 316 is seen. On the left hand side of FIG. 14, space 25 is between the side cutout margin 34 and pad cutout margin 37.

On outermost segment assembly 5′, space 25′ is between segment cutout margin 35 and pad assembly cutout margin 38.

In FIG. 15 of embodiment 3, innermost segment assembly 6′ includes segment 6, internal pad 316′ enclosed by substrates 623, 624 sealed along end edges (not shown) and side seals 28, 28 as at 32.

In FIG. 15, segments 5, 6 are sealed to liners 21, 22 with adhesvie 25 along margins that protrude beyond pad seals 27, 28.

In FIG. 15, upper pad 316′ is enclosed with substrate 623 having pervious area 623′ which extends toward and is spaced from end margins 16, 16′ and side margins 17, 17′ including selected portions of wing areas 39.

Below pad 316, substrate 624 has a pervious area 624′ to allow fluid transmission to the lower coacting pad 315′. Lower pad 315′ is enclosed with an upper impervious substrate 523 having a pervious area 523′. Below pad 315′, substrate 524 is impervious to retain fluids inside the pad assembly.

Pads 315′, 316′ are spaced from ends 7,8, side margins 34, 35, and linear margins 11, 11′ (shown in FIG. 14) to bond end seals 27, 27′ and side seals 28, 28′ and provide space between the seals and margins pf segments 5, 6 for bonding the liners 21, 22 along margin 25.

In FIG. 15, adhesive between end and side boundaries 12, 12′ bond segment assemblies 5′, 6′ together in the rear panel area. Assemblies are not bonded together in the front panel to create an opening.

In FIG. 15, components include elastic strands 18,18′, V-folded strip 26, and bonding 32 of perimeter seals 27, 28.

In FIG. 16 of embodiment 4, the garment assembly includes two segment assemblies 5, 6 bonded in the rear panel overlap area like the garment in embodiment 3 in combination with a support panel 40 attached to innermost sergment assembly 6′ along end margins of the support panel at 41, 42, and suspended from rear 7 and front 8 end margins of the innermost segment assemby 6′.

In FIG. 16 with liner 22 removed, only a portion of pervious area 623′ of top substrate 623 is shown for clarity. Pervious area 623′ extends toward and is spaced from pad end margins 16 (top left) and pad side margins 17 (bottom right) including selected portions of wings 39 (see FIG. 14).

In FIG. 16, pad 415 is supported by cutaway panel 40 to show pervious portion 623′ and spacing from the pad end margin 16.

In FIG. 16, segment assembly 5′ includes segment 5 with V-folded strip 26 (not shown) along linear segment margin 11′, attached pad assembly 315, with wings 39, and inside facing liner 21 (not shown) Each pad assembly 5′, 6′, includes an upper substrate 523, 623, with pervious portions 523′, 623′ extending toward side margins, an enclosed absorbent pads 315′, 316′, sealed between end seals 27, 27′ and side seals 28, 28′. Pad assemblies 315, 316 are contained between a segment and a liner sheet (not shown in FIG. 16) bonded together with adhesive in peripheral area 25, 25′.

In FIG. 16, adhesive area 25′ for segment 5 is between segment cutout margin 35 and pad cutout margin 38. The adhesive area 25 for segment 6 is between the segment cutout margin 34 and pad cutout margin 37 the peripheral adhesive area 25 is along cutout. Margin area 25 is the same width around the outline of the segment.

In FIG. 16, the same description applies to mirror-image innermost segment 6, segment assembly 6′, pad assembly 316, adhesive area 25, liner 22 (not shown), elastic strands 18, and tape 19. Outermost segment assembly %′ includes a V-folded strip 26 and elastic strands 18′.

The same description applies to outermost segment 6, segment assembly 6′ pad assembly 316, and liner 22 (not shown).

Side margin tapes 19, 19′, free ends R, landing areas R1, front closure tape 20, free end R, and landing area R2 are described above.

In the support panel 40 of FIG. 16, elastic strands 43 applied in a stretched condition at spaced intervals to side margins of panel 40 contract when the garment is folded along line F-F and form a concave pocket for pad 415.

In FIG. 17 of embodiment 4, outermost segment 5 with attached pad assembly 315 is bonded at 12 in the rear panel area to innermost segment 6 and attached pad assembly 316.

In FIG. 17, elastic strands, 18′ (shown dashed) are attached to segments 5, at spaced intervals and contract segment side margins to form a shirred leg opening with cuffs when the garment is folded in half along line F-F of FIG. 16 (F-F shown vertical in FIG. 17).

In FIG. 17, support panel 40 is attached at 41 to the rear panel and 42 to the inside panel of innermost segment 6. Panel 40 has stretched elastic strands 43 attached to side margins and when folded along F-F forms shirred cuffs 44.

In FIG. 17, segments 5, 6 each with an attached pad assembly 315, 316 and inside liners 21, 22 (nor shown) are bonded together in the rear panel by adhesive 12, and are not interconnected in the front and form front panel opening 14. Pad assembly 315 includes a V-strip along a linear margin and is attached to outermost segment 5 with adhesive 29 with side tape 19′ shown dashed), and a front closure tape 20 with a refastenable free end R.

Pad 316 is attached to segment 6 at 29′ before being bonded to assembly 5′ by 12 in the rear panel.

In FIG. 18 of embodiment 4, the garment includes pads 315′ in cooperation with pad 316′, and the support panel 40 with pad 415. Other components are as described above. Panel 40 contracts and is spaced from innermost segment assembly 6′ when folded for use.

The garment of FIG. 18 has attached side tapes 19, 19′ and front closure tape 20 with refastenable end R attaches to the outside front panel area R2 (not shown) on inner segment 6. (not shown) of segment 6 to close opening 14.

With the front panel closed, a supplemental pad 45 with protruding tab 46 is inserted between segments 5, 6 for removal.

FIG. 19 shows location of inserted pad 45 in a completed garment (shown as dashed lines).

In FIG. 19, inserted, supplemental pad 45 with tab 46 has adhesive R on the inside surface facing segment 6 is attached to release coated landing area R3. Pad 45 has a peripgeral adhesive area 48 for adding an iinside liner (not shown).

In FIG. 20A, of embodiment 5, support panel 40 is attached along the rear margin 41 and along the front margin 42 of innermost segment 6. Stretched elastic strands 43 are attached at spaced intervals along side margins of 40. Support panel 40 has an aperture 49 in the upper front panel area. Stretched elastic strand 18 is attached at intervals along the cutout margin of segment 6.

In FIG. 20B, innermost segment 6 with support panel 40 omitted has aperture 50 in the central upper front panel area of segment 6. The solid line between support panel aperture 49 and segment aperture 50 is a path for a catheter tube (not shown). Apertire 51 in underlying segment 5 si shown dashed. Elastics strands o segment 6 are described above.

In FIG. 20C, outermost segment 5 has stretched elastic strands 18′ along a cutout margin, a pad 515 bonded to the central overlap area in the front panel area 3, and an area of adhesive applied as at 12 in the rear panel area 2, Aperture 51 in segment 5 is adjacent the rear end of pad 515 and allows the catheter tube to exit the garment.

In FIG. 20D, Segments 5, 6 are attached at 12 (see FIG. 20C) and assembled with support panel 40. Panel 40 has side elastic strands 43 to form a contoured support. Both segment 5, 6 have side elastic strands 18, 18′ that form cuffed leg openings when the garment is folded and tapes 19, 19′ are attached.

In FIG. 20A-20D side tapes and front closure tape 20 have refastenable ends R and are attached to landing areas R1, R2 as described above.

In FIG. 21 of embodiment 5, the garment cross section is viewed along line 21-21 of FIG. 20D and is shown folded for use. Assembly, bonding 41, 42, 1n2 12 between components, apertures, elastics 43 and tapes are as described above.

Apertures in components of the completed garment define a catheter path through aperture 49 in support panel 40, through aperture 50 in segment 6, between segment 6 and the surface of pad 515, advancing rearward on the inside surface of pad 515, and passing through aperture 51 in outermost segment 5 to exit the garment.

In FIG. 20B, note pad 515 attached to segment 5 along one side margin only (solid dots) If preferred the catheter is threaded to advance between pad 515 and outermost segment 5 before exiting through aperture 51.

Claims

1. A disposable garment having a rear panel on one side of a transverse fold line and a front panel on the other side of the transverse fold line forming an intermediate crotch region, said garment further comprising:

first outermost and second innermost segments each having a length between rear panel and front panel end margins of the garment and a- width substantially equal to one half the width of the garment plus an amount for overlap between linear margins of the segments,

the amount of overlap of said first and second segments superposed with each other with the segments in mirror-image orientation to form innermost and outermost segments and a longitudinally extending central area of overlap of said garment,

said shaped segments including curvilinear cutouts intermediate front and rear panels which define said crotch region there between

said first and second segments bonded together in the central area of overlap of the rear panel to define a unitary rear panel,

said first and and second segments unbonded together in the central area of overlap of the front panel to define a front panel opening,

an absorbent pad superposed with and selectively bonded between said first and second segments,

said pad having margins spaced from end margins and the side margins of the overlapped segments,

elastic members attached in a stretched condition at intervals along each garment side margin and contractable within a pre-selected portion between end margins of the garment,

at least one stretchable elastic side fastening means protruding from the rear panel side margins of the garment for attachment of a protruding refastenable free end to a release coated landing area on each segment of the front panel for closure of said side margins,

at least one stretchable elastic central closure fastening means with one end attached to the outer front panel surface of the outermost segment and a protruding refastenable free end for attachment to a release coated fanding area on the outer surface of the innermost segment in the front panel of the garment to define said closure means for the front opening.

2. In the garment of claim 1 wherein each segment and a liner sheet are bonded together along the periphery of the segment to form a segment assembly and at least one of said segment assemblies encloses a pad assembly.

3. The garment of claim 1 wherein the absorbent pad is enclosed by impervious substrates sealed together around the pad periphery and having a pervious top surface area extending toward and spaced from pad end and side margins, said pad bonded to and between the outermost segment and an inner liner sheet and attached to said outermost segment to form a segment assembly.

4. The garment of claim 1 wherein the pad between segments extends from near the front panel end margin of the garment to the crotch region and is bonded to the inside of the outermost segment.

5. The garment of claim 1 wherein the pad between segments extends from adjacent the front panel end margin of the garment to adjacent the rear panel end margin of the garment and is bonded to the inside of the outermost segment.

6. The garment of claim 1 wherein the pad between segments is attached to the outermost segment and defines a first pad and said garment further including a mirror-image second pad attached to the inside of the innermost segment.

7. The garment of claim 6 wherein the first and coacting second pads include portions extending from the central area of overlap toward side margins of the front and rear panels.

8. The garment of claim 1 wherein inside liner sheets of substantially similar size and shape as the outermost segment is bonded to end margins and the side margins of the outermost segment to enclose the absorbent pad between the liner and a segment before overlapping and bonding to the innermost segment in the rear panel.

9. The garment of claim 1 wherein the curvilinear side margins of the first and second segments extend transversely beyond end and side margins of the pad between segments.

10. The garment of claim 6 wherein the innermost pad facing the user is enclosed by impervious upper and lower substrates having central pervious areas, is attached to the innermost segment, and the outermost pad facing away from the user is attached to the outermost segment, has a pervious central area in the upper substrate and an impervious lower substrate.

11. The garment of claim 1 wherein the side margin of each segment defining the central area of overlap being linear and a V-folded strip encloses the linear margin of at least one segment.

12. The garment of claim 1 wherein the side fastening means has a length substantially equal to the length of side margins of the front panel and is operatively connectable to the front panel to form waist and leg openings.

13. The garment of claim 1 wherein said side and central closure fastening means are stretchable and each fastening means includes a refastenable portion at the opposite free end for attachment to release coated landing area on the front panel of the garment.

14. The garment of claim 6 further including a third pad attached to a support panel which is secured at its ends to the innermost segment.

15. The garment of claim 4 further including elastic strands attached at intervals along selected portions of the side margins of the support panel

16. The garment of claim I further including a separate supplemental pad inserted between the unbonded portions of segment assemblies in the front panel region and is releaseably attached to one of the unbonded facing surfaces that define the front opening.

17. The garment of claim 6 wherein the outermost segment has an aperture in the central area of overlap in the front panel and the innermost segment has an aperture in the central overlap area of the crotch area of the garment and, said segment bonded in the rear panel central overlap area to the innermost segment having an aperture, said garment further including a support panel with elastic strands along side margins and an aperture, said apertures in said overlapping segments and support panel defining a path for a catheter above an absorbent pad located on the inside of the outermost segment.

18. The garment of claim 17 wherein the pad is secured to the outermost segment only along one underlying longitudinal margin of the pad without further bonding for threading the catheter tube under the absorbent pad.