Disposable Gown and Method of Constructing the Same

BACKGROUND
Technical Field

This disclosure relates generally to gowns, and more particularly to gowns with sleeves.

Background Art

Gowns are used in many different applications to at least partially cover a wearer. Illustrating by example, in the medical field gowns are commonly used by both patients and by health care providers. Gowns can provide a protective function by helping to prevent the transmission of germs and microbes. Depending upon the material, gowns can further provide a protective function by preventing fluids, waste matter, and pathogens from contacting the skin of the wearer. Additionally, gowns can simply provide a privacy function, thereby helping to preserve patient dignity, by covering the patient's body prior to examination or prior to a medical procedure. Medical applications are merely one application suitable for gowns, as numerous others exist including spas, bathing facilities, dressing rooms, and so forth. It would therefore be advantageous to have an improved gown offering increased durability for such applications.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a component of an explanatory gown in accordance with one or more embodiments of the disclosure.

FIG. 2 illustrates another component of an explanatory gown in accordance with one or more embodiments of the disclosure.

FIG. 3 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 4 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 5 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 6 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 7 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 8 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 9 illustrates a component of an explanatory gown in accordance with one or more embodiments of the disclosure.

FIG. 10 illustrates another component of an explanatory gown in accordance with one or more embodiments of the disclosure.

FIG. 11 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 12 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 13 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 14 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 15 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 16 illustrates a user wearing an explanatory gown in accordance with one or more embodiments of the disclosure.

FIG. 17 illustrates an explanatory method of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 18 illustrates another embodiment of an explanatory gown in accordance with one or more embodiments of the disclosure.

FIG. 19 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 20 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 21 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 22 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 23 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 24 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 25 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 26 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 27 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 28 illustrates one or more steps of manufacturing a gown in accordance with one or more embodiments of the disclosure.

FIG. 29 illustrates a user wearing one or more explanatory gown embodiments in accordance with one or more embodiments of the disclosure.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure are now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise: the meaning of “a,” “an,” and “the” includes plural reference, the meaning of “in” includes “in” and “on.” Relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, reference designators shown herein in parenthesis indicate components shown in a figure other than the one in discussion. For example, talking about a device (10) while discussing figure A would refer to an element, 10, shown in figure other than figure A.

Embodiments of the disclosure provide an improved gown having increased strength and durability features compared to prior art gowns, yet that can be manufactured more easily, more quickly, and less expensively than can prior art gowns. Advantageously, embodiments of the present disclosure provide a gown having thermally bonded seams where those thermal bonds are applied in accordance with one or more predefined methods, each of which eliminates “double passes” across any particular location of a seam. This “single pass” bonding provides for stronger bonds in areas that may experience stress and tension. Moreover, embodiments of the disclosure advantageously locate seams in specific locations to further enhance strength and durability. Other benefits and advantages offered by embodiments of the disclosure will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

In one embodiment, a gown, comprises a first component defining a front body covering portion, a first sleeve portion, a second sleeve portion, and at least a first tie. The first component can include one tie in one embodiment. Alternatively, it can include two ties in another embodiment.

The gown can include a second component. Optionally, the second component can be rotated 180 degrees about a central axis relative to the first component and aligned with the first component. In one or more embodiments, the second component will be exactly the same in shape and dimension as the first component, and can define a rear body covering portion, a third sleeve portion, a fourth sleeve portion, and at least a second tie. As with the at least a first tie, the at least a second tie can be one tie or two ties. Thus, in one or more embodiments, the first component and the second component have common dimensions and shapes.

After alignment with the first component, in one or more embodiments the first component is thermally bonded to the second component by four seams. For example, in one embodiment the front body covering portion, the rear body covering portion, the first sleeve portion, and the third sleeve portion can share a common seam. The front body covering portion, the rear body covering portion, the second sleeve portion, and the fourth sleeve portion share another common seam.

In one embodiment, a first seam can couple the first sleeve portion and the third sleeve portion, while a second seam couples the second sleeve portion and the fourth sleeve portion. A third seam can extend from a base of the gown along an edge of the front body covering portion and the rear body covering portion to a termination point at an end of the first sleeve portion and the third sleeve portion, while a fourth seam extends from the base of the gown along another edge of the front body covering portion and the rear body covering portion to another termination point at an end of the second sleeve portion and the fourth sleeve portion.

As noted, each component can include one tie or two ties. Where one tie is included, it extends from one side of the gown and, in one embodiment, runs parallel to an arm portion. Where two ties are included, they can extend from opposite sides of the gown and run parallel to each sleeve portion. Thus, the first component can include a first tie and a second tie, while the second component includes a third tie and a fourth tie in one embodiment. Where each component includes two ties, in one or more embodiments two of the four ties are later cut from the gown to leave only two remaining. Thus, in one embodiment at least two ties selected from the first tie, the second tie, the third tie, and the fourth tie are cut from the gown.

In another embodiment, each component only includes one tie. Thus, the at least a first tie and the at least a second tie each comprise only one tie.

In one or more embodiments, the first sleeve portion and the second sleeve portion each define thumb insertion apertures. In one or more embodiments, the rear body covering portion defines an opening to assist a user in donning the gown. In one or more embodiments, one or more perforations are disposed between a head insertion aperture and the opening. In one or more embodiments, the head insertion aperture separates two seams of the four seams.

Turning now to FIG. 1, illustrated therein is one component 100 of one explanatory gown configured in accordance with one or more embodiments of the invention. In one or more embodiments, this component comprises a layer 101 of material that defines a first half of a gown configured in accordance with one or more embodiments of the disclosure. In one or more embodiments, the layer 101 of material comprises a single layer of material. For instance, the layer 101 of material can be a single layer of polyethylene or polyurethane. In other embodiments, the layer 101 of material can be a multi-ply layer of material.

In this illustrative embodiment, the layer 101 of material includes a front body covering portion 102, a first sleeve portion 104, a second sleeve portion 105, a first side tie 106, and a second side tie 107. The layer 101 of material can be cut, using a template, from a roll of material for use as a portion of a gown.

In one or more embodiments, the layer 101 of material is manufactured from a disposable material. Examples of disposable material suitable for manufacturing the layer 101 include polyethylene, polyurethane, and other thermoplastic materials. Illustrating by example, in one or more embodiments the layer 101 of material is manufactured from polyethylene. In another embodiment, the layer 101 of material is manufactured from polypropylene. In yet another embodiment, the layer 101 of material is manufactured from a non-woven fabric that is coated with polyethylene, polypropylene, or another fluid resistant coating. In still another embodiment, the layer 101 of material is manufactured from Tyvek.sup.™. One or more antimicrobial layers can be added to the layer 101 of material to further enhance antimicrobial protection.

Numerous other fabrics suitable for the layer 101 of material will be obvious to those of ordinary skill in the art having the benefit of this disclosure. For example, in another embodiment the layer 101 of material can be manufactured from a non-woven fabric. The non-woven fabric can be disposable in one or more embodiments. The non-woven fabric can optionally include a water resistant lining that prevents the passage of fluids through the layer 101 of material in one or more embodiments.

Illustrating by example, in one or more embodiments the layer 101 of material is manufactured from a water-repellent or water-impermeable material and/or is coated with such a water-repellent or water impermeable material to prevent the passage of fluids. For example, the layer 101 of material can include various woven, non-woven, hydroentangled materials, and/or combinations thereof. The layer 101 of material may include absorbent Airlaid, spunlace, blends of polyester, polypropylene, polyethylene, urethane, and/or combinations thereof The layer 101 of material may be manufactured using various methods, including a spunbond metblown spundbond (SMS) method, a spunbond metblown metblown spundbond method (SMMS), and a spunbond metblown metblown spundbond method (SMMMS). The layer 101 of material can further be coated with fluid resistant linings 117, such as polyethylene or polypropylene.

In still other embodiments, the layer 101 of material can be configured such that the resulting gown is reusable. For example, the layer 101 of material could be washable and/or capable of being sterilized so that the gown manufactured from the layer 101 of material can be reused. Illustrating by example, in one embodiment, the layer 101 of material comprises a washable fabric, such as cotton, polyester, or a cotton polyester blend.

In one embodiment, the length 116 of the layer 101 of material is configured to run from a wearer's shoulder to below their knee. The length 116 of the layer 101 of material is configured to run from the wearer's shoulder to a location along their mid-calf. In yet another embodiment, the length 116 of the layer 101 of material extends from a wearer's shoulder to their feet. Other lengths will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

In one embodiment, pockets or other surface features, none of which is shown in FIG. 1 for simplicity, but that will be obvious to those of ordinary skill in the art having the benefit of this disclosure, can be attached to the layer 101 of material. The layer 101 of material may be manufactured in various colors. In one or more embodiments where the gown manufactured from the layer 101 of material is used in medical applications, the layer 101 of material can be blue or yellow. Yellow is a color particularly well suited for medical procedures due to its high visibility and easy differentiation from a person's skin. Blue is advantageous because it can immediately identify the gown as a medical gown manufactured by a particular manufacturer.

In one or more embodiments, the front body covering portion 102 is configured to cover the frontal portion of some or all of a user's body. In another embodiment the frontal portion of some or all of a user's torso, when the user is wearing the gown manufactured from the layer 101 of material.

Turning now to FIG. 2, illustrated therein is another component 200 of a gown configured in accordance with one or more embodiments of the disclosure. In this illustrative embodiment, the other component 200 comprises second layer 201 of material. In one or more embodiments, the second layer 201 of material is identical to the first layer (101) of material in shape, dimension, and type of material. In other embodiments, the second layer 201 of material can have the same dimensions and shape as the first layer (101) of material, but can be manufactured from a different material.

In one or more embodiments, the second layer 201 of material includes a rear body covering portion 202, a first sleeve portion 204, a second sleeve portion 205, a first side tie 206, and a second side tie 207. The second layer 201 of material can be cut, using the exact same template used for the first layer (101) of material, from a roll of material for use as a portion of a gown.

In one or more embodiments, the rear body covering portion 202 is configured to cover at least some of the rear portion of some or all of a user's body. In other embodiments, the rear body covering portion 202 is configured to cover the rear portion of some or all of a user's torso, when the user is wearing the gown manufactured from the second layer 201 of material.

Referring to FIGS. 1 and 2, in one or more embodiments, the first layer 101 of material and the second layer 201 of material have a substantially similar length 116 at the front body covering portion 102 and the rear body covering portion 202. In other embodiments, the length of the front body covering portion 102 and the rear body covering portion 202 can be different. In one embodiment for example, the front body covering portion 102 will be longer than the rear body covering portion 202, thereby covering more of the wearer's body in the front than the rear. In another embodiment, the front body covering portion 102 will be shorter than the rear body covering portion 202, thereby covering less of the wearer's body in the front than in the rear.

In one embodiment, each of the first layer 101 of material and the second layer 201 of material defines a partial head insertion aperture 121,221. For example, in the illustrative embodiment of FIG. 1, the front body covering portion 102 defines a first partial head insertion aperture 121, while the rear body covering portion defines a second partial head insertion aperture 221. When the front body covering portion 102 is attached to the rear body covering portion 202, the first partial head insertion aperture 121 and the second partial head insertion aperture 221 join to define a neck opening. A user may insert their head through the neck opening when donning the gown.

The perimeter of the neck opening, i.e., the boundary lines defining the partial head insertion apertures 121,221, can take a variety of shapes. For example, in the illustrative embodiment of FIGS. 1 and 2, the partial head insertion apertures 121,221 are identical, having been cut from the same template. The partial head insertion apertures 121,221 of this illustrative embodiment includes a double-concave-single convex curvature, including two concave recesses 108,208,109,209 separated by a convex upward curvature 110,210. However, the partial head insertion apertures 121,221 can take other shapes in other embodiments. For instance, the partial head insertion apertures 121,221 can have an angle-tapered flat contour, with two angular side edges radially interfacing with a substantially flat contour. In still other embodiments, the partial head insertion apertures 121,221 can simply be round, resembling a partial circle. The partial head insertion apertures 121,221 can, in other embodiments, have different shapes. Either can be generally circular, egg-shaped, oval-shaped, pear-shaped, football-shaped, or the like. Still other shapes will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

In one or more embodiments, when the components 100,200 of the gown are assembled together as will be described below with reference to FIGS. 3-8, the first sleeve portions 104,204 and the second sleeve portions 105,205 extend distally from the composite body covering portion defined by the front body covering portion 102 and the rear body covering portion 202. The first sleeve portions 104,204 and the second sleeve portions 105,205 are configured to receive wearer's arms when the gown manufactured from the components 100,200 is donned.

In the illustrated embodiment of FIG. 1, the first sleeve portions 104,204 and second sleeve portions 105,205 are illustrated as long sleeves. However, it will be clear to those of ordinary skill in the art having the benefit of disclosure that embodiments of the invention are not so limited. Gowns configured from components 100,200 in accordance with embodiments of the disclosure may equally be configured with short sleeves or no sleeves has a particular application may warrant.

The bases 103,203 of either the front body covering portion 102 or the rear body covering portion 202 can take a variety of shapes. For example, in the illustrative embodiment of FIGS. 1 and 2, the bases 103,203 are shown as split concave downward curvatures, where concave downward curvatures 111,211,112,212, each having an apex 113,213 higher than an outer nadir 114,214, where these concave downward curvatures 111,211,112,212 are separated by a straight central segment 115,215. In other embodiments, the bases 103,203 can simply be straight. The base 103,203 can take other shapes as well. For example, the bases 103,203 can substantially mirror the shape of the perimeter of the partial head insertion apertures 121,221. Other shapes will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Turning now to FIGS. 3-8, illustrated therein are one or more method steps for manufacturing a gown in accordance with one or more embodiments of the disclosure. Beginning with FIG. 3, the first component 100 and the second component 200 are aligned 301. In one or more embodiments, where the layer 101 of material and the second layer 201 of material have different front and rear surfaces, one of the first component 100 or the second component 200 can be turned over prior to alignment 301. For example, where the front surface is shiny and the rear surface is dull, one of the first component 100 or the second component 200 can be rotated 180 degrees about a vertical central axis so that the outwardly facing major faces of the first component 100 and the second component 200 will have a similar appearance, as will the inner surfaces. For instance, this rotation will cause the outer surfaces to both be shiny, while the inner surfaces are dull, or vice versa.

Turning now to FIG. 4, seams 401,402,403,404 are applied to join the first component 100 to the second component (200). In one or more embodiments, the seams 401,402,403,404 comprise only four seams. However, for particular applications, more or less than four seams can be used as well.

As shown in FIG. 4, in one or more embodiments the first component 100 is joined to the second component (200) by using a thermal bonding device 205. The thermal bonding device 205 applies heat to each of the first component 100 and the second component by passing 405 across edges 406,407,408,409 of the first component 100 and the second component (200) to create the seams 401,402,403,404. Accordingly, in this illustrative embodiment the first component 100 and the second component 200 are coupled together by thermal bonding along four seams 401,402,403,404.

However, in other embodiments, other coupling techniques can be used as well. Illustrating by example, in another embodiment the four seams 401,402,403,404 can be created by an adhesive bonding process. In other embodiments, the first component 100 and the second component (200) are coupled together by tape. Sonic welding, mechanical bonding, press-fit bonding, or other techniques can be used as well to create the four seams 401,402,403,404.

In one embodiment, seam 401 comprises a first upper arm seam, which passes atop the first arm of a wearer when the resulting gown is donned. Seam 402 comprises a second upper arm seam, which passes atop the second arm of a wearer when the resulting gown is donned. In one or more embodiments, seam 401 and seam 402 are made with a single pass 405 of the thermal bonding device 205 in one or more embodiments. As shown in FIG. 4, a neck opening 410 forms when the first partial head insertion aperture (121) and second partial head insertion aperture (221) are coupled together. In this embodiment, the seam 401 and seam 402 are separated by the neck opening 410.

In similar fashion, seam 403 and seam 404 are created. In one or more embodiments, each is created by a respective singular passage 411,412 of the thermal bonding device 205 along each of edge 408 of the first component 100 and the second component (200) and edge 409 of the first component 100 and the second component (200), respectively. These passages 411,412 of the thermal bonding device bond the first component 100 and the second component (200) together with continuous thermally bonded seams extending from a base 415 of the first component 100 and the second component (200) to a termination location 416,417 on the first sleeve portions 104,(204) and the second sleeve portions 105,(205), respectively. As those of ordinary skill in the art having the benefit of this disclosure will appreciate, this results in only one, singular passage 411,412 of the thermal bonding device 205 upon the underarm junctions of the first component 100 and the second component (200), thereby providing a more robust, durable, and strong junction than when multiple passes are made across this location. This is especially true when the first component 100 and the second component (200) are manufactured from polyethylene-coated SMS. It should be noted that the termination locations 416,417 can be at various points along the first sleeve portions 104,(204) and the second sleeve portions 105,(205).

The resulting gown 500 is shown in FIG. 5. As shown, the first sleeve portions 104,(204), the front body covering portion 102, and the rear body covering portion (202) each share a continuous thermally bonded seam 403 extending from the base 415 of the gown 500 to the termination location 416 located along the first sleeve portions 104,(204). The first sleeve portions 104,(204) also share a second continuously thermally bonded seam 401 extending along the top of thereof as well.

Similarly, the second sleeve portions 105,(205), the front body covering portion 102, and the rear body covering portion (202) each share another continuous thermally bonded seam 404 extending from the base 415 of the gown 500 to the termination location 417 located along the second sleeve portions 105,(205). The second sleeve portions 105,(205) also share a second continuously thermally bonded seam 402 extending along the top of thereof as well.

In this illustrative embodiment, a first partial arm insertion aperture 502 is defined between the front body covering portion 102 and the rear body covering portion (202) between the continuous thermally bonded seam 403 and seam 401. Additionally, in this embodiment a second partial arm insertion aperture 503 is defined between the front body covering portion 102 and the rear body covering portion (202) between continuous thermally bonded seam 404 and seam 402.

Turning now to FIG. 6, once the four seams 401,402,403,404 are created, thumb loops 601,602 can be cut in the first sleeve 603 and the second sleeve 604 of the gown 500, respectively. Each thumb loop 601,602 comprises a thumb insertion aperture 605,606, through which a wearer's thumb may be inserted when the gown 500 is donned and the wearer's arms are inserted into the first sleeve 603 and the second sleeve 604, respectively. In one embodiment, the thumb loop 601,602 is configured to engage the saddle of a thumb of a wearer. The thumb loops 601,602 permit the heel of a wearer's hand to be exposed when the thumb is inserted into the thumb insertion aperture 605,606.

The thumb loops 601,602, where included, advantageously provide several functions. One illustrative function is that they keep the first sleeve 603 and the second sleeve 604 pulled along the wearer's arms so as to prevent the first sleeve 603 and the second sleeve 604 from “riding up” the arms of the wearer. Another illustrative function is that the thumb loops 601,602 prevent twisting of the first sleeve 603 and the second sleeve 604 about the wearer's arm. Other advantages will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Instead of thumb loops 601,602, the first sleeve 603 and the second sleeve 604 can include other retention devices configured to retain the first sleeve 603 and the second sleeve 604 to the arms of a wearer. Illustrating by example, in other embodiments the retention devices can comprise knitted cuffs. In still other embodiments, the retention devices can comprise drawstrings. In yet additional embodiments, the retention devices can comprise elastic gatherings. Other retention devices will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Turning now to FIG. 7, in one or more embodiments an opening 701 can then be cut into the rear body covering portion 202 of the second component 200. In this illustrative embodiment, the rear body covering portion 202 comprises the opening 701, which is configured as a slit with two sides that abut when the opening 701 is closed by touching together. However, in other embodiments, the opening 701 can be cut in the front body covering portion (102) of the first component (100) instead.

In this illustrative embodiment, the front body covering portion (102) of the gown 500 is configured to be placed against the front of the torso of a wearer. The rear body covering portion 202 then covers the rear of the torso of the wearer and terminates at the opening 701. The opening 701 in this embodiment has a left side and a right side, and is configured as an abutting, but openable, slit that runs most of the length 716 of the rear body covering portion 202, up the back of the gown 500. Said differently, the opening 701 extends from the base 103 of the gown 500 toward, but not to, the neck opening 410 defined by the partial head insertion apertures (121,221). As used herein, a “slit” means “a long, narrow cut or opening,” in accordance with the plain, ordinary, English meaning as set forth in the New Oxford American Dictionary. It is not a gaping hole and does not include sides that do not abut when the opening 701 is closed.

The opening 701 can be used to assist in donning the gown 500. For instance, a user may open the opening 701 and pass their head, shoulders, and/or torso portions through the opening 701 when donning the gown. Said differently, the right side and left side of the opening 701 can be configured to permit the wearer to don the gown 500 by wrapping the right side and left side of the gown 500 about the wearer's torso.

In one or more embodiments, optional perforations 702,703 can be cut in the rear body covering portion 202 to assist a user in removing the gown 500 after use. In the illustrative embodiment of FIG. 7, two perforations 702,703 are cut between the opening 701 and the neck opening 410. They are configured in a partial V-shape, thereby defining the outer edges of an inverted frustoconical shape. In other embodiments, a single perforation can be cut in the rear body covering portion 202. In still other embodiments, no perforations will be cut in the rear body covering portion 202. While perforations are shown in the rear body covering portion 202 only for illustration, the front body covering portion (102) can include perforations as well.

Where includes, the perforations 702,703 can assist the user in removing the gown 500 by providing a score line that can be easily torn. Said differently, in one embodiment the perforations 702,703 are configured to tear when the front body covering portion (102) is pulled away from the wearer. When this occurs, the perforations 702,703 tearing, thereby splitting the rear body covering portion 202. The splitting and/or tearing can cause the rear body covering portion 202 to separate between the neck opening 410 and the opening 701. A user can therefore easily remove the gown 500 by simply tearing the perforations 702,703 and pulling the gown 500 off.

In one embodiment, each perforation 702,703 comprises a plurality of scores. Each of the scores is separated by a corresponding length of material. While the configuration of the perforations 702,703 can take a variety of configurations, some configurations are more suited to easy removal of the gown 500 than others. Additionally, some configurations are easier to manufacture than are others. One such example of a perforation 702,703 is where the plurality of scores is each about one inch long. (The term “about is used to describe a quantity inclusive of manufacturing and other tolerances. For example, in a score designed to be one inch in length, manufacturing and other tolerances may result in the score being, for example, 1.02″ or 0.972″,each if which is “about” one inch as the term is used herein.) In one exemplary embodiment, the lengths of material separating the scores are each about one half inch long. In one exemplary embodiment, four scores are used to make each perforation 702,703.

Another example is a perforation 702,703 in which the plurality of scores is each about three-quarters of an inch long. In this embodiment, the lengths of material separating the scores are each about one quarter-inch long. While these illustrations provide a few examples of how the scores can be configured, others will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

In one embodiment, to further assist the user in removing the gown, first component (100) and the second component 200 are manufactured from material configured so as to be tearable by a wearer. For example, the first component 100 and the second component 200 may be manufactured from a material having a tensile strength of between four and ten pounds. Thus, if a user were to grasp opposing sides of a section of the material, and then pull with a force of between four and ten pounds, the material would tear.

Turning now to FIG. 8, in one or more embodiments, one set of ties can be cut off so that the gown 500 includes only one set of ties. For example, in one embodiment the first tie 106 and the second tie 107 of the first layer (101) of material are cut from the gown 500. In the illustrative embodiment of FIG. 8, the first tie 206 and the second tie 207 of the second layer 201 of material are cut away from the gown 500. In yet another embodiment, the first tie 106 of the first layer 101 of material and the second tie 207 of the second layer 201 of material can be cut from the gown 500, or vice versa. Any of these embodiments leaves the gown 500 with a single set of ties, i.e., one tie extending from the right side of the gown 500 and one tie extending from the left side of the gown 500.

Turning now to FIG. 9, illustrated therein is another component 900 of one explanatory gown configured in accordance with one or more embodiments of the invention. In one or more embodiments, this component comprises a layer 901 of material that defines a first half of a gown configured in accordance with one or more embodiments of the disclosure. In one or more embodiments, the layer 901 of material comprises a single layer of material. For instance, the layer 901 of material can be a single layer of polyethylene or polyurethane. In other embodiments, the layer 01 of material can be a multi-ply layer of material.

In this illustrative embodiment, the layer 901 of material includes a front body covering portion 902, a first sleeve portion 904, a second sleeve portion 905, and a single side tie 906. The layer 901 of material can be cut, using a template, from a roll of material for use as a portion of a gown.

Turning now to FIG. 10, illustrated therein is another component 1000 of a gown configured in accordance with one or more embodiments of the disclosure. In this illustrative embodiment, the other component 1000 comprises second layer 1001 of material. In one or more embodiments, the second layer 1001 of material is identical to the first layer (901) of material in shape, dimension, and type of material. In other embodiments, the second layer 1001 of material can have the same dimensions and shape as the first layer (901) of material, but can be manufactured from a different material.

In one or more embodiments, the second layer 1001 of material includes a rear body covering portion 1002, a first sleeve portion 1004, a second sleeve portion 1005, and a single side tie 1006. The second layer 1001 of material can be cut, using the exact same template used for the first layer (901) of material, from a roll of material for use as a portion of a gown.

In one or more embodiments, the other characteristics of the first component (900) and the second component (1000) are the same as that described above with reference to the first component (100) of FIG. 1 and the second component (200) of FIG. 2, with the exception of the omitted second ties (107,207). For example, the shapes, contours, lengths, materials, and so forth can be the same as described above.

Turning now to FIGS. 11-15, illustrated therein are one or more method steps for manufacturing a gown in accordance with one or more embodiments of the disclosure. The advantage of using the first component 900 of FIG. 9 and the second component 1000 of FIG. 10 is that no tie cutting step, as described above with reference to FIG. 8, is required.

Beginning with FIG. 8, the first component 900 and the second component 1000 are aligned 1101. Prior to doing so, however, one of the first component 900 or the second component 1000 is turned over so that one tie 1006 extends from one side of the assembly and another tie 906 extends from the other side of the assembly.

Turning now to FIG. 12, seams 1201,1202,1203,1204 are applied to join the first component 900 to the second component (1000) as previously described. In one or more embodiments, the seams 1201,1202,1203,1204 comprise only four seams. However, for particular applications, more or less than four seams can be used as well. As shown in FIG. 12, in one or more embodiments the first component 900 is joined to the second component (1000) by using a thermal bonding device 205. The resulting gown 1300 is shown in FIG. 13.

Turning now to FIG. 14, once the four seams 1201,1202,1203,1204 are created, thumb loops 1401,1402 can be cut in the first sleeve 1403 and the second sleeve 1404 of the gown 1300, respectively. Each thumb loop 1401,1402 comprises a thumb insertion aperture through which a wearer's thumb may be inserted when the gown 1300 is donned.

Turning now to FIG. 15, in one or more embodiments an opening 1501 can then be cut into the rear body covering portion 1002 of the gown 1300. The opening 1501 can be used to assist in donning the gown 1300. Optional perforations 1502,1503 can be cut in the rear body covering portion 1002 to assist a user in removing the gown 1300 after use.

Since only single ties 906,1006 were included with the first component (900) and the second component 1000, no tie cutting (as described above with reference to FIG. 8) is required. By design, one tie 1006 extends from the right side of the gown 1300 while another tie 906 extends from the left side of the gown 1300. A user 1600 is shown wearing a gown 500,1300 configured in accordance with one or more embodiments of the disclosure in FIG. 16.

Turning now to FIG. 17, illustrated therein is one explanatory method 1700 for making a gown in accordance with one or more embodiments of the disclosure. At step 1701, the method 1700 includes cutting a first component from a section of material. In one embodiment, the first component comprises a first layer of material defining a front body covering portion, a first sleeve portion, a second sleeve portion, a first partial head insertion aperture, and at least a first tie.

At step 1702, the method 1700 includes cutting a second component from the section of material. The section of material from which the first component is cut can be the same as that from which the second component is cut in one embodiment. In other embodiments, the section of material from which the first component is cut can be different from that from which the second component is cut. In one or more embodiments, the second portion comprises a second layer of material defining a rear body covering portion, a third sleeve portion, a fourth sleeve portion, a second partial head insertion aperture, and at least a second tie. In one or more embodiments, the second component has a common shape and common dimensions with the first component.

At optional step 1703, the method 1700 can include rotating the first component 180 degrees with respect to the first component. At step 1704, the method 1700 includes thermally bonding the first component to the second component with four seams to create the gown. In one or more embodiments, the first partial head insertion aperture of the first component and the second partial head insertion aperture of the second component separate a first seam and a second seam.

In one embodiment, a third seam created at step 1704 extends from a base of the gown along an edge of the front body covering portion and the rear body covering portion to a termination point at an end of the first sleeve portion and the third sleeve portion. In one embodiment, a fourth seam created at step 1704 extends from the base of the gown along another edge of the front body covering portion and the rear body covering portion to another termination point at an end of the second sleeve portion and the fourth sleeve portion.

At step 1705, the method 1700 includes cutting a first thumb insertion aperture in the first arm portion and a second thumb insertion aperture in the second arm portion. At optional step 1706, which is included when the first component and the second component each include two ties, at least two ties are cut from the gown.

At step 1707, the method 1700 includes cutting an opening in the rear body covering portion to assist a user in donning the gown. At step 1708, the method 1700 optionally includes cutting one or more perforations in the rear body covering portion of the gown.

Turning now to FIG. 18, illustrated therein is another component 900 of one explanatory gown configured in accordance with one or more embodiments of the invention. In one or more embodiments, this component comprises a layer 1801 of material that defines an entire gown configured in accordance with one or more embodiments of the disclosure. In one or more embodiments, the layer 1801 of material comprises a single layer of material. For instance, the layer 1801 of material can be a single layer of polyethylene or polyurethane. In other embodiments, the layer 1801 of material can be a multi-ply layer of material.

In this illustrative embodiment, the layer 1801 of material includes a front body covering portion 1802, a first sleeve 1804, a second sleeve 1805, a first tie 1806, and a second tie 1807. The layer 1801 of material in this illustrative embodiment also includes the rear body covering portion 1808. Additionally, a head insertion aperture 1810 is cut into the gown. Rather than being created from two components, as was the case in FIGS. 1-16, in this embodiment only a single component is required. As before, the layer 1801 of material can be cut, using a template, from a roll of material for use as a portion of a gown.

In one or more embodiments, the rear body covering portion 1808 of the layer 1801 of material is identical to the front body covering portion 1802 in shape and dimension. In one or more embodiments, the other characteristics of the component 1800 are the same as that described above with reference to the first component (100) of FIG. 1. For example, the shapes, contours, lengths, materials, and so forth can be the same as described above.

In this embodiment, rather than aligning a first component and a second component to construct the gown, the component 1800 is simply folded at a medial axis 1809 passing through the head insertion aperture 1810 and along the first sleeve 1804 and the second sleeve. The medial axis 1809 divides the component 1800 into a first half 1811 and a second half 1812.

Once this folding step has been completed, turning now to FIG. 19, only two seams 1901,1902 are required to construct the gown. Seams 1901,1902 are applied to join the first half 1811 and the second half (1812) of the component 1800 together, as well as to seal the first sleeve 1804 and the second sleeve 1805 at their respective bottom portions. In one or more embodiments, the seams 1901,1902 comprise only two seams. As shown in FIG. 19, in one or more embodiments the first half 1811 of the component 1800 and the second half (1812) of the component 1800 are joined by using a thermal bonding device 205 to create seams 1901,1902. As shown, this results in each seam 1901,1902 extending from a base 1915 of the first half 1811 and the second half (1812) of the component 1800 to a termination location 416,417 on the first sleeve 1804 and the second sleeve 1805, respectively. As those of ordinary skill in the art having the benefit of this disclosure will appreciate, this results in only one, singular passage of the thermal bonding device 205 upon the underarm junctions of the first sleeve 1804 and the second sleeve 1805, thereby providing a more robust, durable, and strong junction than when multiple passes are made across this location. The resulting gown 2000 is shown in FIG. 20.

Turning now to FIG. 21, once the two seams 1901,1902 are created, thumb loops 2101,2102 can be cut in the first sleeve 1803 and the second sleeve 1805 of the gown 2000, respectively. Each thumb loop 2101,2102 comprises a thumb insertion aperture through which a wearer's thumb may be inserted when the gown 2000 is donned.

Turning now to FIG. 22, in one or more embodiments an opening 2201 can then be cut into the rear body covering portion 1808 of the gown 2000. The opening 2201 can be used to assist in donning the gown 2000. Optional perforations 2202,2203 can be cut in the rear body covering portion 1808 to assist a user in removing the gown 2000 after use.

Since only two ties 1806,1807 were included, no tie cutting (as described above with reference to FIG. 8) is required. By design, one tie 1806 extends from the right side of the gown 2000 while another tie 1806 extends from the left side of the gown 2000.

To this point, gowns have been shown with ties that extend from opposite sides of the gown. For example, in FIG. 22 one tie 1806 extends from the right side of the gown 2000 while another tie 1806 extends from the left side of the gown 2000. However, in other embodiments, the ties can extend from a common side of the gown. This can be accomplished in several ways.

For example, turning now to FIG. 23, illustrated therein is the gown 500 of FIG. 7. In FIG. 8 above, a tie 206,207 from each side of the gown 500 was cut away, thereby leaving one tie 106 extending from the left side of the gown 500, while another tie 107 extended from the right side of the gown 500. In FIG. 23, to create ties 107,207 extending from a common side of the gown, i.e., the right side of the gown 500, ties 106,206 are cut from the gown 500. This leaves two ties 107,207 extending from the right side of the gown 500. If the application called for two ties 106,206 extending from the left side of the gown 500, ties 107,207 could have been cut instead. Any of these embodiments leaves the gown 500 with a single set of ties, i.e., two ties (either ties 106,206 or ties 107,207) extending from one of the right side of the gown 500 or the left side of the gown 500, as desired.

Another way to create a gown with single side ties is to use the first component (900) of FIG. 9 and the second component (1000) of FIG. 10. Instead of rotating one of these components prior to aligning, as was the case in FIG. 11, they are simply aligned without rotation.

Turning now to FIGS. 24-28, illustrated therein are one or more method steps for manufacturing a gown having ties on a common side in accordance with one or more embodiments of the disclosure. Beginning with FIG. 24, the first component 900 and the second component 1000 are aligned 1101. Turning now to FIG. 25, a thermal bonding device 205 creates seams 1201,1202,1203,1204 to join the first component 900 to the second component (1000) as previously described. The resulting gown 2600 is shown in FIG. 26.

In one or more embodiments, the seams 1201,1202,1203,1204 comprise only four seams. However, for particular applications, more or less than four seams can be used as well. For example, a gown having ties at a common side could be constructed using the component (1800) of FIG. 18, but with tie (1807) extending from the rear body covering portion (1808) on the right side above (as viewed in FIG. 18) first sleeve 1804 rather than its position as shown, with the resulting gown assembled as shown in FIGS. 19-22 as well.

Turning now to FIG. 27, once the four seams 1201,1202,1203,1204 are created, thumb loops 1401,1402 can be cut in the first sleeve 1403 and the second sleeve 1404 of the gown 2600, respectively. Each thumb loop 1401,1402 comprises a thumb insertion aperture through which a wearer's thumb may be inserted when the gown 2600 is donned.

Turning now to FIG. 28, in one or more embodiments an opening 1501 can then be cut into the rear body covering portion 1002 of the gown 2600. The opening 1501 can be used to assist in donning the gown 2600. Optional perforations 1502,1503 can be cut in the rear body covering portion 1002 to assist a user in removing the gown 2600 after use.

Since only single ties 906,1006 were included with the first component (900) and the second component 1000, no tie cutting (as described above with reference to FIG. 8) is required. By design, each tie 906,1006 extends from a common side of the gown 2600. A user 1600 is shown wearing a gown 2000,2600 configured in accordance with one or more embodiments of the disclosure in FIG. 29.

In the foregoing specification, specific embodiments of the present disclosure have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present disclosure as set forth in the claims below. Thus, while preferred embodiments of the disclosure have been illustrated and described, it is clear that the disclosure is not so limited. Numerous modifications, changes, variations, substitutions, and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present disclosure as defined by the following claims. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present disclosure. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims.

Disposable Gown and Method of Constructing the Same

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