Neck Engaging Hospital Gown and Method of Manufacture

Abstract

A protective garment comprising a gown and an improved collar mechanism and method of use for securing protective gowns, typically used in health care settings, around the neck of a user without the need to secure with ties, tabs, snaps or other securing devices. The collar mechanism is made pliable when fastened to the garment so as to be deformed without fracture when force is applied but with a sufficient memory when combined with the gown that allows the collar to return to its original position once the force is removed. The collar mechanism may be manufactured efficiently by using a rotary die cutting machine to created nested pairs of pieces of a two-piece embodiment arranged spirally on a stock.

What is claimed is:  
     
         1 . A two-piece collar member for a protective garment, comprising:
 a. a first collar piece having
 i. a first curvature, wherein the first collar piece comprises a first inner edge and a first outer edge, the first inner edge and the first outer edge defining a first flat surface, a second flat surface opposite the first flat surface, 
 ii. a first terminal end, and 
 iii. a second terminal end opposite the first terminal end; and 
   b. a second collar piece similar to the first curved collar piece, the second collar piece having
 i. a second curvature, wherein the second collar piece comprises a second inner edge and a second outer edge, the second inner edge and the second outer edge defining a third flat surface, a fourth flat surface opposite the third flat surface, 
 ii. a third terminal end, and 
 iii. a fourth terminal end opposite the third terminal end, 
   c. wherein the first curvature is defined by a first radius of curvature and a second radius of curvature,   d. wherein the second curvature is defined by a third radius of curvature and a fourth radius of curvature, and   e. wherein the third radius of curvature is smaller than the first radius of curvature and the fourth radius of curvature is smaller than the second radius of curvature, such that the second outer edge of the second collar piece abuts the first inner edge of the first collar piece.   
     
     
         2 . The two-piece collar member of  claim 1 , wherein the first and second collar pieces are made from cardboard. 
     
     
         3 . The two-piece collar member of  claim 1 , wherein the first and second collar pieces are fastenable to a neckline of a protective garment. 
     
     
         4 . The two-piece collar member of  claim 3 , wherein the neckline comprises a securing flap securable to the second terminal end and the fourth terminal end of the first and second collar pieces, respectively. 
     
     
         5 . The two-piece collar member of  claim 3 , wherein the protective garment comprises a second securing flap and a third securing flap securable to the first terminal end and the third terminal end, respectively. 
     
     
         6 . A method of manufacturing two-piece collar members for a protective garment, comprising: cutting a stock to generate a plurality of two-piece collar members spirally arranged in a square area, wherein each two-piece collar member comprises a larger, curved piece and a smaller, curved piece, wherein the smaller, curved piece is nested within the larger, curved piece, wherein each of the larger, curved pieces and each of the smaller, curved pieces comprise a first terminal end, a second terminal end, and a curved middle portion connecting the first terminal end with the second terminal end. 
     
     
         7 . The method of  claim 6 , further comprising fastening the two-piece collar member to a neckline of a protective garment with the first terminal ends of each piece adjacent to each other and the second terminal ends of each piece adjacent to each other, and the curved middle portions positioned away from each other to form an oval shape. 
     
     
         8 . The method of  claim 7 , further comprising creating a securing flap at a bottom of the neckline. 
     
     
         9 . The method of  claim 8 , further comprising:
 a. folding the securing flap over the second terminal ends; and   b. fastening the securing flap to the gown and the second terminal ends.   
     
     
         10 . The method of  claim 7 , further comprising creating a pair of securing flaps at a top of the neckline. 
     
     
         11 . The method of  claim 10 , further comprising:
 a. folding a first securing flap over the first terminal end of the larger, curved piece;   b. folding a second securing flap over the first terminal and of the smaller, curved piece;   c. fastening the first securing flap onto the first terminal end of the larger, curved piece and the protective garment; and   d. fastening the second securing flap on to the first terminal end of the smaller, curved piece and the protective garment.   
     
     
         12 . The method of  claim 6 , wherein an amount of wasted stock generated is less than 80%. 
     
     
         13 . The method of  claim 6 , wherein an amount of wasted stock generated is less than 70%. 
     
     
         14 . A protective garment, comprising:
 a. a curved collar member having an outer edge, an inner edge opposite the outer edge, a first free end, and a second free end opposite the first free end, wherein the outer edge and inner edge define a first flat surface and a second flat surface opposite the first flat surface, wherein the curved collar member comprises at least two different radii of curvature so as to form an oval configuration such that the inner edge at the first free end abuts the outer edge at the second free end when in its natural state; and   b. a gown having an oval shaped neckline, wherein the curved collar member is fastened to the oval shaped neckline of the gown.   
     
     
         15 . The protective garment of  claim 14 , wherein the curved collar member further comprises a third free end and a fourth free end opposite the first free end and the second free end, thereby creating a two-piece curved collar member, wherein each piece is generally C-shaped. 
     
     
         16 . The protective garment of  claim 15 , wherein a first piece of the two-piece curved collar member is at least the same size as a second piece of the two-piece curved collar member. 
     
     
         17 . The protective garment of  claim 16 , wherein the first piece of the two-piece curved collar member is larger than second piece of the two-piece curved collar member. 
     
     
         18 . The protective garment of  claim 14 , wherein a cross-section of the collar member is a flat, rectangular shape.