1 2014218471 28 Μ 2016
PROTECTIVE INSERT AND GARMENTS HAVING INCLUDED THEREIN A
PROTECTIVE INSERT
TECHNICAL FIELD
[0001] This invention relates to a protective insert for garments. More particularly, this invention relates to reusable protective garments, and to a method of manufacturing a protective insert and protective garments containing such a protective insert.
BACKGROUND ART
[0002] The following discussion of the background art is intended to facilitate an understanding of the present invention only. No acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application is intended.
[0003] Women and men occasionally experience failing underwear or sometimes have to deal with uncomfortable, inadequate, unappealing and eco-damaging solutions to manage unwanted moisture and odour concerns. The Applicant is aware of conventional reusable briefs offering in most cases short-term protection against minor moisture (1 ml or less) issues, while other purpose-made protective products offer protection against larger leaks such as those caused by incontinence (250 ml above). However, for unexpected and unwanted but common lighter leaks such as light bladder leaks (experienced by 30% of women with one child or more, and often a result of urge incontinence in young toilet training children), menstrual overflow (experienced by 50% of women during menstruation due to tampon or mooncup failure), heavier discharge, sweat, or odour (experienced regularly by many women and men), breast milk leaks (experienced by most breastfeeding mothers) often disposable liners and pads and, in certain instances, reusable liners and pads are used. These are bulky and uncomfortable, unsightly to many, cumbersome to apply correctly, may be environmentally hazardous, a potential source of 2 2014218471 28 Jul2016 embarrassment, and tend to move around which may lead to staining or wetting of outer garments.
[0004] It is an objective of this invention to address some of the issues of existing products in this field.
SUMMARY OF INVENTION
[0005] According to one aspect of the invention, there is provided a protective insert attachable to a garment, the protective insert comprising: a first, operatively inner layer comprising a moisture-wicking fibre; a second, intermediate layer of a moisture absorbing material; and a third, operatively outer layer of a low-breathable, substantially moisture-resistant material for protecting outer clothing in the event of a bodily discharge or inadvertent fluid leakage.
[0006] The fibre used in the first, operatively inner layer may be natural fibre, derived from natural fibre, or may be a synthetic fibre, or a combination of natural and synthetic fibres.
[0007] The first, operatively inner layer fibre may be hydrophilic or contain a hydrophilic compound.
[0008] The first, operatively inner layer fibre may be in the form of a proteinaceous compound.
[0009] The proteinaceous compound may be a keratinous compound.
[0010] The keratinous compound may be a knitted, woven, compacted, comminuted, or reconstituted keratinous compound.
[0011] As such, the keratinous compound may be in the form of a knitted fabric.
[0012] The keratinous compound may be moisture-wicking or pre-treated to enhance the moisture-absorbing capabilities thereof. 3 2014218471 28 Μ 2016 [0013] The keratinous compound may be a stain-resistant compound or may be treated to make it stain-resistant.
[0014] The keratinous compound may have natural antimicrobial properties or may be treated with an antimicrobial composition.
[0015] The antimicrobial composition may be an antibacterial, antiviral, or antifungal compound, or a combination of such compounds.
[0016] The antimicrobial composition may be in the form of silver ions.
[0017] The keratinous compound may be in the form of wool.
[0018] In one embodiment, the wool may be merino wool.
[0019] Alternatively, or additionally, the fibre used in the first, operatively inner layer may be cellulosic. In certain embodiments, the fibre may be in the form of fibre derived from bamboo, cotton, silk, or any combination or organic variation thereof. As such, the fibre may be a fibre commercially available under the trade names Modal® or Tencel®.
[0020] The first, operatively inner layer fibre may be included in a weight in a range of 100 gsm to 300 gsm in the protective insert, preferably between 150 gsm and 250 gsm, most preferably 180 gsm [0021] The first, operatively inner layer may have a thickness of between 0.5 mm and 5 mm, preferably between 0.8 mm and 2 mm, most preferably under 1 mm.
[0022] The intermediate layer may include an absorbent, quick drying compound or material.
[0023] The intermediate layer may comprise a microfibre.
[0024] The microfibre may be made from a synthetic fabric such as a polyester/polyamide or polyester/nylon fabric.
[0025] The intermediate layer may be manufactured from a cellulosic material, such as hemp, bamboo, cotton or combination of these fibres. 4 2014218471 28 Jul2016 [0026] The intermediate layer may be manufactured from a keratinous compound, such as wool [0027] The intermediate layer may have a thickness of between 0.5 mm and 5 mm, preferably 1-2 mm.
[0028] The third, operatively outer layer may comprise a polyester/polyurethane laminate fabric (100% polyester knit fabric bonded to polyurethane breathable and waterproofing film) generally having a thickness of 1 mm or less. The fabric may have a film laminate making it moisture impenetrable. The outer surface of this fabric may allow for air penetration, which assists with drying the middle layers and ameliorating microbial growth.
[0029] Typically, the third, operatively outer layer comprises a fabric commercially available under the trade name PUL.
[0030] The third, operatively outer layer may have a thickness of between 0.1 mm and 2 mm, preferably between 0.2 mm and 1.5 mm, most preferably no more than 1.0 mm.
[0031] The total thickness of the protective insert may be between 2 mm and 10 mm, preferably having a maximum thickness of no more than 5 mm, most preferably having a maximum thickness of no more than 3 mm.
[0032] Outer edges of the third, operatively outer layer may be in the form of wing formations that may extend past and fold around the intermediate layer toward the first, operatively inner layer, to minimise leakage.
[0033] The wing formations may be in contact with the outer edges of the inner and intermediate layers.
[0034] One or more of the layers may include one or more hypoallergenic compounds. The keratinous compound may be pre-treated to enhance the hypo-allergenicity thereof.
[0035] The protective insert may form part of a garment, particularly an undergarment, and as such may be non-removably attached to the undergarment. 5 2014218471 28 Jul2016 [0036] As such, the protective insert may be sewn or fused to the garment.
[0037] The garment may be in the form of briefs, pantyhose, leggings, gym shorts, a brassiere, a singlet, a t-shirt, a sports bra, or toilet-training garments for children.
[0038] The protective insert may be fixed or attached to the garment in, proximal to, substantially covering, or extending over, at least part of a bodily discharge zone.
[0039] In use, the first, operatively inner layer may be proximal to the body of a wearer, while the outer zone is then distal from a wearer.
[0040] According to another aspect of the invention, there is provided a garment having included therein a protective insert of the invention.
[0041] The article of clothing may be an undergarment.
[0042] When in the form of briefs, pantyhose, or leggings, the protective insert may be attached to the clothing in the general crotch area of a user.
[0043] When in the form of a brassiere, singlet, sports bra, or T-shirt, the protective insert may be attached to the clothing in the general chest area of a user, the underarm area, or both.
[0044] The invention further extends to a method of manufacturing an protective insert, the method including the steps of: providing a first, operatively inner layer comprising a moisture-wicking natural fibre as described hereinbefore; bringing into close contact with the first, operatively inner layer a second, intermediate layer of a moisture absorbing, quick drying material as described hereinbefore; and bringing into close contact with the intermediate layer, a third, operatively outer layer of a low-breathable, substantially moisture-resistant material for protecting outer clothing in the event of a bodily discharge.
[0045] More particularly, the invention extends to a method of manufacturing a protective insert, the method including the steps of: providing a first, operatively inner layer comprising a moisture-wicking natural moisture-wicking fibre in the form of merino wool fabric or bamboo fabric as described hereinbefore; bringing into close contact with the first, operatively inner layer a second, intermediate layer of a 6 2014218471 28 Μ 2016 moisture absorbing material as described hereinbefore; and bringing into close contact with the intermediate layer, a third, operatively outer layer of a low-breathable, substantially moisture-resistant material as claimed hereinbefore for protecting outer clothing in the event of a bodily discharge [0046] According to a still further aspect of the invention, there is provided a protective insert attachable to a garment, the protective insert comprising: a first, operatively inner layer comprising a moisture-wicking fibre made of merino wool fabric; a second, intermediate layer comprising a microfibre fabric; and a third, operatively outer layer of a low-breathable, substantially moisture-resistant material for protecting outer clothing in the event of a bodily discharge or inadvertent fluid leakage.
[0047] In yet another aspect of the invention, there is provided a protective insert attachable to a garment, the protective insert comprising: a first, operatively inner layer comprising a natural, moisture-wicking fibre in the form of merino wool fabric or bamboo fabric in a weight range of 150 to 250 gsm, the merino wool fabric or bamboo fabric having a thickness of between 1 mm and 2 mm; a second, intermediate layer of a moisture absorbing material comprising a polyester/polyamide microfibre fabric having a synthetic fibre finer than 1.3 denier or less, the microfibre fabric having a thickness of 2 mm or less and having a saturation level of at least 30 ml per 10 cm2 of microfibre fabric; and a third, operatively outer layer, comprising a polyester/polyurethane laminate fabric having a thickness of 1 mm or less and which is moisture impenetrable but allows for air penetration, for protecting outer clothing in the event of a bodily discharge or inadvertent fluid leakage.
[0048] The second, intermediate layer may comprise microfibre fabric impregnated or coated with silver ions. 7 2014218471 28 Jul2016 [0049] According to yet another aspect of the invention, there is provided a method of manufacturing a garment having one or more moisture-absorbing zone, the method including the steps of: providing a protective insert of the invention; and attaching the protective insert to an area of a garment such that the positioning of the protective insert corresponds to a moisture leakage or odour producing area of a wearer’s body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Further features of the present invention are more fully described in the following description of several non-limiting embodiments included solely for the purposes of exemplifying the present invention. The following description is not a restriction on the broad summary, disclosure or description of the invention as set out above and is made with reference to the accompanying drawings in which: [0051] Figure 1 is a cross-sectional view of a protective insert in accordance with one aspect of the invention, showing three layers.
[0052] Figure 2a is a front view of briefs in accordance with one aspect of the invention.
[0053] Figure 2b is a rear view of briefs in accordance with one aspect of the invention.
[0054] Figure 3 is a rear view of a singlet in accordance with one aspect of the invention.
[0055] Figure 4 is a front view of a brassiere in accordance with one aspect of the invention.
DESCRIPTION OF EMBODIMENTS
[0056] Throughout this spec ification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to 8 2014218471 28M2016 imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.
[0057] With reference to the drawings, the invention provides a protective insert 10 comprising an first, operatively (in use) inner layer 12, an intermediate layer 14, and a third, operatively (in use) outer layer 16, also referred to herein as first (or inner), second (or middle or intermediate), and third (or outer) layers.
[0058] The protective insert 10 is a slim (3 mm in thickness or less), wicking, super absorbent, quick drying, antibacterial, stain resistant, breathable, comfortable lining, which can absorb insults or fluid leakages of up to 5 ml in a single insult. As such, the protective insert 10 wicks, absorbs and evaporates moisture or sweat, reduces odour and bacteria, provides a generally leakproof barrier to ensure no leakage onto clothes, is breathable and resistant to stains, and is machine washable, obviating the need for hand washing.
[0059] The protective insert 10 thus provide the wearer with a machine washable and comfortable way to stay dry and fresh from light bladder leaks, menstrual overflow/spotting, discharge, sweat and odour, without the need for disposable liners or insert fabric liners.
[0060] The inner (first) layer 12 comprises slim, wool mesh fabric. The Applicant has found after much experimentation that merino mesh wool has rapid absorption capabilities, specifically that it can absorb up to 35% of its dry weight in moisture. This property, when combined with a hydrophilic, highly absorbent, quick drying fabric structure in the second layer 16, results in moisture being quickly absorbed and moved away from the skin, keeping the wearer feeling dry and fresh.
[0061] Applicant has also found that merino wool possesses a natural crimp, giving it excellent insulation and breathability properties, which allows air to flow through to the middle layer and assist the drying process. Advantageously, the Applicant has found that merino fibres have a natural protective layer/composition that prevents stains from being formed and these properties generally last the life of the merino wool, unlike other synthetic or natural fabrics in which the stain-preventing compounds often wash out in 25 washes or less. In one embodiment, MerinoState® produced by Charles Parsons® is used. 9 2014218471 28 Jul2016 [0062] The middle layer 14 comprises a lightweight (180 gsm), super-absorbent, quick drying, breathable stretch microfibre (polyester 80%/polyamide 20%) fabric, the fabric generally having a thickness of 1 mm or less. By microfibre is meant a synthetic fibre finer than 1.3 denier or decitex/thread. The Applicant has found that this microfibre is usefully paired with the first, operatively inner layer to provide a product having an first, operatively inner layer which is super-absorbent (i.e. has a saturation level of at least 30 ml per 10 cm2 of microfibre fabric) and is very quick drying, which decreases microbial growth. The microfibre is coated or impregnated with antimicrobial and/or odour absorbing finishes, and in one embodiment the microfibre is impregnated or coated with silver ions. In other embodiments the microfibre is impregnated or coated with commercially available antimicrobial products such as Ultra-Fresh®, Silpure®, Purex®, and other commercially available antimicrobial compounds or compositions, or mixtures thereof, to further enhance the antimicrobial and/or odour eliminating capabilities.
[0063] The operatively outer (third) layer comprises a polyester/polyurethane laminate fabric (100% polyester knit fabric bonded to polyurethane breathable and waterproofing film) generally having a thickness of 1 mm or less. The fabric has a film laminate making it moisture impenetrable and acts as a barrier against leaks. However, the outer surface does allow for air penetration, which assists with drying the middle layers and ameliorating microbial growth. Typically, this layer comprises a fabric commercially available under the trade name PUL.
[0064] Outer edges 16.1, 16.2 of the outer layer may be in the form of wings which fold around the second layer 14 toward the first, operatively inner layer 12, in one embodiment being in contact with the outer edges of the first 12 and second 14 layers, to minimise leakage.
[0065] The three layers are sewn/fused together and sewn/fused into the garments as required, as shown in Figure 2a to Figure 4. Therefore, the protective insert/lining is hidden or at least partially obscured by the outer performance fabric of either bamboo/cotton or merino wool jersey. In one embodiment, the outer fabric is a merino wool fabric. 2014218471 28 Jul2016 10 [0066] Turning now to Figures 2a and 2b, there is shown a pair of briefs 20 having included therein an insert of the invention 10. The briefs 20 include a body 22, cutouts for legs 24, and a general crotch area 26. The protective insert in accordance with the invention 100 is sewn or fused to the general crotch area 26 and extends sufficiently to cover crotch areas prone to accidental fluid leakage that may be experienced by a wearer.
[0067] Turning now to Figure 3, there is provided a singlet (indicated generally by reference numeral 30), the singlet having included therein an insert of the invention 200. The singlet 30 includes a body 32 and cutouts 34 for a wearer’s arms (not shown) and a cutout 36 for a wearer’s neck (not shown). The protective insert 200 is sewn or fused to the material of the body 32 of the singlet 30 and extends sufficiently to cover all areas prone to accidental fluid leakage experienced by a wearer, including the breast area as well as partially extending to the underarm area.
[0068] Turning now to Figure 4, there is provided a brassiere 40 for lactating women, the brassiere having included therein an insert of the invention 300. The brassiere 40 includes a body, generally comprising two cups 42, and connecting straps 44, 46, 48. The protective insert 300 is sewn or fused to the inside of each cup (and may in certain embodiments replace the cups 42 themselves) and extends sufficiently to cover all areas prone to accidental fluid leakage experienced by a wearer.
[0069] The Applicant is of the opinion that they have invented an environmentally friendly, reusable, launderable, moisture control undergarment which is unobtrusive and discreet, yet can absorb and contain light amounts (5 ml or less) of bodily fluids in the crotch or upper body area and which prevents penetration of moisture to the exterior of the undergarment and consequently to a wearer's outer garments or clothing. Advantageously, the combination of layers in accordance with the protective insert of the invention results in an effective protective insert having a cross-sectional thickness of 3 mm or less.