Abstract
The present invention involves a method for permanently embedding a protective covering in an article of clothing over at least one predetermined portion of the clothing that can be worn by infants, children and adults. The protective covering is made from a thermoplastic material that is applied to and thermally bonds or co-mingles with the outermost fabric fibers of the clothing creating a permanently embedded, liquid impermeable, non-porous protective covering, including an increased height edge, which covering retains the same flexibility as the underlying fabric of the clothing article. The protective covering can be positioned across the top front portion of the clothing article and extend downward to a lower portion of the front of the clothing article creating an easy to clean particle and dirt resistant covering for the clothing article.
Claims
1. A method for permanently embedding in an article of clothing a non-porous impermeable protective covering into at least one area of the article of clothing comprising the steps of: providing an article of clothing to be worn by an infant, child or adult that may be of woven or non-woven fibers, said article of clothing having exterior and interior surfaces; printing a thermoplastic material onto at least one predetermined area of the exterior of the article of clothing at increased temperature and pressure for a period of time sufficient for the thermoplastic to penetrate only into the top garment fibers of the fabric of the article of clothing; cooling the thermoplastic material immediately following said period of time to create a permanent non-porous impermeable protective covering embedded into and interweaved with the top garment fibers of the predetermined area of said article of clothing without penetrating to the interior surface thereof such that a main portion of the protective covering is formed with an edge portion along the outer edges of the main portion of the protective covering, said edge portion being formed with an increased thickness greater than that of the main portion of the protective covering and an extended width for retarding outflow of materials from the main portion of the protective covering, said protective covering retaining the flexibility of the underlying article of clothing.
2. The method of claim 1, wherein the at least one predetermined area of the article of clothing for embedding the protective covering is selected from the group consisting of the upper front portion, the upper and mid front portions, the lower arm portions, and the lower and mid arm portions.
3. The method of claim 1, wherein said permanently embedded protective covering is non-toxic, moisture impervious, and flame retardant.
4. The method of claim 1, wherein the thermoplastic material may be a plastisol ink.
5. The method of claim 1, wherein the thermoplastic material may have color, translucency, or be substantially transparent.
6. The method of claim 1, wherein said temperature to thermally bond the thermoplastic material to the underlying fabric of the article of clothing is in a range between 150° F. to 330° F.
7. The method of claim 6, wherein said temperature is preferably in a range between 150° F. to 200° F.
8. The method of claim 1, wherein the formed edge portion of the protective covering has an increased thickness in the range between 1-3 mm above the surface of the main portion of the protective covering and the surface of the article of clothing and a width in the range between 0.5 and 1.5 cm.
9. (canceled)
10. (canceled)
11. An article of clothing to be worn by an infant, child or adult comprising: a fabric that may be of woven or non-woven fibers having exterior and interior surfaces; a thermoplastic material printed onto at least one predetermined area of the exterior surface of the article of clothing transferring the thermoplastic into the top fibers of the fabric to create a permanent protective covering embedded into and interweaved with the top fibers of said at least one predetermined area of said article of clothing without penetrating to the interior surface thereof; said thermoplastic material forming a main portion of the protective covering with an edge portion along the outer edges of the main portion of the protective covering, said edge portion being formed with an increased thickness greater than that of the main portion of the protective covering and an extended width for retarding outflow of materials from the main portion of the protective covering; and, said protective covering retaining the flexibility of the underlying fabric.
12. The article of claim 11, wherein said permanently embedded protective covering is non-toxic, moisture impervious, and flame retardant.
13. The article of claim 11, wherein the thermoplastic material may be a plastisol ink.
14. The article of claim 11, wherein the thermoplastic material may have color, translucency or be substantially transparent.
15. The article of claim 11, wherein the formed edge portion of the protective covering has an increased thickness in the range between 1-3 mm above the surface of the main portion of the protective covering and the surface of the article of clothing and a width in the range between 0.5 and 1.5 cm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0022] FIG. 1 is a front view of an infant's jumper with the permanent protective covering of the present invention extending from the neckline to approximately the mid torso portion of the intended wearer.
[0023] FIG. 2 is a front view of a child's shirt with the permanent protective covering of the present invention extending over the upper torso area of the intended wearer.
[0024] FIG. 3 is a front view of an adult shirt-like garment with the permanent protective covering of the present invention extending from the neckline to approximately the lower torso area of the intended wearer.
[0025] FIG. 4 is a partial sectional view of the permanent protective covering of the present invention embedded through the outer layer of the fabric and under the cross-weave fibers of an article of clothing.
[0026] FIG. 4A is a partial sectional view of the permanent protective covering of the present invention showing one edge of the embedded material and the outer layer of the fabric of the article of clothing.
[0027] FIG. 5 is a front view of an infant's sleeper with the permanent protective covering of the present invention extending from the neck to approximately the lower torso portion of intended wearer.
[0028] FIG. 6 is a front view of an adult's work overalls with the permanent protective covering of the present invention extending from the top of the overalls to the waist portion of intended wearer.
[0029] FIG. 7 is a front view of an adult healthcare worker's uniform shirt with the permanent protective covering of the present invention extending from the neckline to approximately the lower torso portion of intended wearer.
[0030] FIG. 8 is a front view of a dress with the permanent protective covering of the present invention extending from the neckline to approximately the waist of the wearer.
[0031] FIG. 9 is of a perspective view of a man's tie with the permanent protective coating of the present invention extending almost the entire length of the outer surface of the tie.
[0032] FIG. 10 is a front view of a patient gown with the permanent protective coating of the present invention extending from the neckline to approximately the lower torso of the intended wearer.
[0033] FIG. 11 is a front view of a medical practitioner's gown with the permanent protective coating of the present invention extending from the neckline to approximately the lower torso of the intended wearer and along the distal areas of the sleeves.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
[0035] Referring now to the drawings in detail, where like numerals refer to like parts or elements, there are shown in FIGS. 1-3 and 5-11 a number of different articles of clothing for a variety of differently sized persons. However, before describing each of the varying sized articles of clothing carrying the protective covering, the method of manufacturing the specialized article of clothing with the impermeable protective covering of the present invention is best described in connection with FIGS. 4 and 4A.
[0036] FIG. 4 is a partial sectional view of the article of clothing showing the thermoplastic material 42 used for creating the permanent protective covering interweaved with the fabric fibers of the garment 44, 46 and 48. The thermoplastic material of the permanent protective covering 42 of the present invention is applied to and impregnated or embedded into the fibers of the fabric of the garment. This process results in an interweaving of the thermoplastic material through the outermost layer of fibers 42 of the fabric of the garment. The thermoplastic material is applied in a fluid state so that the material will flow in and around the fibers of the fabric of the garment such as the individual fibers 44 and the cross-weave fibers 46 of the garment shown in FIGS. 4 and 4A. This creating of the protective covering into the desired areas of the various garments is accomplished in the following manner.
[0037] The protective covering 42 is preferred to be of a thermoplastic material, such as plastisol ink, which is considerably thicker than most graphic inks. The plastisol material will fuse rapidly into the garment fibers 44, 46 due to its fine particle structure. The temperature at which the plastisol material will attain a fluid state so that it will flow into the fabric of the garment is in the range of 150° F. to 200° F., but the temperature may be increased up to 330° F. The plastisol material is embedded into and between the fibers of the fabric by the use of a combination of the higher temperature and a high-pressure application. Once applied and following a time period sufficient for dispersion through the outer layer of the fabric of the garment and into an intermediate layer of the fabric, the thermoplastic material and the garment are cooled before the thermoplastic material can flow into and through all the layers of the fabric. The cooling process ensures that the plastisol material penetrates and embeds only within the outermost fabric fibers of the garment by flowing under and through the outer fibers 44 and under the cross-weave fibers 46, but not onto the inner surface of the garment shown by fibers 48. When cooled below the threshold temperature of 150° F., the plastisol material remains within the outer layers of fiber of the garment. In this manner, the thermoplastic material creates a non-porous liquid shedding covering along the outer surface of the garment and does not penetrate through all the layers of the fabric, such that direct contact with the skin of the user is avoided.
[0038] Alternatively, a heat transfer may be made by screen-printing plastisol ink on a special release paper. The “transfer” is then applied to the garment using a heat press that applies pressure and changes the state of the plastisol ink from solid to fluid so that it will flow and bond with the fibers of the garment, as it is pressed into the garment fibers 44 and cross-weave fibers 46 by the heat press. The heat applied by the heat press is maintained for a time period sufficient for the plastisol ink to liquefy and flow into and around the outer fibers 44, 46 of the fabric of the garment and is then removed to allow the plastisol material to cure by forming a permanent bond with the fabric fibers 44, 46., but the innermost fibers 48 of the garment. The permanently embedded protective covering 42 can be seen to entirely surround the outermost layer of the fabric, which consist of the individual fibers 44, and be seen to impregnate the individual cross-weave fibers 46, so that protective covering becomes one with the fabric and attains the same flexibility as the fabric of the garment. In this way the plastisol coating produces a non-porous covering that sheds liquids and prevents the penetration of liquids through the area of the covering on the garment.
[0039] In both methods of embedding of the protective covering 42 into the fibers of the garment, an edge portion 45 is formed along the outer edge of the protective covering 42. The edge portion 45 that is formed extends outward from the main body of the protective coating 42 creating a rib or ridge having an increased height and an extended width that coast together to prevent or retard the overflow of liquids splashed upon the outer surface of the protective covering 42 from flowing outward and being wicked into the garment fabric allowing the liquid to be, in most instances, wiped away. The edge portion 45 has a preferred height above the level of the protective coating 42 and the outer surface of the article of clothing in the range of 1-3 mm of increased height or thickness creating a barrier wall against outflow of liquids or liquefied materials. The edge portion 45 also has a preferred width for the barrier wall extending outward from the main portion of the protective coating 42 continuing the height of the edge portion 45 outward a distance in the range of 0.5 to 1.5 cm providing for a greater distance for any overflow to travel so as to be noticed and wiped away preventing any liquefied material from actually overflowing the edge portion 45 and being wicked into the fabric of the article being protected.
[0040] Referring now to FIG. 1, there is shown a garment 10 for an infant with leg openings 14, arm openings 16 and a neck opening 18. The garment 10 has a permanently embedded protective covering 12 thermally applied, as described above, directly onto the garment 10, beginning with the neck opening 18 of the garment and extending downward to approximately the mid torso area. Other areas, or an extension of the protected area shown, may also have the protective covering 12 added over and into the fabric of the garment 10. The garment 10 can be made from various materials, but is preferably made of a soft woven fabric. The protective covering 12 is liquid impervious (non-porous), non-toxic and flame retardant, and may hold debris temporarily, which can be easily wiped away with soap and water. Assisting in the temporary retarding of any liquid splashed upon the protective covering 12 from sliding or flowing outward onto the garment 10 is the edge portion 15 along surrounding the protective covering 12. The protective covering 12 is preferably opaque and can be a variety of colors, however, it may also be colorless in which case it would be translucent permitting the coloring of the garment to be seen through the covering 12.
[0041] Referring to FIG. 2, there is illustrated a t-shirt style garment 20 for a small child or infant with arm openings 26 and a neck opening 28. The garment 20 has a protective covering 22 beginning at the neck opening 28 of the garment 20 and extending downward to approximately the mid torso area. The garment 20 has a permanently embedded protective covering 22 thermally applied, as described above, directly onto the garment 20, beginning with the neck opening 28 of the garment and extending downward to approximately the mid torso area. Other areas, or an extension of the protected area shown, may also have the protective covering 22 added over and into the fabric of the garment 20. Assisting in the temporary retarding of any liquid splashed upon the protective covering 22 from sliding or flowing outward onto the garment 20 is the edge portion 25 surrounding the protective covering 22. The protective covering 22 has the same properties as described above.
[0042] In FIG. 3 there is shown a garment 30 for an adult that may be used as a chef's coat, smock or shirt, or be used by a healthcare professional. The garment 30 has a neck opening 38, arm openings 36 and a protective covering 32. The protective covering 32 begins at the neckline and extends downward ending approximately at the lower torso area. The garment 30 has a permanently embedded protective covering 32 thermally applied, as described above, directly onto the garment 30, beginning with the neck opening 38 of the garment and extending downward to approximately the mid torso area. Other areas such as the sleeves of the over blouse 30, or an extension of the protected area shown, may also have the protective covering 32 added over and into the fabric of the garment 30. Assisting in the temporary retarding of any liquid splashed upon the protective covering 32 from sliding or flowing outward onto the garment 30 is the edge portion 35 surrounding the protective covering 32. The protective covering 32 has the same properties as described above.
[0043] Another garment utilizing the protective covering of the invention is illustrated in FIG. 5 showing a garment 50 in the style of an infant's sleeper, with a permanently embedded protective covering 52, a neck opening 58, and a pair of arm openings 56. The protective covering 52 is shown beginning at the neck opening 58 and extending downward to and ending approximately at the lower torso area. As with the other types of garments, garment 50 has a permanently embedded protective covering 52 thermally applied, in accord with the method described above, directly onto the garment 50, beginning with the neck opening 58 of the garment and extending downward to and ending approximately at the lower torso area. Also, as above, other areas, or an extension of the protected area shown, may also have the protective covering 52 added over and into the fabric of the garment 50. Assisting in the temporary retarding of any liquid splashed upon the protective covering 52 from sliding or flowing outward onto the garment 50 is the edge portion 55 surrounding the protective covering 52. The protective covering 52 has the same properties as described above.
[0044] Another garment is illustrated in FIG. 6 that shows a different type of clothing. The article of clothing 60 is in the form of a child's overalls, or may be an adult worker's overalls, with a permanently embedded protective covering 62. The protective covering 62 extends from the top of the bib portion of the overalls downward to approximately the waist portion of the garment 60. As in the case of the other articles of clothing, garment 60 has a permanently embedded protective covering 62 thermally applied, in accord with the method described above, directly onto the garment 60. Also as above, other areas, or an extension of the protected area shown, may have the protective covering 62 added over and into the fabric of the garment 60. Assisting in the temporary retarding of any liquid splashed upon the protective covering 62 from sliding or flowing outward onto the garment 60 is the edge portion 65 surrounding the protective covering 62. The protective covering 62 has the same properties as described above.
[0045] Another article of clothing utilizing the method of the present invention, as illustrated in FIG. 7, shows a garment 70 in the form of an adult healthcare worker's uniform shirt or smock with a permanently embedded protective covering 72, a neck opening 78, and a pair of arm openings 76. The protective covering 72 extends from the seams joining the front and back sides at top of the garment 70 downward around neck opening 78 and farther downward to end approximately at the lower torso area. Assisting in the temporary retarding of any liquid splashed upon the protective covering 72 from sliding or flowing outward onto the garment 70 is the edge portion 75 surrounding the protective covering 72. The protective covering 72 has the same properties as described above.
[0046] FIG. 8 illustrates a garment 80 in the form of a dress with a permanently embedded protective coating 82, a neck opening 88, and arm openings 86. The protective covering 82 extends from the top portion of the dress downward to approximately the waist portion of the garment 80. As in the case of the other articles of clothing, garment 80 has a permanently embedded protective covering 82 thermally applied, in accord with the method described above, directly onto the garment 80. Also as above, other areas, or an extension of the protected area shown, may have the protective covering 82 added over and into the fabric of the garment 80. Assisting in the temporary retarding of any liquid splashed upon the protective covering 82 from sliding or flowing outward onto the garment 80 is the edge portion 85 surrounding the protective covering 82. The protective covering 82 has the same properties as described above.
[0047] A garment 90 shown in FIG. 9 is a man's tie with a permanently embedded protective coating 92. The protective covering 92 extends from the top portion of the tie downward over the outer surface of the tie to the bottom portion of the garment 90. As in the case of the other articles of clothing, garment 90 has a permanently embedded protective covering 92 thermally applied, as described above, directly onto the garment 90. Also as above, it can be envisioned that different areas of the tie may have the protective covering 92 added over and into the fabric of the garment 90. Assisting in the temporary retarding of any liquid splashed upon the protective covering 92 from sliding or flowing outward onto the garment 90 is the edge portion 95 along the folded side edge of the protective covering 92 along the front face of the tie 90 and at the bottom of the front face of the tie 90. The protective covering 92 has the same properties as described above.
[0048] FIG. 10 illustrates another garment 100 depicting a patient gown with a permanently embedded protective coating 102, a neck opening 108, and a pair of arm openings 106. The protective covering 102 extends from the top of the neck portion of the gown downward to below the waist portion of the garment 100. As in the case of the other articles of clothing, garment 100 has a permanently embedded protective covering 102 thermally applied, in accord with the method described above, directly onto the garment 100. Also as above, other areas, or an extension of the protected area shown, may have the protective covering 102 added over and into the fabric of the garment 100. Assisting in the temporary retarding of any liquid splashed upon the protective covering 102 from sliding or flowing outward onto the garment 100 is the edge portion 105 surrounding the protective covering 102. The protective covering 102 has the same properties as described above.
[0049] Garment 110, as illustrated in FIG. 11, is a medical practitioner's gown showing the permanently embedded protective coating 112, a neck opening 118, and a pair of arm openings 116. As depicted in FIG. 11, the protective coating 112 is applied, according to the methods described above, to multiple regions of the medical practitioner's gown. Specifically, the protective coating 112 extends from the neck portion of said gown downward to below the waste portion of garment 110. Additionally, the protective coating 112a is also applied to the arm portions of garment 110; extending from the wrist region of said gown upwards above the elbow portion of garment 110. Also as above, other areas, or an extension of the protected areas shown, may have the protective covering 112, 112a added over and into the fabric of the garment 110. Assisting in the temporary retarding of any liquid splashed upon the protective covering 112 and 112a from sliding or flowing outward onto the garment 110 is the edge portion 115 and 115a surrounding the protective covering 112 and encircling the upper edge of the protective coverings 112a along the arms of garment 110. The protective coverings 112 and 112a have the same properties as described above.
[0050] As in the cases of the previously described garments, the protective coverings 12, 22, 32, 52, 62, 72, 82, 92, 102, 112 and 112a are each positioned to extend over and protect that area or portion of the garment or article of clothing that is most likely to be spilled on, or to receive splatter or some other form of deposit of a foodstuff, or the deposit of a human bodily fluid that would normally dampen, in the case of infant saliva, or create an area of contact with the garment leaving on the garment some form of material that has splattered or spilled during eating or using the garment during the course of regular workplace routine. In each case the protective covering resists the adherence of solids and prevents the inward penetration of liquids by the non-porosity of the covering embedded in the garment, while allowing the easy wiping away of the majority of the spillage or spatter, and then the easier washing of the article of clothing to remove any remainder of the deposit. Assisting with the retaining of the spillage or splatter on the protective covering are the edge portions 15, 25, 35, 55, 65, 75, 85, 95, 105, 115 and 115a of the main protective coverings 12, 22, 32, 52, 62, 72, 82, 92, 102, 112 and 112a. The edge portions 15, 25, 35, 55, 65, 75, 85, 95, 105, 115 and 115a, by providing an increased height or thickness to the protective coating along its edges, as well as a predetermined width for the increased height or thickness, retard the outflow of the spilled or splashed material beyond the edges of the protective covering. The impermeability to liquids of the coverings 12, 22, 32, 52, 62, 72, 82, 92, 102, 112 and 112a through the non-porosity of the covering material as set into the fabric and the outflow retarding edge portion or ridge of material are believed to be unique to this invention.
[0051] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.
