Protective insert and a garment including such protective insert

Abstract

A protective insert (10) operatively attachable to an inner, body-facing layer of a garment. The protective insert generally comprises, a first, operatively inner layer (12) comprising a moisture-wicking, odour resistance, fluid absorbent fibre with or without a waterproof laminate-film; and a second, operatively outer layer (14) comprising a breathable, odour resistant, water repellent fibre to further prevent fluid passage through the garment; wherein the operatively inner layer faces the body of a user while the operatively outer layer faces away from the body of a user, in use.

Claims

1. A garment that absorbs up to 10 mls of body fluid in a single insult from a moisture leakage producing area of a wearer's body through to an exterior of the garment, the garment consisting of: a body-facing inner fabric layer configured to be disposed adjacent the moisture leakage producing area of a wearer's body and comprising a moisture-wicking, fluid absorbent natural fibre, a moisture-wicking, fluid absorbent fibre derived from a natural fibre, or a moisture-wicking, fluid absorbent synthetic fibre, or a combination of moisture-wicking, fluid absorbent natural and synthetic fibres in the form of a woven or knitted fabric having a thickness of less than about 2 mm and a fibre weight of between 100 gsm and 300 gsm, with or without a breathable fluid resistant laminate-film interposed between the inner fabric layer and an outer layer of the garment; wherein the outer layer of the garment comprises breathable, water repellent fibres of nylon or a polymer of polyester or polyamide elastane with a fibre weight of between 100 gsm to 300 gsm, the outer layer comprising a water repelling substance and having a thickness of less than about 2 mm; and wherein the garment dries from saturation in less than about 30 minutes.

2. The garment of claim 1, wherein the garment is a swimwear garment, an active wear garment, or a dance wear garment.

3. The garment of claim 1, wherein the fabric of the outer layer or each face of the fabric of the outer layer is treated with a water-repelling substance to prevent fluid passage through the garment.

4. The garment of claim 1, wherein the water repellent fibre of the fabric of the outer layer is treated with a water repellent hydrocarbon polymer treatment.

5. The garment of claim 3, wherein the water-repelling substance comprises perfluoroctanesulfonamide or a hydrocarbon polymer.

6. The garment of claim 1, wherein the fluid resistant laminate film is interposed between the inner and the outer layer.

7. The garment of claim 1, wherein the inner layer fabric is configured to be hydrophilic and/or contains a hydrophilic compound.

8. The garment of claim 1, wherein the inner layer fabric is selected to allow for the spreading and drying of 5-10 ml of moisture or bodily secretions in less than 5 to 10 minutes for drying each mL of moisture of bodily secretions per 10 cm×10 cm.

9. The garment of claim 1, wherein the inner layer fabric is pre-treated to enhance the moisture-absorbing or moisture-wicking capabilities thereof.

10. The garment of claim 1, wherein the inner layer fabric is in the form of natural fabric or a synthetic fabric selected from polyester or nylon.

11. The garment of claim 1, wherein the outer fabric comprises nylon, or a polyester or polyamide elastane polymer.

12. The garment of claim 1, wherein the inner layer is in the form of a nylon or polyester woven or knitted mesh fabric.

13. The garment of claim 1 which is a swimwear garment, wherein: the inner layer comprises a moisture-wicking, fluid absorbent nylon or polyester fibre in the form of a woven or knitted fabric; the outer layer comprises a water repellent nylon or polyamide elastane fabric, wherein the outer layer of the insert forms an outside layer of the garment; wherein a waterproof laminate-film is interposed between the inner and the outer layer; and wherein the outer layer is treated with a water-repelling substance to prevent fluid passage through the swimwear garment.

14. The garment of claim 1 which is an active wear or dance wear garment, wherein: the inner layer comprises a moisture-wicking, fluid absorbent nylon or a moisture-wicking, fluid absorbent polyester fibre in the form of a woven or knitted fabric; and the outer layer comprises a nylon or a polyamide elastane fabric, wherein the outer layer is treated with a water repelling substance to prevent fluid passage through the garment.

15. The garment of claim 14, wherein the outer layer of the insert forms an outside layer of the active wear or dance wear garment.

16. The garment of claim 13, wherein the outer layer of the insert forms an outside layer of the swim wear garment.

17. The garment of claim 1, wherein the moisture leakage producing area of a wearer's body is a crotch region.

18. The garment of claim 1, wherein the garment is machine launderable.

19. The garment of claim 1, wherein the moisture-wicking, fluid absorbent woven or knitted fabric comprises a polyester.

20. The garment of claim 1, wherein the woven or knitted fabric is a mesh.

21. The garment of claim 1, wherein the water repelling substance comprises a hydrocarbon polymer.

22. The garment of claim 1, in the form of a swimwear garment, wherein: the inner layer is associated with a breathable waterproof laminate-film on an outer part of the inner layer for additional waterproof effect; and the outer layer comprises nylon or polyamide elastane, whereby the outer layer or each face of the outer layer is treated with the water repelling substance to prevent fluid passage through the garment.

23. The garment of claim 22, wherein: the inner layer is a wicking knitted polyester fabric with a waterproof laminate to prevent fluid passage through the garment; and the outer layer or each face of the outer layer is treated with a synthetic hydrocarbon polymer treatment and is extended to form a body of the swimwear garment.

24. The garment of claim 22, wherein the outer layer has a thickness of about 1 mm or less, and the synthetic hydrocarbon polymer treatment is applied to front and back surfaces of the outer layer making it moisture repellent but air penetrable.

25. A garment in the form of an active wear, a dance wear or a swim wear garment that absorbs up to 10 mls of body fluid received in a single insult from a crotch area of the garment through to the garment exterior, the garment comprising: a body-facing inner layer in the crotch area comprising a moisture-wicking, fluid absorbent woven or knitted fabric comprising nylon or polyester having a thickness of less than about 2 mm and a fibre weight of between 100 gsm and 300 gsm, with or without a breathable fluid resistant laminate-film interposed between the inner layer and an outer layer of the garment; and wherein the outer layer of the garment comprises breathable, water repellent fibres of nylon or a polymer of polyester or polyamide elastane with a fibre weight of between 100 gsm to 300 gsm, the outer layer or each face of the outer layer treated with a water-repelling substance to prevent fluid passage through the garment and has a thickness of less than about 2 mm, wherein the garment dries from saturation in less than about 30 minutes.

26. A garment in the form of a swim wear garment that absorbs up to 10 mls of body fluid received in a single insult from a crotch area of the garment through to the garment exterior, the garment comprising: a body facing inner layer in the crotch area comprising a moisture-wicking, fluid absorbent woven or knitted fabric comprising nylon or polyester having a thickness of less than about 2 mm and a fibre weight of between 100 gsm and 300 gsm, with a breathable fluid resistant laminate-film interposed between the inner layer and an outer layer of the garment; and wherein the outer layer of the garment comprising breathable, water repellent fibres of nylon or a polymer of polyester or polyamide elastane with a fibre weight of between 100 gsm to 300 gsm, the outer layer or each face of the outer layer treated with a water-repelling substance to prevent fluid passage through the garment and has a thickness of less than about 2 mm, wherein the garment dries from saturation in less than about 30 minutes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The description will be made with reference to the accompanying drawings in which:

(2) FIG. 1 is a top plan view of an inner groin area of a protective swimwear or dance leotard in accordance with one aspect of the invention, showing the two layers of an insert in accordance with one aspect of the invention;

(3) FIG. 2A is a front view of a swimwear bikini bottom in accordance with one aspect of the invention;

(4) FIG. 2B is a rear view of swimwear bikini bottom in accordance with one aspect of the invention;

(5) FIG. 3A is a rear view of swimwear full piece or dance leotard in accordance with one aspect of the invention;

(6) FIG. 3B is a front view of a swimwear full piece or dance leotard in accordance with one aspect of the invention.

(7) FIG. 4 is a front view of a swimwear maternity top, in accordance with one aspect of the invention.

DESCRIPTION OF EMBODIMENTS

(8) Further features of the present invention are more fully described in the following description of several non-limiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention to the skilled addressee. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. In the figures, incorporated to illustrate features of the example embodiment or embodiments, like reference numerals are used to identify like parts throughout.

(9) With reference now to the accompanying drawings, the invention provides for a quick drying, antibacterial, odour absorbing, breathable and protective insert 10 comprising a first, operatively (in use) inner layer 12, and an operatively (in use) outer layer 14, shown in the context of an article of active, dance or swimwear 18, best shown as a lower section of a bikini as represented in FIG. 2A.

(10) However, the skilled addressee will appreciate that the insert 10 can be used with a wide variety of garments, depending on requirements. As such, the insert 10 may be used with active wear, dancewear, swimwear and/or any other types of garments where such protective insert may find an application.

(11) The protective insert 10 is a slim (3 mm in thickness or less), wicking, moisture spreading, quick drying, antibacterial, breathable, comfortable water repellent insert, which can prevent leakages of up to 5-10 ml in a single insult. The swimwear 18 (including insert 10) is machine washable, obviating the need for hand washing, while being durable and capable of lasting as long as regular swimwear.

(12) The protective insert 10 and resultant swimwear 18 provide a comfortable and sustainable way to stay dry and fresh from light bladder leaks, menstrual overflow/spotting, discharge, and breastmilk leaks without the need for disposable liners, allowing women (and men susceptible to bladder leakage) to participate in swimming, dancing and exercise without fear.

(13) The inner (first) layer 12 comprises a slim synthetic material, commercially available under the brand name “Coolmax” or “Coolmesh”, which comprises polyester wicking fibres. Coolmax fibres are not round, but are slightly oblong in cross-section with grooves running lengthwise along the threads. They are manufactured in either a tetrachannel or hexachannel style. The series of closely spaced channels creates capillary action that wicks moisture through the core and out to a wider area on the surface of the fabric which increases evaporation.

(14) The Applicant has found much experimentation that a polyester wicking fibre like Coolmax or Coolmesh fabric has rapid moisture wicking (hydrophilic) and fast drying capabilities. Applicant has also found that that the polyester wicking fabric is highly absorbent, given that the fabric allows the moisture to rapidly spread over the entire surface, the fabric typically being capable of absorbing and retaining up to 10 ml for every 10 cm×10 cm area of the fabric of the inner layer 12. The absorption is further improved with a water laminate film on the bottom of the fabric.

(15) The polyester fabric forming part of the inner layer 12, is in the form of a mesh fabric. Applicant has found the mesh structure aids rapid drying, as the structure allows air to flow through the fabric and insert 10, thereby assisting in the drying process.

(16) Applicant has also found that the polyester fabric either combined with bamboo-charcoal fibres or impregnated or coated with odour absorbing compositions or treatment acts to absorb and eliminate unwanted odour caused by ammonia and body odour.

(17) The polyester fabric, in certain embodiments, may be further impregnated or coated with antimicrobial treatments, usually silver ion-based products, like Silpure® or UltraFresh®, or other commercially available antimicrobial compounds or compositions, or mixtures thereof, to further enhance the antimicrobial and/or odour eliminating capabilities of the polyester fabric.

(18) The polyester fabric, in certain embodiments, can also be fused to a waterproof laminate-film to support the absorbency and to give additional leak-proof capacity.

(19) In the embodiment shown in FIG. 1, the operatively outer fabric 14 comprises a nylon or polyester fabric generally having a thickness of 1 mm or less, commercially available, in this embodiment, as polyamide elastane. The fabric has a water repellent hydrocarbon polymer treatment, typically Aquapel® by Nano Tex®, on the front and back surfaces making it moisture repellent, thereby acting as a further barrier against leaks and, increasing the drying time by double in comparison to regular untreated active, dance or swimwear fabric after full submersion in water. However, this layer does allow for air penetration, which assists with drying the inner layer and ameliorating microbial growth.

(20) The first, inner, layer is sewn and/or fused onto the outer fabric as shown in FIG. 1.

(21) Turning now to FIGS. 2A and 2B, there is shown a pair of bikini bottoms that include a body 22, cut-outs for legs 24, and a general crotch area 26. The protective first layer of the insert 10 of the invention is sewn or fused to the outer fabric of the general crotch area 26 and extends sufficiently to cover crotch areas prone to accidental fluid leakage that may be experienced by a wearer.

(22) Turning now to FIG. 3, there is provided a full-piece swimwear or dance leotard garment 28. The garment includes a body 30, cut-outs 32 for wearer's legs, cut-outs 34 for a wearer's arms (not shown) and a cut-out 36 for a wearer's neck. The protective first layer is sewn or fused to the outer fabric of the general crotch area 38 and extends sufficiently to cover crotch areas prone to accidental fluid leakage that may be experienced by a wearer.

(23) Turning now to FIG. 4, there is provided a swimwear maternity top 40 for lactating women. The swimwear maternity top 40 includes a body 42, generally comprising two cups 44, and connecting straps 46. The protective first layer 12 of the insert 10 is sewn or fused to the inside of each cup 44 (and may in certain embodiments replace the cups 44 themselves in their entirety) and extends sufficiently to cover all areas prone to accidental fluid leakage experienced by a wearer.

(24) The skilled addressee will appreciate that the insert 10 is applicable to any type of garment or article of clothing, depending on user requirements. As such, the insert of the present invention extends to any suitable garment, including all dance, active and swimwear, such as leggings, upper body garments, etc.

(25) The Applicant is of the opinion that they have developed a protective insert and a line of active, dance and swimwear that can be worn during a woman's menstrual cycle or for pelvic floor support that protects against light bladder leakage or period flow (up to 10 ml). To this end, several experiments were conducted over a period of 4 months, as described below.

Experiment 1

(26) A polyamide elastane with 3M Scotchgard-treated fabric was soaked in pool water for 30 minutes and then washed by hand with a dab of laundry detergent and then dried. After drying, 10 ml of liquid was poured onto the garment to test that the fabric is still waterproof for longer than 15 minutes

(27) Water Repellent Durability

(28) Under 30 washes—Fail

(29) Over 50 washes—Pass

(30) Drying Speed

(31) Slow=2 hrs or more

(32) Moderate=1-2 hrs

(33) High=30 minutes-1 hr

(34) Very High=Less than 30 minutes

(35) TABLE-US-00001 Day 10 ml water Drying Speed 1 Passed 2 tests Very high 2 Passed 2 tests Very high 3 Passed 1 test Very high 4 Passed 2 tests Very high 5 Passed 1 test Very high 6 Passed 3 tests Very high 7 Passed 2 tests Very high 8 Passed 3 tests High 9 Passed 1 test High 10 Passed 2 tests High 11 Passed 2 tests High 12 Passed 2 tests High 13 Passed 1 test, High Failed 2 tests 14 Failed 1 test High 15 Failed 2 tests High 16 Failed 2 tests High

Experiment 2

(36) A polyamide elastic Aquapel by Nano-Tex fabric was soaked in pool water for 30 minutes and then washed by hand with a dab of laundry detergent and then dried. After drying, 10 ml of liquid is poured onto the garment to test that the fabric is still waterproof for longer than 15 minutes.

(37) Water Repellent Durability

(38) Under 30 washes—Fail

(39) Over 50 washes—Pass

(40) Drying Speed

(41) Slow=2 hrs or more

(42) Moderate=1-2 hrs

(43) High=30 minutes-1 hr

(44) Very High=Less than 30 minutes

(45) TABLE-US-00002 Day 10 ml water Drying Speed 1 Passed 3 tests Very high 2 Passed 3 tests Very high 3 Passed 3 test Very high 4 Passed 2 tests Very high 5 Passed 1 test Very high 6 Passed 2 tests Very high 7 Passed 2 tests Very high 8 Passed 3 tests Very high 9 Passed 3 test Very high 10 Passed 3 tests Very high 11 Passed 3 tests Very high 12 Passed 4 tests Very high 13 Passed 4 tests Very high 14 Passed 2 tests Very high 15 Passed 1 test Very high 16 Passed 3 test Very high 17 Passed 4 test Very high 18 Passed 1 test Very high 19 Passed 1 test Very high 20 Passed 3 test Very high 21 Passed 3 test Very high

Experiment 3

(46) From the above experiments it was found that a synthetic nylon or polyester fabric, treated with commercially available water repellent under the trade name Aquapel produced by Nano-Tex, was superior. This fabric was combined with a number of moisture-wicking fabrics to determine a fabric that offers superior moisture wicking properties (so that it feels dry following leakage), can hold the most fluid, and is most quick drying and dry to the skin.

(47) Wicking polyester mesh

(48) Moisture wicking nylon spandex

(49) Carbon-Polyester spandex

(50) TABLE-US-00003 Speed of Speed of drying when wicking Dryness level Absorption worn in sun Wicking 1 s Could hold 7 ml 20 ml 28 minutes polyester and still feel mesh semi-dry to touch Wicking 1 s Could hold 7 ml 15 ml 25 minutes polyester and still feel mesh semi-dry to touch Wicking 1 s Could hold 5 ml 20 ml 29 minutes polyester and still feel mesh semi-dry to touch Moisture 3 s Could hold 2.5 ml 5 ml 26 minutes wicking and still feel nylon semi-dry to spandex Moisture 2 s Could hold 2.5 ml 7 ml 22 minutes wicking and still feel nylon semi-dry to spandex Moisture 3-4 s   Could hold 3.5 ml 10 ml 25 minutes wicking and still feel nylon semi-dry to spandex Carbon- 1 s Saturation Low, water 15 minutes Polyester pools spandex Carbon- 1 s Saturation Low, water 17 minutes Polyester pools spandex Carbon- 2 s Saturation Low, water 20 minutes Polyester pools and spandex leaked off the edge

Experiment 4

(51) A synthetic Aquapel fabric was made into swimwear with a gusset layer of wicking polyester mesh fabric without waterproof laminate. The garment was soaked in pool water for 30 minutes and then washed by hand with a dab of laundry detergent and then dried. After drying, 10 ml of liquid was poured onto the garment to test that the fabric can hold the liquid without leaking through the bottom and to test how long the garment takes to dry. 50 tests were performed to ensure durability of garment.

(52) Water Repellent to Hold 10 ml

(53) Fail

(54) Pass

(55) Drying Speed

(56) Slow=2 hrs or more

(57) Moderate=1-2 hrs

(58) High=30 minutes-1 hr

(59) Very High=Less than 30 minutes

(60) TABLE-US-00004 Day 10 ml water Drying Speed 1 Passed 3 tests Very high, very high, Very high 2 Passed 3 tests Very high, very high, Very high 3 Passed 3 test Very high, very high, Very High 4 Passed 2 tests Very high, very high 5 Passed 1 test Very high 6 Passed 2 tests Very high, Very High 7 Passed 2 tests Very high, very high 8 Passed 3 tests Very high, Very High, Very high 9 Passed 3 test Very high, VH, VH 10 Passed 3 tests Very high, VH, VH 11 Passed 3 tests Very high, very High, Very high 12 Passed 4 tests Very high, very high, very high 13 Passed 4 tests Very high, very high, very high 14 Passed 2 tests Very high, very high 15 Passed 1 test Very high 16 Passed 3 test Very high, Very high, Very high 17 Passed 4 test Very high, Very high, Very high, Very high 18 Passed 1 test Very high 19 Passed 1 test Very high 20 Passed 3 test Very high, Very high, Very high 21 Passed 3 test Very high, Very high, Very high

Experiment 5

(61) Because Nano-Tex is only water repellent when not fully submerged in water to further leak proof a swimwear garment when it was wet it was decided a layer of waterproof laminate was required. A synthetic Aquapel fabric was made into swimwear with a gusset layer of wicking polyester mesh fabric with waterproof laminate. The garment was soaked in pool water for 30 minutes and then 10 ml of liquid was poured onto the garment to test that the fabric can hold the liquid without leaking through the bottom. 50 tests were performed to ensure durability of garment.

(62) Water Repellent to Hold 10 ml

(63) Fail

(64) Pass

(65) Drying Speed

(66) Slow=2 hrs or more

(67) Moderate=1-2 hrs

(68) High=30 minutes-1 hr

(69) Very High=Less than 30 minutes

(70) TABLE-US-00005 Day 10 ml water Drying Speed 1 Passed 1 tests Very high 2 Passed 1 tests Very high 3 Passed 1 tests Very high 4 Passed 2 tests Very high, very high 5 Passed 1 test Very high 6 Passed 1 test Very high 7 Passed 1 test Very high 8 Passed 5 tests Very High × 5 9 Passed 1 test Very high 10 Passed 1 test Very high 11 Passed 3 tests Very high, very High, Very high 12 Passed 5 tests Very high, very high, very high, Very High 13 Passed 5 tests Very high, very high, very high, Very High 14 Passed 2 tests Very high, very high 15 Passed 2 tests Very high, very high 16 Passed 1 test Very high 17 Passed 1 test Very high 18 Passed 1 test Very high 19 Passed 1 test Very high 20 Passed 1 test Very high 21 Passed 1 test Very high 22 Passed 1 test Very high 23 Passed 1 test Very high 23 Passed 4 test Very high, very high, very high, very high 23 Passed 2 test Very high, very high 23 Passed 4 test Very high, very high, very high, very high

(71) The Applicant is of the opinion that they have invented an environmentally friendly, reusable, launderable, moisture and odour controlling, fashionable, comfortable active, dance or swimwear which is unobtrusive and discreet yet can absorb and prevent up to 10 ml of bodily fluids leaking through in the crotch or upper body area and which prevents penetration of moisture to the exterior of the garment. Advantageously, the combination of layers in accordance with the protective active, dance or swimwear results in a garment that is even quicker drying than regular active, dance and swimwear thus could be worn by any person seeking more comfort and more dryness in their active, dance and swimwear.

(72) Optional embodiments of the present invention may also be said to broadly consist in the parts, elements and features referred to or indicated herein, individually or collectively, in any or all combinations of two or more of the parts, elements or features, and wherein specific integers are mentioned herein which have known equivalents in the art to which the invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth. In the example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail, as such will be readily understood by the skilled addressee.

(73) The use of the terms “a”, “an”, “said”, “the”, and/or similar referents in the context of describing various embodiments (especially in the context of the claimed subject matter) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. No language in the specification should be construed as indicating any non-claimed subject matter as essential to the practice of the claimed subject matter.

(74) It is to be appreciated that reference to “one example” or “an example” of the invention, or similar exemplary language (e.g., “such as”) herein, is not made in an exclusive sense. Various substantially and specifically practical and useful exemplary embodiments of the claimed subject matter are described herein, textually and/or graphically, for carrying out the claimed subject matter.

(75) Accordingly, one example may exemplify certain aspects of the invention, whilst other aspects are exemplified in a different example. These examples are intended to assist the skilled person in performing the invention and are not intended to limit the overall scope of the invention in any way unless the context clearly indicates otherwise. Variations (e.g. modifications and/or enhancements) of one or more embodiments described herein might become apparent to those of ordinary skill in the art upon reading this application. The inventor(s) expects skilled artisans to employ such variations as appropriate, and the inventor(s) intends for the claimed subject matter to be practiced other than as specifically described herein.

(76) Any method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.