Protective sanitary garment and method of manufacturing a protective sanitary garment

Abstract

An absorbent garment (FIG.2A:10) having a gusset assembly (FIG.3:12), comprising a crotch panel coupled together at their respective side edges and the crotch region of the garment, and a gusset panel

Description

Field of the Invention This invention relates generally to a protective sanitary garment and, more particularly, but not necessarily exclusively to a garment incorporating a protective sanitary gusset, particularly, but by no means exclusively, for use during menstruation and light vaginal leakages; the invention also relates to a method of manufacturing such a garment. Background of the Invention Sanitary products, such as tampons and sanitary towels, are well known and in widespread use throughout the world by women during menstruation to protect the gusset (and surrounding area) of their undergarments. Period pants also exist, which are, in general, washable and re-usable pants, having a protective gusset region, that can be used instead of (or alongside) the more traditional disposable products such as tampons and sanitary towels. In terms of the environment, re-usable sanitary products are obviously greatly advantageous because most, if not all, disposable sanitary products currently in widespread use are not fully or readily biodegradable, and / or involve a manufacturing process that is not eco-friendly. In the current climate, the widespread use of sanitary product that tend to end up in landfill and are not readily biodegradable is obviously undesirable. Nevertheless, re-usable sanitary products, such as period pants may not, on their own, provide sufficient protection, especially for heavy flows, and any leakage would be externally visible at the gusset (and surrounding) area of the wearer’s clothing. Accordingly, it is not unusual for a user to supplement a pair of re-usable period pants with a disposable product for extra confidence that such externally visible leakage will not occur. In some cases, re-usable period pants may not even be appropriate, because they can be seen through the user’s main clothing. This is particularly relevant for, for example, swimmers, dancers and gymnasts, who wear tight-fitting swimsuits / leotards, under which re-usable period pants would be clearly visible and, therefore, not very modest. In such cases, the user must rely on the more traditional disposable sanitary products, leaving them open to the risk of embarrassing leakage occurring in an area that may be readily visible to onlookers, for example, whilst performing their respective activities. Of course, this problem is not limited to sports (and similar) participants, and is relevant to anyone that wants to wear a tight fitting garment that may not lend itself to the use of re-usable period pants and, even if it does, they may tend to supplement their protection with disposable, non eco-friendly sanitary products to avoid embarrassment and staining of their clothing, not to mention the risk of externally discernible odours, during menstruation. Some people may even avoid performing certain activities during menstruation, in case of such embarrassing externally visible leakage and / or externally discernible odours. In addition to the menstruation period, some women may experience slight discharge during their day-to-day activities. Hence, they may have to rely on a disposable sanitary napkin ora pantylinerto feel comfortable throughout the day. Using disposable panty liners constantly can become a burden to the lifestyle with inconvenience and may cause irritation in the sensitive areas and health risks with long term constant wear. There is, therefore, clearly a need for a re-usable period sanitary product that offers sufficient protection in the gusset area to enable them to be used stand alone or without supplementing them with non eco-friendly disposable sanitary products, and aspects of the present invention seek to address at least one or more of these issues. Statements of Invention According to a first aspect of the invention, there is provided an absorbent garment having a gusset assembly comprising a crotch panel having a front portion and a rear portion coupled together at their respective side edges and the crotch region of said garment, and a gusset panel coupled to said crotch panel at said crotch region of said garment, said gusset panel comprising a first layer of absorbent or moisture wicking material, a second one or more layers of absorbent material, and a third, barrier, layer of water-resistant or waterproof material, wherein a pocket is defined between said first and second layers, said pocket having an opening at or adjacent said crotch region of said garment, said gusset panel further comprising a binding tape of waterproof or water-resistant material covering the edges of the gusset panel where said first, second and third layers thereof are coupled together. The layers of the gusset panel can be coupled together by any known means, such as bonding, stitching or welding, and the present invention is not intended to be limited in this regard. In an exemplary embodiment, the binding tape may extend beyond the edges of said gusset panel and over a portion of said crotch panel. Accordingly, the binding tape can extend beyond the edges of the gusset panel and along the leg hem of the garment, to offer extra leak protection at the edges of the gusset assembly. Although not necessarily essential, the pocket opening may conveniently be at the front of said garment, Beneficially, the binding tape covering the edge of the first layer adjacent the pocket opening may extend beyond the pocket opening by 0.5 - 3cm, and typically 1.25-2.5cm. This is intended to assist the user when inserting a separate, re-usable absorbent pad into the pocket. The user can hold the top (first) layer using the extended or wider binding tape, which is not just convenient, but also beneficial for sanitary reasons. An absorbent garment according to any of the preceding claims, wherein one or more of said layers of said gusset panel is / are coated with an antimicrobial finishing agent containing no silver or silver ions. Beneficially, the first layer of said gusset panel may comprise or include a layer of honeycomb mesh material or other engineered wicking structure, coated fabric, so as to ensure that any liquids, such as blood or vaginal secretions, are quickly absorbed and passed through to the absorbent second layer. The first layer may alternatively comprise a one-way wicking layer with an engineered knit or fabric structure to support liquid flow in (only) one direction. A separate re-usable or disposable absorbent pad may be provided to use as a back-up for an unexpectedly high level of discharge. The pad may, in use, be inserted into the pocket (via the pocket opening) when required. Accordingly, according to another aspect of the invention, there is provided an absorbent garment system comprising an absorbent garment substantially as described above, and a removable and an absorbent pad shaped and configured to, in use, be inserted into said pocket of said gusset panel. According to another aspect of the invention, there is provided an absorbent pad for use in the absorbent garment system substantially as described above, the pad comprising one or more absorbent fabric layers and a waterproof layer, said layers being coupled together at their respective side edges. The waterproof layer may, beneficially comprise a fabric fused with a plastics material which may, optionally, be covered, on at least one surface thereof, with a waterproof or water-resistant fabric. For example, the waterproof layer may comprise a polyurethane laminate material covered, on at least one surface thereof, with a waterproof or water-resistant fabric. Beneficially, a stiffening layer may be incorporated into the absorbent pad, between the waterproof layer and the absorbent layer, in order to aid the user in manoeuvring the pad into the pocket. In one exemplary embodiment, the pad may comprise one or more layers of moderate-high absorbent material, a stiffening layer next to the absorbent layer, a third layer of waterproof material, such as polyurethane film. A fourth layer of water resistant fabric may be provided over the waterproof material to act as a barrier for leakages and to protect the polyurethane (or other waterproof) film (which can be fragile). As an alternative to the stiffening layer, a malleable wire (for example, flexible boning wire or fishing wire) may be incorporated between the edges of the waterproof layer and an adjacent absorbent layer. Beneficially, a water-resistant fabric (or waterproof) binding tape may be provided around the and over the edges of the pad (where the absorbent layer(s) and waterproof / water-resistant layer(s) are coupled together. This provides further protection against leakages from the sides and offers better aesthetic appeal. As stated above, the pad may be disposable. However, in a preferred embodiment (from the perspective of the environment as well as cost and convenience to the user), the pad may be washable and re-usable. Beneficially, the pad may comprises a loop or tab at an outer edge thereof, to make it easier for the user to remove the pad from the pocket. These and other aspects of the invention will be apparent from the following detailed description. Brief Description of the Drawings Figure 1 is a schematic front view of an undergarment which may consists of functional gusset assembly. Figure 1B illustrates a garment according to an exemplary embodiment of the invention; Figure 2B is a schematic rear view of the garment of Figure 1B ; Figure 3 is a front perspective view illustrating the gusset pocket construction in the front of a garment, in between the functional gusset layers, according to an exemplary embodiment of the invention; Figure 4 is illustrates removable absorbent pads for use with a garment according to an exemplary embodiment of the invention; Figure 5 is a schematic exploded view illustrating the various layers of a gusset for a garment according to an exemplary embodiment of the invention; Figure 6 is a schematic top view of a gusset assembly of an absorbent garment according to an exemplary embodiment of the invention; Figure 7 is a schematic cross-sectional view of the gusset assembly of Figure 6; Figure 8 is a schematic top view of re-usable absorbent pad according to an exemplary embodiment of the invention; and Figure 9 illustrates a re-usable absorbent pad according to an exemplary embodiment of the invention. Detailed Description Referring to Figures 1 of the drawing illustrates the undergarment which consists of the said functional gusset embodiment, which can be incorporated in any garment. Referring to Figures 2A and 2 B of the drawings, in the illustrated embodiment, an example garment may comprise a bodysuit 10. However, other example garments may include (but are by no means limited to) leotards, underpants, cycling (or other) shorts, etc. The garment 10 comprises a gusset region 12. Referring now to Figure 3 of the drawings, the gusset region 12 is formed of multiple protective layers (to be described in more detail hereinafter) that, together, form a pocket (not shown) and the front of the gusset region 12 comprises an opening 14 to provide external access to the pocket defined within the gusset region 12. The pocket is configured to receive an additional absorbent pad 16, as shown in Figure 4 of the drawings, which is preferably (although not absolutely necessarily) washable and reusable. The additional absorbent pad 16 can be inserted into, and removed from, the pocket via the opening at the front of the gusset 14, as required. Referring now to Figure 5 of the drawings, the gusset region 12, including the above-referenced pocket, is formed of multiple (in this case, four) layers of material, with the option of adding a fifth layer in the form of the above-mentioned additional pad 16 into a pocket formed between two of the layers, via the above-mentioned opening 14. In the example illustrated, the gusset region (12 - Figure 1) may be formed of an outer layer 18 (furthest from the skin, in use), one or more mid layers 20, 22 and / or an inner layer 24 (nearest the skin, in use) with the pocket being formed between the inner layer 24 and its immediately adjacent mid layer 22. The outer layer 18 may be formed of the same material as the garment (10 - Figure 1) itself, and may even be formed integrally therewith, to avoid any unsightly seams or bonding joints externally visible on the garment. The outer layer would be the body material of the product. The material of the outer layer 18 may, at least to some extent, be dependent on the garment in question, but may, for example comprise a polyester elastane mix. Purely by way of example, this may comprise but not limited to 80 / 20 polyester / elastane of, say, around 280 gsm (again dependent, though, on the garment in question). On an alternative exemplary embodiment, the outer layer 18 may be formed of a mix of nylon and spandex and, in this case, purely by way of example, 80 / 20 nylon / spandex may be used, again of around, say, 280 gsm. The outer layer can also be of more environmentally friendly materials such as bamboo or Tencel variations. In any event, the outer layer 18 may be treated to improve moisture wicking. Appropriate such treatments will be apparent to a person skilled in the art and will not be discussed in any further detail herein. The outer layer 18 may be backed with a liquid resistant / proof backing material, such as polyurethane or the like, to further help to prevent leakage, although this is not deemed necessary in all embodiments, in view of the nature of the first mid layer 20 to be described hereinafter. The first mid layer 20, adjacent to the outer layer 18, may be formed of a thermoplastic elastomer, such as thermoplastic polyurethane of, say, around 100gsm (although the present invention is in no way intended to be limited in this regard). The first mid layer 20 may thus be formed of 100% polyurethane or, alternatively, treated polyester, for example, and is intended to be liquid proof as well as being resistant to oil, grease and abrasion, thereby in itself providing a ‘backing layer’ for the outer layer 18. The second mid layer 22, adjacent to the first mid layer 20, may, beneficially, be formed of an absorbent material such as Terry towelling or microfibre material, for example. In a specific exemplary embodiment, the second mid layer may be formed of 100% polyester of around, say, 245 gsm, it can also be made of absorbent nonwoven materials or super absorbent particle embedded materials, but the present invention is in no way intended to be limited in this regard, and other suitable absorbent materials will be apparent to a person skilled in the art. The thickness, level of absorbency of the layer and the gsm would depend on the type of product and the flow rates that it targets. Finally, the inner layer 24 is intended to quickly absorb liquids, such as blood and / or vaginal secretions, and ensure they are passed quickly through to the absorbent layer below (whether that is the second mid layer 22 or a removable pad inserted into the above-mentioned pocket (to be described hereinafter), to keep the adjacent skin dry as well as being comfortable against the user’s skin, especially if the garment is intended for use in an activity involving a lot of movement, and hypoallergenic in nature. Many suitable options may be apparent to a person skilled in the art, but in one preferred embodiment, the inner layer 24 may be formed of a honeycomb mesh material such made of a mix of polyester and nylon. Purely by way of example, 80 / 20 polyester nylon may be used of, say, around 165gsm, which may optionally have been treated with a polygiene or any sustainable antibacterial treatment. Such antibacterial treatments will be familiar to a person skilled in the art, and will not be discussed any further herein. The principal functions of the inner layer 24 are to keep the adjacent skin dry and comfortable, in use, and prevent odours, and many other suitable materials may be apparent to a person skilled in the art, such as bamboo lyocell jersey, bamboo viscose jersey, merino wool jersey or organic cotton jersey, and the present invention is not necessarily intended to be limited in this regard. However, an advantage of Merino wool and bamboo in particular is its natural antibacterial properties, such that the need / desire for any additional antibacterial treatment is mitigated. The outer layer 18 and the first and second mid layers 20, 22 are stitched, welded, glued or otherwise bonded together all the way around their respective side edges, to hold them together securely and prevent “bunching” during use. The shape of the gusset assembly is generally elongate, having a pair of opposing concave side edges (when viewed from the plan view illustrated in Figure 4 of the drawings) with a pair of convex, longitudinally opposing end edges. The width of the gusset assembly is greater at a first end 26 than at the opposing second end 28, and the radius of curvature of the second end 28 is less than that at the first end 26, the second end 28 defining the ‘front’ (i.e. the portion of the gusset assembly facing the front of the garment 10), and the first end 26 defining the rear. The inner layer 24 and the second mid layer 22 are glued, sewn or other wise bonded together along their respective side edges and first ends 26, leaving the second end 28 of the inner layer 24 open to form a pocket between the inner layer 24 and the second mid layer 22. The second end 28 of the inner layer 24 may be bonded / sealed, to form a neat, robust edge to protect the pocket opening. Indeed, the front end edge 28 of the second mid layer 22 may also be additionally bonded / sealed to form a neat, robust edge. The front edge of the inner layer is slightly extended (typically, for example, 1.25 -2.5cm) and covered with water resistant fabric to make it a secure edge for the user to hold while replacing the pad so that it provides better user experience and a cleaner approach to a used pad replace. This is illustrated in Figure 7 with a cross section of the gusset construction. The complete functional gusset and the outer body fabric of the product are secured at the edges with a water resistant fabric tape 29, as shown in Figure 6, being attached / stitched / bonded to the body of the fabric and this water resistant fabric tape will be attached along the leg hem of the underwear. This is intended to eliminate leakage from the sides of the gusset. However, the water resistant tape attachment along the hem depends on the type of garment this functional gusset is included in. The pocket formed between the inner layer 24 and the second mid layer 22 is designed to removably and replaceably receive another (optional) re-usable layer 16 of substantially the same size, shape and configuration as the other layers 18, 20, 22, 24, which i s beneficially formed of an absorbent material such as Terry towelling or microfibre material or super absorbent material, although other suitable absorbent materials will be apparent to a person skilled in the art. The removable layer 16 need not be re-usable, of course, although from an environmental perspective at least (and the reasons set out above in relation to disposable sanitary products), it is beneficially formed of a washable / re-usable absorbent material. As shown in Figure 8 of the drawings, a separate absorbent pad 35 has a construction is wherein there are one or more absorbent layers 30, a waterproof barrier layer made of PUL 32 and a water resistant fabric material 34, covering the PUL material. This construction enhances the durability of the separate pad. The separate absorbent pad should be sufficiently rigid to provide ease of handle and insertion. For this, a stiffening material 31 is provided in between the PUL layer and water-proof fabric material. Alternatively, a light, thin, flexible plastic boning wire could be inserted on the sides of the reusable pad. There is a small loop 36, as shown in Figure 9 of the draw made of waterproof fabric at the edge of the absorbent pad to make it easier to pull it out when replacing. The gusset assembly, comprising the outer layer 18, the two mid layers 20, 22 and the inner layer 24 is incorporated into a garment 10, such as a swimsuit, leotard, underwear, sports (or other) shorts, etc in the normal manner, with the outer layer 18 optionally (and, in practice, ideally) being formed integrally with the garment 10 itself. The garment 10 can be used with or without the addition of the removable pad 16 that can, if required, simply be inserted by the user into the above-described pocket of the assembly via the pocket opening 14, and removed (and, optionally, replaced) as required, again via the above-described pocket opening 14. At least the outer layer 18, first and second mid layers 20, 22 and the inner layer 24 are fully washable, such that the garment 10 in which the gusset assembly is incorporated can be washed and re-worn in the normal manner. It will be apparent to a person skilled in the art, from the foregoing description, that modifications and variations can be made to the described embodiments without departing from the scope of the invention as defined by the appended claims.

Claims

1. An absorbent garment having a gusset assembly comprising a crotch panel having a front portion and a rear portion coupled together at their respective side edges and the crotch region of said garment, and a gusset panel coupled to said crotch panel at said crotch region of said garment, said gusset panel comprising a first layer of absorbent or moisture wicking material, a second one or more layers of absorbent material, and a third, barrier, layer of water-resistant or waterproof material, wherein a pocket is defined between said first and second layers, said pocket having an opening at or adjacent said crotch region of said garment, said gusset panel further comprising a binding tape of waterproof or water-resistant material covering the edges of the gusset panel where said first, second and third layers thereof are coupled together.

2. An absorbent garment according to claim 1, wherein said binding tape extends beyond the edges of said gusset panel and over a portion of said crotch panel.

3. An absorbent garment according to claim 1 or claim 2, wherein said pocket opening is at the front of said garment,4. An absorbent garment according to any of claims 1 to 3, wherein said binding tape covering the edge of the first layer adjacent the pocket opening extends beyond the pocket opening by 0.5 - 3cm.

5. An absorbent garment according to any of the preceding claims, wherein one or more of said layers of said gusset panel is / are coated with an antimicrobial finishing agent containing no silver or silver ions.

6. An absorbent garment according to any of the preceding claims, wherein said first layer of said gusset panel comprises or includes a layer of honeycomb mesh material or other engineered wicking structure coated fabric, an / or comprises or includes a one-way wicking layer.

7. An absorbent garment system comprising an absorbent garment according to any of the preceding claims and a removable and an absorbent pad shaped and configured to, in use, be inserted into said pocket of said gusset panel.

8. An absorbent pad for use in the absorbent garment system of claim 7, the pad comprising one or more absorbent fabric layers and a waterproof layer, said layers being coupled together at their respective side edges.

9. An absorbent pad according to claim 8, wherein said waterproof layer comprises a fabric fused with a plastics material.

10. An absorbent pad according to claim 8 or claim 9, wherein the waterproof layer is covered, on at least one surface thereof, with a waterproof or water-resistant fabric.

11. An absorbent pad according to claim 10, wherein said waterproof layer comprises a polyurethane laminate material covered, on at least one surface thereof, with a waterproof or water-resistant fabric.

12. An absorbent pad according to any of claims 8 to 11, further comprising a stiffening layer.

13. An absorbent pad according to claim 12, when dependent on claim 10, wherein said stiffening layer is provided between said waterproof layer and said waterproof or water-resistant fabric.

14. An absorbent pad according to any of claims 8 to 13, wherein a malleable wire is incorporated between the edges of the waterproof layer and an adjacent absorbent layer.

15. An absorbent pad according to claim 14, wherein said malleable wire comprises a flexible boning wire or fishing wire.

16. A re-usable pad according to any of claims 8 to 15, further comprising a loop or tab at an outer edge thereof.

17. An absorbent pad according to any of claims 8 to 16, further comprising a waterproof or water-resistant binding tape covering the edges of the absorbent and waterproof layers where the are coupled together.

18. An absorbent pad according to any of claims 8 to 17, said pad being washable and re-usable.

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