Abstract:
The invention provides protective garments that comprise a liquid impermeable garment body having an inner surface with first and second portions, an absorptive device associated with the first portion of the garment body, and fibers affixed to at least a part of the inner surface of the second portion of the garment body. The protective garment may further comprise a connector, and tubing. The tubing can be used for absorbing or draining fluids away from a person&#39;s body, or for transmitting fluids to a person&#39;s body.

Description:
CROSS-REFERENCE  
       [0001]    This application claims the benefit of U.S. provisional application Serial No. 60/429,647 filed Nov. 27, 2002 and is a continuation-in-part application of U.S. patent application Ser. No. 09/744,779, filed Jan. 26, 2001, which is a section  371  of International application no. PCT/IL99/00434, filed Aug. 7, 1999, which claims priority from Israeli patent application no. 125695, filed Aug. 7, 1998, the disclosures of which is incorporated herein by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to protective garments generally as well as to methods for manufacture thereof.  
         BACKGROUND OF THE INVENTION  
         [0003]    Various types of protective undergarments are known in the patent literature. The following patents and patent applications and the references cited therein are believed to represent the state of the art: U.S. Pat. No. 5,098,419; PCT Published Patent Application WO 96/36248 and European Patent 327,823.  
         SUMMARY OF THE INVENTION  
         [0004]    The present invention seeks to provide a protective garment which is 3D body fitting, body tight, generally lighter and more comfortable than conventional protective garments and which can be manufactured in large quantities at relatively low cost. The protective garment may be worn under other clothing, may be worn in a portion of the body without clothing or may be worn over clothing. As used herein, a “garment” refers to an undergarment or any article to be worn on the body such as a dressing. As used herein, a “dressing” includes, but is not limited to, any covering for a sore or wound or any opening in the body from which a body fluid is excreted or discharged, such as a bandage or nursing pad or any external treatment given through the skin, like pain relievers.  
           [0005]    There is thus provided in accordance with one embodiment of the present invention, a protective garment. In one embodiment, the protective garment is a protective undergarment. In another embodiment, the protective garment is a protective dressing. The protective garment may be used in a variety of applications including clothing applications or medical applications. The protective garment may include two portions: (1) a garment body (which may be integrally formed and which may be composed of a liquid impermeable material); and (2) an absorptive device or material (such as a pad) associated with the garment body.  
           [0006]    Preferably, the garment body may include a first portion which is formed with multiple perforations to permit passage of perspiration therethrough, and a second portion which may be substantially not perforated, so as to prevent passage of body secretions and medical dressings therethrough.  
           [0007]    In accordance with one embodiment of the present invention, the absorptive device or material is associated with the garment body at the second portion.  
           [0008]    In one embodiment, the second portion extends beyond the absorptive device or material. In alternate embodiment, the absorptive material or pad may extend beyond the second portion of the garment body.  
           [0009]    There is additionally provided in accordance with a preferred embodiment of the present invention a protective garment comprising an integrally formed garment body formed of a liquid impermeable material, the garment body including a first portion which is formed with multiple perforations to permit passage of perspiration therethrough, and a second portion which is substantially not perforated, so as to prevent passage of body secretions and medical dressings therethrough.  
           [0010]    Preferably, the liquid impermeable material is a natural elastomer like latex.  
           [0011]    Alternatively, the liquid impermeable material is artificial elastomer like silicone rubber or polyurethane.  
           [0012]    In accordance with an embodiment of the present invention, the garment body may have a thickness of less than 300 microns.  
           [0013]    Preferably, the protective garment also comprises an absorbent device or material associated to the undergarment body.  
           [0014]    The protective garment may be a brassiere, underpants, medical dressing or any other suitable garment or medical device.  
           [0015]    The protective garment may have fibers affixed to at least part of one surface of the garment body.  
           [0016]    In accordance with one embodiment of the present invention, the absorbent device or material includes a portion extending downward from the crotch along the thigh.  
           [0017]    There is additionally provided in accordance with a preferred embodiment of the present invention a method of manufacture of protective garments comprising the steps of forming a garment body of a liquid impermeable material, and forming multiple perforations on a first portion of the garment body to permit passage of perspiration therethrough.  
           [0018]    Additionally, in accordance with a preferred embodiment of the present invention, the method includes the step of affixing fibers to at least one surface of the undergarment body. For example, cotton fibers may be affixed to at least one surface of the undergarment body.  
           [0019]    In an alternate embodiment of the invention, the protective garment may include two portions: (1) a garment body and a connector (which may be integrally formed and which may be composed of a liquid impermeable material); and (2) tubing. The garment body may be worn on any portion of the body. One example of the portion of the body may include a portion of the face. Another example of the portion of the body may include a portion of the arm.  
           [0020]    The connector may be integral with the garment body. Or, alternatively, the connector may be separate from, but attached to, the garment body. The connector connects the tubing to the protective garment. Tubing may be used to absorb or drain liquid from or transmit liquid to the body. The garment body may be composed of a liquid impermeable material such as natural and artificial elastomers. Non-limiting examples of synthetic elastomers include polyisobutylene, isobutylene-isoprene copolymer (butyl elastomer), polyvinyl acetate, polyisoprene, polyethylene, vinyl acetate-vinyl laurate copolymers having vinyl laurate contents of about 5% to about 50% by weight of the copolymer, neoprene (polychloroprene), thermoplastic elastomers, nitrile rubber, synthetic latex (which has no proteins), styrenic elastomers, polyurethane, and silicone rubber, and combinations thereof. Non-limiting examples of natural elastomers include natural rubber such as smoked or liquid latex and guayule, and combinations thereof. Further, the garment body may include a portion which is formed with multiple perforations to permit passage of perspiration therethrough.  
           [0021]    The connector may be composed of a shape-retaining material, such as metal, plastic, a composite (e.g. of metal and plastic), or any other suitable material. Non-limiting examples of plastic include polyurethane, polyacrylamide, and polyvinyl chloride (PVC). The connector may have associated with it a material (for example, an absorbent material). The connector may fit with the tubing via a variety of ways, such as by a press fit, by threading on the connector, the tubing or both the connector and the tubing.  
           [0022]    A protective garment of the invention can also comprise colors (e.g. pigments or dyes) and/or fragrances (e.g. perfumes) in the liquid impermeable material and/or fibers. A color or fragrance can be added, for example, to an elastomeric emulsion before immersing a mold (which will give the protective garment its shape) into the emulsion. Furthermore, a protective garment of the invention can comprise embossed designs or patterns. The designs or patterns can be created by engraving a design in the garment mold. For example, if the protective garment is to be used by children, a teddy bear design can be created in the mold, thereby giving the garment a more attractive appearance to the user. Furthermore, the design can be created with different thicknesses within the same garment (e.g., by further dipping of the desired areas in the liquid latex (either pre- or post-vulcanized) or a synthetic elastomer precursor solution, or by applying coagulants on the mold before dipping, on the desired area to get a thicker result.) 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:  
         [0024]    [0024]FIGS. 1A, 1B,  1 C,  1 D,  1 E,  1 F,  1 G,  1 H and  1 I are illustrations of a method for producing protective garments in accordance with a preferred embodiment of the present invention; and  
         [0025]    [0025]FIG. 2 is a simplified illustration of protective undergarments produced generally by the method of FIGS.  1 A- 1 F in accordance with a preferred embodiment of the present invention.  
         [0026]    [0026]FIG. 3A is a simplified illustration of a medical protective garment.  
         [0027]    [0027]FIG. 3B is a simplified illustration of a sanitary brassiere (for nursing) or medical brassiere (to be used after breast surgery) garments.  
         [0028]    [0028]FIG. 4 is a simplified illustration of another medical protective garment.  
         [0029]    [0029]FIG. 5 is a simplified illustration of a medical protective garment with a garment body, a connector and tubing. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0030]    Reference is now made to FIGS. 1A, 1B,  1 C,  1 D,  1 E,  1 F,  1 G,  1 H and  1 I are simplified illustrations of a method for producing protective undergarments in accordance with a preferred embodiment of the present invention. The invention is described hereinbelow with reference to FIGS.  1 A- 1 I, with specific reference to underpants, it being appreciated that the invention applies equally to any other suitable garment (undergarment, garment worn over some other garment, or garment worn in conjunction with no other garment).  
         [0031]    As seen in FIG. 1A, a three dimensional garment form  10  is provided on which an array  12  of protrusions  14 , such as needles, is formed in the general shape of underpants to be formed. The protrusions  14  are preferably covered with TEFLON®. The crotch area  16  of the underpants is preferably not formed with protrusions  14 . The remained of the form  10  is preferably coated with a non-adhesion substance, such as TEFLON®. Otherwise perforations can be made by mechanical means (e.g., roller press).  
         [0032]    As shown in FIG. 1B, garment form  10  is preferably dipped in a liquid  17 , such as latex or silicone, which when allowed to dry, forms a stretchable, light weight garment  18  over array  12  and crotch area  16 . It may be appreciated that the provision of protrusions  14  causes the garment  18  to be perforated except at crotch area  16 . Thus the garment  18  is “breathable” except at the crotch area  16 , where it is liquid impermeable.  
         [0033]    Following dipping of garment form  10  into liquid  17 , the garment  18  may be rubbed with a mechanical device (not shown) in order to remove any superfluous elastomer material.  
         [0034]    In accordance with a preferred embodiment of the present invention, as illustrated in FIG. 1C, and absorptive pad  20  is associated with the light weight garment  18  at the crotch area  16 . However, the absorptive pad  20  can be extended beyond the crotch area if desired. It may be associated by the use of an adhesive or attached to the reminder of garment  18  by virtue of the fact that the latex is allowed to dry on the form  10  in engagement with the absorptive pad  20 .  
         [0035]    Prior to removal of the garment  18  from the form  10 , the exterior surface of the garment on the form  10 , which will eventually be turned inside-out to form the interior surface, is preferably sprayed with adhesive  22 , as shown in FIG. 1D and thereafter with cotton fibers  24  or any other suitable material as indicated in FIG. 1E, thereby to provide a comfortable and non-stick skin engaging surface. Preferably pad  20  is covered during the steps of FIGS. 1D and 1E with a cover  26 , which extends somewhat beyond the pad, so as to prevent liquid migration form the pad to the cotton fibers.  
         [0036]    The resulting garment  30  may then be removed from the form  10 , as seen in FIG. 1F and turned inside out. The outer surface of garment  30  may be coated or otherwise covered with cotton fiber or any other suitable material and finished in an appropriate manner.  
         [0037]    The completed garment  40 , as seen in FIG. 1G, is preferably extremely light weight, low cost, stretchable, underpants, which is perforated generally except at the specific areas mostly covered with the absorbent material and which is preferably integrally formed with an internal absorptive pad. The garment is preferably formed of an elastic material, such as latex or silicone, and has a thickness of less than 300 microns. In accordance with a preferred embodiment of the present invention, as seen in FIG. 1H, a tear region  42  may be incorporated in the garment, such as at a side thereof. This enables ease of removal of the garment, by tearing it at region  42 . Once removed the torn, worn garment may be disposed of, as illustrated in FIG. 1I.  
         [0038]    The final stage of manufacturing of the garment  18  may include a vulcanization process and edge-cutting of the garment, as known in the art.  
         [0039]    As can be seen from FIG. 2, the garment may be underpants  50 , a brassiere  60 , or any other suitable garment. It is noted that the pad  62  of the underpants  50  may have a portion which extend downwardly along the wearer&#39;s legs.  
         [0040]    Referring to FIG. 3A, there is shown a medical protection garment  70 . The medical protection garment may include a garment body  72 . A portion of the garment body (or the entire garment body) may be composed of an elastic material or a liquid impermeable material. Examples of materials may include latex or silicone. The garment body  72  may include straps  74  or other types of adjustment devices (such as snaps, clips, fasteners, or the like) in order to adjust the garment body so that it fits snugly or comfortably with the wearer. Some or all of the garment body may be perforated. A portion of the garment body (not shown in the figure) may be covered with material (such as cotton fibers), thereby to provide a comfortable and non-stick skin engaging surface. The medical protection garment  70  shown in FIG. 3A may be used to protect, bandage and treat a portion of the body, such as single breast, after a medical procedure (such as a breast surgery). The absorptive device or material associated with the garment body may include medical ointments, medicine for treatments or diagnostic materials. Referring to FIG. 3B, there is shown an alternate embodiment of the garment  76  showing a simplified illustration of a sanitary brassiere (for nursing when a woman is breast feeding) or medical brassiere (to be used after breast surgery) garments.  
         [0041]    Referring to FIG. 4, there is shown a simplified illustration of another medical protective garment  80 . The medical protective garment  80  may include a garment body  82 . A portion of the garment body (or the entire garment body) may be composed of an elastic material or a liquid impermeable material. Examples of materials may include latex or silicone. The garment body  82  may include straps  84  or other types of adjustment devices (such as snaps, clips, fasteners, or the like) in order to adjust the garment body so that it fits snugly or comfortably with the wearer. Some or all of the garment body may be perforated. A portion of the garment body (not shown in the figure) may be covered with material such as cotton fibers, thereby to provide a comfortable and non-stick skin engaging surface. As shown in FIG. 4, an absorptive material  86  is attached to garment body  82  while another portion of material  86  may not be attached to garment body  82 . The material  86  may be connected at various portions to the garment body. For example, the material  86  may be attached at two of its ends, one to the upper portion of the garment body  82  and the other to the lower portion of the garment body  82 . In this manner, a pocket may be formed. The medical protective garment  80  shown in FIG. 4 may be used on a limb, such as a foot, and may help in the treatment of those who suffer from diabetes.  
         [0042]    Referring to FIG. 5, there is shown a simplified illustration of a medical protective garment  90  with a garment body  92 , a connector  94  and tubing  96 . The garment body  92  and the connector  94  may be integrally formed. Alternatively, the garment body  92  and the connector  94  may be composed of separate pieces and may be attached to one another (such as by glue, fasteners or the like). The garment body may be composed of an elastic or liquid impermeable material. Similarly, the connector may be composed of an elastic or liquid impermeable material. The garment body  92  may be worn on any portion of the body. One example of the portion of the body may include on a portion of the face, as shown in FIG. 5. Another example of the portion of the body may include a portion of the arm, such as when a user requires Intravenous liquid.  
         [0043]    The garment body  92  may include a portion which is formed with multiple perforations to permit passage of perspiration therethrough. Further, the garment body  92  may include straps (not shown) or other types of adjustment devices (such as snaps, clips, fasteners, or the like) in order to adjust the garment body  92  so that it fits snugly or comfortably with the wearer. In the example shown in FIG. 5, the adjustment device may adjust to fit the head of the user.  
         [0044]    The connector  94  connects the tubing  96  to the protective garment  90 . Tubing  96  may be used to absorb liquid from or transmit liquid to the body. For example, as shown in FIG. 5, the tubing may be used for drainage from the body. Alternatively, tubing may be used to supply fluid or liquid to the body.  
         [0045]    The connector may have associated with it a material (for example, an absorbent material). In this manner, the tubing  96  may be connected to the connector  94  with less discomfort to the user. The connector may fit with the tubing via a variety of ways, such as by threading  98 . The threading may be on the tubing  96 , on the connector  94  or on both the connector  94  and the tubing  96 . Alternatively, the tubing  96  may be fit by a press fitting the tubing  96  with the connector  94 .  
         [0046]    It will be appreciated by persons skilled in the art of that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes variations and modification of the various features described in the specification and shown in the drawings which may occur to a person of ordinary skill in the art upon reading the foregoing description and which are not in the prior art.