Patent Publication Number: US-10314349-B2

Title: Seamless protective apparel

Description:
CROSS REFERENCE TO PRIOR APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 13/565,252, filed Aug. 2, 2012, now U.S. Pat. No. 8,715,452, which is incorporated by reference for all purposes, and which claimed priority and benefit under 35 U.S.C. § 119(e) from U.S. Provisional Application No. 61/521,646, filed Aug. 9, 2011. 
    
    
     BACKGROUND 
     Technical Field 
     This invention relates generally to protective apparel, and more particularly to protective apparel components suitable for use with medical gowns. 
     Background Art 
     Medical professionals frequently interact with patients who have communicable diseases. When treating such patients, the medical professional must take care not become infected or ill due to the microorganisms or pathogens related to the disease. This is frequently accomplished by donning a medical gown. These medical gowns are sometimes referred to as an “isolation gown.” 
     One problem associated with prior art medical gowns involves their construction. When multiple parts of the gown are sewn together, the resulting seam can act as a pathway for pathogens and other infections substances to pass through the medical gown. Such pathways put the medical services provider at risk of becoming ill. It would be advantageous to have a gown that overcomes some of the issues associated with prior art medical gowns. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention. 
         FIG. 1  illustrates a front elevation view of a protective garment configured in accordance with one or more embodiments of the invention. 
         FIG. 2  illustrates a rear elevation view of a protective garment configured in accordance with one or more embodiments of the invention. 
         FIG. 3  illustrates side elevation view of one embodiment of a seamless sleeve configured in accordance with one or more embodiments of the invention. 
         FIG. 4  illustrates a front elevation view of one embodiment of a seamless sleeve configured in accordance with embodiments of the invention. 
         FIG. 5  illustrates one method for coupling a barrier layer with textile material to form a seamless sleeve configured in accordance with one or more embodiments of the invention. 
         FIG. 6  illustrates one method for coupling a barrier layer with textile material to form a seamless sleeve configured in accordance with one or more embodiments of the invention. 
         FIG. 7  illustrates one method for manufacturing a sleeve in accordance with one or more embodiments of the invention. 
         FIG. 8  illustrates one circular knitting machine suitable for use in forming elements of embodiments of the invention. 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention. 
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     Embodiments of the invention are now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise: the meaning of “a,” “an,” and “the” includes plural reference, the meaning of “in” includes “in” and “on.” Relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, reference designators shown herein in parenthesis indicate components shown in a figure other than the one in discussion. For example, talking about a device ( 10 ) while discussing figure A would refer to an element,  10 , shown in figure other than figure A. 
     Embodiments of the present invention provide sleeves for a medical gown or other protective apparel that have no seams. The elimination of seams along the sleeves serves to protect a medical professional from coming into contact with pathogens and microorganisms carrying communicable diseases. As medical professionals generally interact with patients with their hands and arms, rather than other parts of their bodies, the inclusion of seamless sleeves in a medical gown eliminates a large majority of pathways between the patient and medical professional. This is true even when the seamless sleeves are sewn or otherwise joined to a body covering portion of a medical gown with seams, or where the body covering portion has seams. 
     In one or more embodiments, a textile material or fabric is constructed in a tubular form. Examples of explanatory constructions include weaving and knitting. For example, a circular knit fabric can be formed into the outer portion of a sleeve. A complementary circular knit fabric can be formed into an inner portion of a sleeve. An interior layer can then be extruded in a tubular fashion. The material for the interior layer can vary based upon application. Embodiments of the invention contemplate at least eight different types of materials that may be used for the interior layer: water resistant materials, water impermeable materials, chemical resistant materials, chemical impermeable materials, viral or bacterial resistant materials, viral or bacterial impermeable materials, vapor impermeable materials, and vapor permeable materials. For example, the interior layer may be vapor impermeable in some embodiments. Alternatively, it may be vapor permeable in other embodiments. It may be water resistant in still other embodiments, and water impermeable in other embodiments. Each embodiment can be extruded in a tubular configuration. To provide viral or bacterial impermeable properties, the interior layer can be coated or impregnated with antimicrobial or antiviral agents as well. Regardless of material used, the three components can then be laminated together to form a tubular, seamless construction. Seamless sleeves configured in accordance with one or more embodiments of the invention can be configured with multiple layers of textile material or barrier material as required by a particular standard or application. 
     Turning now to  FIG. 1 , illustrated therein is a protective garment  100  configured in accordance with one or more embodiments of the invention. For ease of illustration, the illustrative protective garment  100  shown throughout the views is configured as a medical gown. However, it will be clear to those of ordinary skill in the art having the benefit of this disclosure that the protective garment  100  could be configured in accordance with the needs of other professions, applications, and requirements. A medical gown is merely one explanatory embodiment. 
     A body covering portion  101  is configured to wrap about the torso of a wearer. In one embodiment, the body covering portion  101  is manufactured from a non-woven fabric. In another embodiment, the body covering portion  101  is manufactured from a woven fabric. In yet another embodiment, the body covering portion  101  is manufactured from a knitted fabric. The body covering portion  101  can optionally include and water resistant lining that prevents the passage of fluids through the body covering portion  101 . Where a non-woven fabric is used, the non-woven fabric can be a disposable material. Alternatively, where a woven, non-woven, or knitted fabric is used, body covering portion  101  can be configured for laundering and reuse. 
     Using non-woven fabrics as an example, the body covering portion  101  can be manufactured from spunbond-meltblown-spunbond material. Other materials can be used for the body covering portion  101 , including, for example, various woven, non-woven, hydroentangled materials, and/or combinations thereof, absorbent Airlaid, spunlace, blends of polyester, polypropylene, polyethylene, urethane, and/or combinations thereof, using various methods, including a spunbond metblown spundbond (SMS) method, a spunbond metblown metblown spundbond method (SMMS), and a spunbond metblown metblown spundbond method (SMMMS). Suppliers of such materials include Cardinal Health in Dublin, Ohio, Kimberly Clark in Neena, Wis., Molnycke Health Care in Newtown, Pa., and Precept Medical Products, Inc., in Arden, N.C. These materials and methods are illustrative only, as others will be readily apparent to those of ordinary skill in the art having the benefit of this disclosure. For example, one or more antimicrobial layers can be added to further enhance antimicrobial protection. Additionally, the material can optionally include a water resistant lining that prevents the passage of fluids through the material. In one embodiment, the length  113  of the body covering portion  101  is configured to run from at least a wearer&#39;s shoulder to below their knee. 
     A first sleeve  102  and a second sleeve  103  extend distally from the body covering portion  101 . The first sleeve  102  and the second sleeve  103  are configured to receive wearer&#39;s arms when the protective garment  100  is donned. As will be described below with reference to  FIGS. 3-6 , one or both of the first sleeve  102  and the second sleeve  103  comprise a knit layer having a inner side and an outer side and a seamless barrier layer coupled to one of the inner side or the outer side of the knit layer. 
     As shown in  FIG. 1 , protective garment  100  may optionally include pockets  117  or other surface features. A front portion  112  of the body covering portion  101  is configured to be placed against the front of the torso of a wearer. The body covering portion  101  then wraps around and terminates at a body opening  104  that is bounded by a first side  106  and a second side  107 . 
     In the illustrative embodiment of  FIG. 1 , the body opening  104  is configured as a slit that runs the length  113  of the body covering portion  101 , up the back of the protective garment  100 , terminating at a neck opening  105 . It will be clear to those of ordinary skill in the art having the benefit of this disclosure that the explanatory configuration of  FIG. 1  is illustrative only. For example, the protective garment  100  could be configured as a poncho in which it is pulled over the wearer&#39;s head as well. In this illustrative embodiment, the first side  106  and second side  107  of the body opening  104  are configured to permit the wearer to don the protective garment  100  by wrapping the first side  106  and second side  107  about the wearer&#39;s torso. 
     In one embodiment, one of the first side  106  or the second side  107  includes a coupling tab  108  that extends therefrom. The coupling tab  108  is configured to wrap about the wearer and span the body opening  104 . In one embodiment, the coupling tab  108  includes an adhesive  115  that is configured to attach to the non-woven material on the other side of the body opening. Where a coupling tab  108  is included, once the wearer dons the garment, the coupling tab  108  can be wrapped about the torso, such as about the wearer&#39;s waist, and adhesively affixed to the other side. 
     Turning now to  FIG. 2 , illustrated therein is a rear view of a protective garment  100  configured in accordance with embodiments of the invention. From this view, the body opening  104  and neck opening  105  can more readily be seen. Additionally, the coupling tab  108  and adhesive  115  may be seen extending from the first side  106  of the body opening. 
     As shown in  FIG. 2 , one coupling tab  108  is disposed approximately waist-high so as to span the body opening  104  to the second side  107  about the waist of the wearer. It will be clear to those of ordinary skill in the art having the benefit of this disclosure, however, other configurations are possible. For example, multiple coupling tabs could be employed. Additionally, the coupling tabs may be disposed at other locations along the body opening  104 , such as shoulder-high or mid-back. 
     Turning now to  FIGS. 3 and 4 , illustrated therein is one embodiment of a multilayer, seamless garment portion  300 , which in this embodiment is a sleeve configured for attachment to the body covering portion ( 101 ) of a protective garment ( 100 ) in accordance with embodiments of the invention. In this illustrative embodiment, the sleeve comprises at least a first layer  301 , and a seamless layer  302 . The first layer  301  of this embodiment is configured as a circular knit layer having an inner side  305  and an outer side  304 . The seamless layer  302  is configured as a seamless barrier layer that is one or more of eight materials: water resistant materials, water impermeable materials, chemical resistant materials, chemical impermeable materials, viral or bacterial resistant materials, viral or bacterial impermeable materials, vapor impermeable materials, and vapor permeable materials. Of course, combinations could also be used. While the second seamless layer  302  could be coupled to either the inner side  305  of the first layer  301  or the outer side  304  of the first layer  301 , in this illustrative embodiment the seamless layer  302  is coupled to the inner side  305  of the first layer  301  such that the circular knit fabric forms a soft, outer layer of the sleeve. When the first layer  301  is coupled to the second seamless layer  302 , a laminated tubular layer is formed. The laminated tubular layer of  FIG. 1  is configured to form a tubular garment portion. 
     The multi-layered seamless sleeve may also have a plurality of other layers as well. For instance, in this illustrative embodiment an optional third layer  303  is coupled to the second seamless layer  302 . The third layer  303  is coupled to the seamless barrier layer on a side opposite the outer circular knit fabric layer with the seamless barrier layer being disposed between the circular knit layer and the third layer  303 . Thus, when the third layer  303  is a circular knit layer, it forms a soft, interior of the sleeve or tubular garment portion. Additional barrier layers or textile layers can be added as applications warrant. In this embodiment, the three layers are laminated together to form a unitary sleeve. The sleeve is coupled to other garment portions, e.g., body covering portion ( 101 ) of  FIG. 1 , to form a complete garment such as a medical gown or other protective apparel. All three layers may be seamless. Alternatively, the circular knit layers may have seams with at least one of the barrier layers being seamless. In general the at least one seamless layer forms a barrier layer limiting unwanted material from passing from the outside of the barrier to the wearer of the garment. The circular knit layer(s) can provide structure to the garment where the barrier film layer is thin. The thickness of the barrier layer is a result of its function. The circular knit layer may also have wicking characteristics. Further, the circular knit layer may provide comfort to the user. 
     The first layer  301  may be made of material typically used in woven fabrics such as polyester, cotton, nylon or combinations thereof, or any other woven fabric material. As noted above, the material may also be non-woven or knitted. The first layer  301  can be woven together and laminated to the seamless layer  302 . The seamless layer  302  may be an extruded material, such as an extruded film or coating. In one embodiment, the sleeve tapers along a length  306  extending from a first end  307  to a second end  306 . The broader end of the taper can be attached to the body covering portion ( 101 ) of a protective garment ( 100 ) to form a sleeve. Elastic or other sleeve finishing elements may be coupled to the narrower end. 
     In one embodiment, the seamless layer  302  comprises properties that prevent unwanted substances from passing through the garment to the wearer. The seamless layer  302  can be any of eight different materials: water resistant materials, water impermeable materials, chemical resistant materials, chemical impermeable materials, viral or bacterial resistant materials, viral or bacterial impermeable materials, vapor impermeable materials, and vapor permeable materials. Of course, combinations could also be used. 
     In one embodiment, the seamless layer  302  can be configured to meet the PB70 Standard of the Association for the Advancement of Medical Instrumentation (AAMI). For example, the barrier layer may have a moisture vapor transmission rate (MVTR) that allows for comfort during wearing while still meeting the Spray impact test (AATCC42), Hydrostatic Pressure testing (AATCC127) and Viral Penetration testing (ASTM-F1671) guidelines. For medical applications the barrier layer has properties that prevent contaminants from passing through to the care giver. For example the barrier layer may be a polyurethane, PTFE, latex, PF latex, powdered latex, powdered vinyl, nitrile, PF vinyl, polyvinyl, or other synthetic material having vapor and moisture barrier characteristics that may be required by an applicable AAMI level. This allows the garment to perform as an infection protection measure. In one alternate embodiment, the first layer  301  has a seam. The third layer  303  may optionally have a seam as well. However, the seamless layer  302  of this embodiment is still seamless so as to meet applicable AAMI requirements. 
     The layers may be formed independently and then laminated together or they may be formed simultaneously, or at least substantially simultaneously and laminated together without steps in-between. In one embodiment, the first layer  301  and the seamless layer  302  are adhesively coupled together. In another embodiment, the first layer  301  and the seamless layer  302  are thermally bonded together. Other manufacturing techniques can be used as well. 
     In the illustrative embodiment of  FIGS. 3 and 4 , the first layer  301 , seamless layer  302  and third layer  303  are concentrically aligned with each other. The first layer  301 , seamless layer  302 , and the third layer  303  are also coextensive. The sleeve of  FIGS. 3 and 4  can be manufactured in a variety of ways. 
     Turning briefly to  FIG. 8 , in one example a seamless sleeve machine  800  may include circularly disposed material spools  801 , 802 , 803 , etc., that have material drawn into a circular knitting apparatus  804  to form a seamless, circularly knit layer  805 . In another process, the seamless layer can be formed by an extrusion process. The layers formed by the seamless sleeve machine  800  can be formed independently and subsequently coupled to one another. In one example, illustrated in  FIG. 5 , a first layer  503  is place on a form  550 . A layer of adhesive  551  is applied to the first layer  503 . Then a second layer  502 , which is the seamless layer in this explanatory embodiment, is placed over the adhesive coated first layer  503 . The adhesive  551  may be active upon application to the first layer or it may be activated after the second layer  502  is applied. For example, the adhesive  551  may be thermally activated, pressure activated or chemically activated. The adhesive  551  may be a two part adhesive, wherein a first adhesive part is applied to the first layer and a second adhesive part is applied to the second layer. Having an adhesive  551  that is later capable of actuation, post application, allows for placement and alignment of the second layer  502  on the first layer without the layers sticking prior to the desire configuration. The outer layer  501  can be applied in a similar fashion. 
     Turning to  FIG. 6 , illustrated therein is another knitting apparatus  600  configured to make seamless sleeves configured in accordance with embodiments of the invention in a single step. The knitting apparatus  600  can comprise a first and second circular knitting apparatuses that are concentrically aligned, with an extruder that is configured between the two circular knitting portions of the machine. All three layers  601 , 602 , 603  could then be concentrically and simultaneously formed in a coextensive arrangement. Said another way, the circular knit layers  601 , 603  and the extruded barrier layer  602  are all created substantially simultaneously. Once formed, they are continuously run  604  through a laminating portion  605  of the machine to be thermally or adhesively coupled together. While this illustrates one embodiment, it will be clear to those of ordinary skill in the art having the benefit of this disclosure that other embodiments are contemplated as well. For example, the process outlined above could also be done in separate steps. Moreover, the circular knit layers  601 , 603  could be knitted and finished and then laminated together. 
     Turning to  FIG. 7 , illustrated therein is a method  700  of making a sleeve for protective apparel in accordance with one or more embodiments of the invention. At step  701 , a circularly knit layer and seamless barrier layer are manufactured or formed. At step  702 , the seamless barrier layer is attached to the circularly knit layer to form a sleeve. The seamless barrier layer can be attached either to an inner side or outer side of the circularly knit layer. At optional step  703 , a second knit layer can be attached to the seamless barrier layer on a side opposite the side where the knit layer was attached in step  702 . At step  704 , the sleeve can be attached to a body covering portion to form a gown or protective apparel. 
     In the foregoing specification, specific embodiments of the present invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Thus, while preferred embodiments of the invention have been illustrated and described, it is clear that the invention is not so limited. Numerous modifications, changes, variations, substitutions, and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the following claims. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims.