AU2021354328A1

AU2021354328A1 - A fabric insert

Info

Publication number: AU2021354328A1
Application number: AU2021354328A
Authority: AU
Inventors: Kristy Chong
Original assignee: Modibodi Australia Pty Ltd
Current assignee: Modibodi Australia Pty Ltd
Priority date: 2020-09-30
Filing date: 2021-09-30
Publication date: 2023-05-18
Also published as: EP4221657A1; WO2022067392A1

Abstract

A fluid trapping core component which is fused to a leakproof barrier component by a stitch free leakproof seam, in a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin.

Description

A fabric insert

Field of the invention

The invention relates to a high performance moisture management fabric insert for a garment.

Background to the invention

Garments capable of managing bodily fluid leaks and secretions including blood and other vaginal discharge, urine, liquid faecal discharge, breast milk and sweat are rapidly becoming a preferred solution to one or more problems including unwanted wet marks or stains, leaks, odour. Such garments appeal to consumers not wishing to use disposable, bulky and uncomfortable liners and pads which often include plastic and non-recyclable material components. Although reusable pads and liners are also available, these products tend to be bulky, uncomfortable, visible through certain types of clothing, and tend to move around which may lead to staining or wetting of outer garments.

The present inventors have previous developed a protective insert attachable to a garment, the protective insert comprising: a first, operatively inner layer comprising a moisture-wicking fibre; a second, intermediate layer of a moisture absorbing material; and a third, operatively outer layer of a low-breathable, substantially moisture resistant material for protecting outer clothing in the event of a bodily discharge or inadvertent fluid leakage, and where by the fabric layers are sewn or fused together to form a fabric assembly. Such inserts are described in detail in Australian Patent No. 2014218471 and the technology is commercially referred to as Modifier Technology™. Whilst the Modifier Technology™ enables an excellent first-generation product which is perfect for management of bodily fluid volumes of up to about 20 mis without leaking, when volumes greater than about 20 mis are absorbed, the fluid or moisture held in the intermediate layer can leak out of the sides/edges of the insert which can cause embarrassment, odours, and/or stain damage to clothing. Thus, for users who require management of higher volumes of fluid, further innovative solutions are required with greater bodily fluid management capability which can handle larger fluid/moisture volumes without experiences leakage, in particular leakage from the sides of the insert, while not sacrificing the comfort, wearability and reliability associated with the first generation Modifier Technology™ products.

One aspect of the present invention provides an improved garment or insert for a garment which is capable of management of volumes of 20 mis or greater, 25 mis or greater 40 mis or greater without experiencing leaks, particularly side or edge leaks at the leg area or odour problems.

A reference herein to a patent document or any other matter identified as prior art, is not to be taken as an admission that the document or other matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims.

Where any or all of the terms "comprise", "comprises", "comprised" or "comprising" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components.

Statements of the invention

In a first aspect of the invention, there is provided a launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the fabric insert comprising as an assembly: the fluid trapping core component sandwiched between a fluid wicking component contactable against the wearer's skin and a leakproof barrier component for protecting the garment from fluid leaks from the fluid trapping core component, characterised in that edges of the fluid trapping core component do not align with the peripheral edges of the leakproof barrier component thereby providing a margin around the outer edges of the leakproof barrier component which is devoid of contact with the fluid trapping core component, wherein the fluid trapping core component is fused to the leakproof barrier component by a stitch free leakproof seam which includes the edges of the core therein and is positioned at peripheral edges of the fluid trapping core component where the edges of the core meet the leakproof barrier component, whereby the fluid wicking component is secured to the margin without interference with the fluid trapping core component in the seam, and whereby the stitch free leakproof seam in conjunction with leakproof barrier component retains trapped bodily fluid in the fluid trapping core component and forces wicked bodily fluid away from the edges deeper into the fluid trapping core component to prevent accumulation or pooling of trapped fluid at the edges of the fabric insert.

In a second aspect of the invention, there is provided A launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a polyester microfibre fabric fluid trapping core component of the insert, the fabric insert comprising as an assembly: the polyester microfibre fabric fluid trapping core component being at least one layer of a polyester microfibre fabric sandwiched between a merino wool fluid wicking component contactable against the wearer's skin and a polyester polyurethane laminate leakproof barrier component for protecting the garment from fluid leaks from the polyester microfibre fabric fluid trapping core component, wherein edges of the polyester microfibre fabric are fused to the polyester polyurethane laminate leakproof barrier component by stitchfree leakproof heat activated adhesive seam, which in conjunction with the polyester polyurethane laminate leakproof barrier component retains trapped bodily fluid the polyester microfibre fabric fluid trapping core component; characterised in that edges of the polyester microfibre fabric fluid trapping core component do not align with the peripheral edges of the polyester polyurethane laminate leakproof barrier component thereby providing a margin around the outer edges of the polyester polyurethane laminate leakproof barrier component which is devoid of contact with the polyester microfibre fabric fluid trapping core component, wherein the fluid trapping core component is fused to the polyester polyurethane laminate leakproof barrier component by a stitch free leakproof seam which includes the edges of the core component therein and is positioned at peripheral edges of the polyester microfibre fabric fluid trapping core component where the edges of the core meet the polyester polyurethane laminate leakproof barrier component, whereby the fluid wicking component is secured to the margin without interference with the polyester microfibre fabric fluid trapping core component in the seam, and whereby the stitch free leakproof seam in conjunction with polyester polyurethane laminate leakproof barrier component retains trapped bodily fluid in the polyester microfibre fabric fluid trapping core component and forces wicked bodily fluid away from the edges deeper into the polyester microfibre fabric fluid trapping core component to prevent accumulation or pooling of trapped fluid at the edges of the fabric insert.

In a third aspect of the invention, there is provided a garment having included therein a fabric insert according to the first aspect or the second aspect.

In a fourth aspect of the invention, there is provided an underwear garment having included therein a fabric insert according to the first aspect or second aspect.

In a fifth aspect of the invention, there is provided a garment having a bra cup having a fabric insert according to the first aspect or second aspect.

In a sixth aspect of the invention, there is provided a method of manufacturing a launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the method comprising providing a margin around the outer edges of the leakproof barrier component which is devoid of contact with the fluid trapping core component by overlaying a smaller fluid trapping core component on a provided larger leakproof barrier component, such that outer edges of the fluid trapping core component do not extend to the outer edges of the leakproof barrier component; forming a stitch free leakproof seam between the outer edges of the fluid trapping core component and the leakproof barrier component to form a fused component construct, wherein the stitch free leakproof seam includes the edges of the core therein; overlaying a fluid wicking component over the fused component construct and bonding the outer edges of the fluid wicking component to the margin of the leakproof barrier component to form a component assembly. Also described herein is a use of a fluid trapping core component which is fused to a leakproof barrier component by a stitch free leakproof seam, in a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin.

Also described herein is a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin, the insert comprising a fluid trapping core component which is fused to a leakproof barrier component by a stitch free leakproof seam, whereby the seam and the leakproof barrier component work together to retains bodily fluid trapped in the core component.

Also described herein is a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the fabric insert comprising, as an assembly: the fluid trapping core component sandwiched between a fluid wicking component contactable against the wearer's skin and a leakproof barrier component for protecting the garment from fluid leaks from the fluid trapping core component, wherein edges of the fluid trapping core component are fused to the leakproof barrier component by a stitch free leakproof seam which in conjunction with leakproof barrier component, retains trapped bodily fluid the fluid trapping core component.

Also described herein is a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the fabric insert comprising as an assembly: the fluid trapping core component being at least one layer of a polyester microfibre sandwiched between a fluid wicking component being merino wool contactable against the wearer's skin and a leakproof barrier component being a polyester polyurethane laminate for protecting the garment from fluid leaks from the fluid trapping core component, wherein edges of the fluid trapping core component are fused to the leakproof barrier component by stitch free leakproof heat activated adhesive seam, which in conjunction with leakproof barrier component retains trapped bodily fluid the fluid trapping core component.

Also described herein is a method of manufacturing a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin, the method comprising: overlaying a fluid trapping core component on a provided leakproof barrier component, wherein outer edges of the fluid trapping core component do not extend to the outer edges of the leakproof barrier component; forming a stitch free leakproof seam between the outer edges of the fluid trapping core component and the leakproof barrier component to form a fused component construct; overlaying a fluid wicking component over the fused component construct and bonding the outer edges of the fluid wicking component to the outer edges of the leakproof barrier component to form a component assembly.

Also described herein is a moisture management fabric insert obtainable by the method of the invention described herein.

Brief description of the drawings

Further features of the present invention are more fully described in the following description of several non-limiting embodiments included solely for the purposes of exemplifying the present invention. The following description is not a restriction on the broad summary, disclosure or description of the invention as set out above and is made with reference to the accompanying drawings in which:

Figure la is a cross-sectional view of a first embodiment of the fabric insert of the invention; and Figure lb is a cross-sectional view of a second embodiment of the fabric insert of the invention.

Detailed description of the invention

The present invention provides a bodily fluid management fabric insert for a garment for wicking bodily fluid away from a wear's skin (referred to hereinafter as a "fabric insert"). The fabric insert may be used with, or as part of, a garment, e.g., active or sportswear, underwear, maternity or breastfeeding garments or the like. Desirably, the garment is made from textile fabrics, that is, launderable fabrics. As such, the insert is hand or machine washable, and thus reusable. Suitably, the garment into which the insert is provided is not constructed of plastic and/or other materials such as those typically used in disposable sanitary products, e.g., polypropylene, polyethylene, wood pulp, paper pulp, rayon, viscose, etc.

A preferred embodiment provides a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin, the insert comprising a fluid trapping core component which is fused to a leakproof barrier component by a stitch free leakproof seam, whereby the seam and the leakproof barrier component work together to retain bodily fluid trapped in the core component. In particular, as an improvement over the original Modifier insert, the higher moisture capacity inserts of the invention do not experience leakage, particularly side or edge leakage at the legs, which is observed for the Modifier product over volumes of 20 mis and greater. This is because, the stitch free leakproof seam which includes edges of the fluid trapping core within the seam, operates in conjunction with leakproof barrier component, to retain the higher volumes of trapped bodily fluid in the fluid trapping core component. These components, in operation, force bodily fluid which accumulates or pools at the edges of the core/insert, away from those edges pushing that fluid deeper into drier areas of the fluid trapping core component. This results in a much safer insert which exhibits notably less side leakage than the Modifier insert at higher volumes of 20 mis or greater. To preserve the operational integrity of the stitch free leakproof seam, when attaching the wicking component and/or including the insert in a garment, stitching in the stitch free seam is avoided. Thus, a margin of a seam free area of the barrier layer beyond the seam outside the seam is provided to facilitate attachment of the wicking component to the barrier component, and where desired, the insert to a garment without risk of damage to the stitch free seam.

Advantageously, it has been found that using a stitch free leakproof seam as described herein supports a bodily fluid management capability of greater than 10 mis of the insert, and in some embodiments, volumes of up to at least 35mls of the insert and in some embodiment up to at least 50 mis of the insert. Such bodily fluid management capability is not possible with the equivalent closest prior art inserts which do not have the stitch free leakproof seam of the invention. Further advantageously, the stitch free leakproof seam used in the fabric insert of the invention results, not only in a superior fabric insert in terms of enhanced bodily fluid management capability, but also in terms of compactness of the insert at its peripheral edges where the seal is formed. The fabric insert of the invention may have thinner or less bulky edges that an equivalent prior art insert which does not have the stitch free leakproof seam of the invention. Using the stitch free leakproof seam translates to a much more comfortable fitting insert, particularly for an underwear garment, which comprises the fabric insert of the invention. This is the case where there is less bulk at the contact point between the edge of the insert and the user's inner thigh/groin and/or buttock areas. A further advantage is that the edges of the inserts may be less obvious in the final garment product leading to a more aesthetically pleasing product.

The fabric insert may be in the form of a fabric composite made up of several fabric layers intimately disposed together in a sandwiched configuration to form an insert assembly. A preferred fabric insert of the invention has a total maximum thickness of between 2 mm and 10 mm, preferably of no more than 5 or 6 mm, most preferably of no more than 3 mm. Advantageously, these thicknesses are the same as thicknesses of the Modifier insert. Thus, the wearer feels the same conform when using the insert of the invention as it achieved with the Modifier insert, despite the significantly higher volume capacity than the Modifier insert.

Depending on the nature of the chose core, a preferred fabric insert of the invention is capable of managing even greater volumes of bodily fluids than similar prior art solutions for fabric garments, e.g., the applicant's own Modifier Technology™ fabric insert which can manage bodily fluid volumes of up to and including 10 mis and in some cases, where more than two layers of core absorbent fabric are used in the Modifier insert, up to and including 20 mis without leaking.

Suitably, a preferred fabric insert of the invention can manage volumes of bodily fluid up to and including: at least 30 mis, at least 40 mis, at least 50 mis, at least 60 mis, at least 70 mis, at least 80 mis, at least 90 mis, at least 100 mis, at least 125 mis, at least 150, at least 175 mis, at least 200 mis, at least 250 mis, at least 300 mis, at least 350 mis, at least 400 mis, or at least 500 mis of the insert without leaking. Higher bodily fluid capacities are associated with thicker inserts, while lower bodily fluid capacities are associated with thinner inserts. For the average user, inserts with a thickness of up to 100mm can be worn without too much discomfort. Thinner inserts are however preferred due to higher wearability and comfort. Suitably, a preferred fabric insert of the invention can manage volumes of bodily fluid up to at least 30 mis, at least 40 mis, at least 50 mis, at least 60 mis, at least 70 mis, at least 80 mis, at least 90 mis, or at least 100 mis of the insert without leaking. These capacities are particularly preferred as they are associated with thinner inserts of thickness of about 10 mm or less. Suitably, a preferred fabric insert of the invention can manage volumes of bodily fluid up to and including 30 mis of the insert, and even up to and including 50 mis of the insert without leaking. In one embodiment, these volumes are associated with a fabric insert suitably sized for an Australian size 8 underwear garment, an Australian size 10 underwear garment, an Australian size 12 underwear garment, an Australian size 14 underwear garment, or an Australian size 16 underwear garment.

In preferred embodiments, a fluid trapping core component, which may have a single layer, two layers or multiple layers as described herein of absorbent fabric, preferred fabric inserts have a maximum fluid absorbency capacity, measured as a water absorbency in terms of ml/g of core component, of up to 0.5 ml/g, up to 0.65 ml/g, up to 0.85 ml/g, up to 1 ml/g, up to 1.5 ml/g, up to 2.0 ml/g, or up to 5.0 ml/g of the core fabric component. A maximum fluid absorbency capacity is one corresponding to the amount of fluid retained without leaking out of the fabric insert. These maximum fluid absorbency capacities can be arrived at through a combination of selection of fabric of the core as described herein, including gsm, number of layers of fabric in the core, etc. In one embodiment, these capacities can be achieved with a 240 gsm, more preferably with a 280 gsm, microfibre fabric as described herein, particularly when provided in the form of two or more layers.

In one embodiment, a fabric insert for an Australian size 12 underwear garment comprises a core comprising fabric weighing about 15.8 g, for example a single fabric layer of 240 gsm microfibre fabric. In one embodiment, a fabric insert for an Australian size 12 underwear garment comprises a core comprising two weighing about 27.8 g, e.g., a two-fabric layer core, each layer of 240 gsm microfibre fabric. In some embodiments, a single layer fabric insert for an Australian size 12 underwear garment has combined a surface area of about 16 cm² to 20 cm², preferably around 18 cm², when the surface area of the individual layers is combined. It will be appreciated that different sized inserts are possible, but the overall capacity will be similar for similar sizes where equivalent components are included. The capacity will be significantly more where more than one layer of core fabric is used.

The fabric insert of the invention is intended to provide a total replacement to disposable hygiene products conventionally used for moisture management. When used as an absorbent gusset in underwear, the fabric insert has sufficient bodily fluid management capability to absorb bodily fluids and particularly heavy body fluid such as menstrual blood flow e.g., around 50 mis or upwards, or urine leakages which can be anywhere up to 250 mis. This means the insert of the invention can be readily worn for long periods during the day and/or overnight (e.g., 8-12-24 hours). However, the fabric insert can absorb all manner of bodily fluids such as sweat, urine, blood, menstrual flow or vaginal discharge, liquid faecal discharge or other bodily discharges. Furthermore, a preferred fabric insert solves the problem of odours arising from bodily fluids as well as keeping the wearer's skin dry. A preferred fabric insert provides comfort and a good fit when incorporated into a garment, particularly underwear, as the insert for underwear which preferably has a thickness of 10 mm or less, and does not feel overtly bulky to the wearer, particularly at the juncture between the upper inner thigh and the groin where the sides of moisture management inserts can be directly felt by the wearer and may chaff and/or cause irritation. A preferred fabric insert of the invention is air permeable and/or breathable. A preferred fabric insert of the invention is hand and/or machine washable/launderable and reuseable.

A preferred fabric insert of the invention has antimicrobial and/or odour minimising properties. One or more components of the fabric insert can comprise an odour elimination treatment such as one or more of Sciessent Lava XI and Agion. Further, one or more of the components may include one or more hypoallergenic compounds. Suitably, one or more of the components may be pre-treated to enhance the hypo allergenicity thereof.

Suitably, the fabric composite comprises a fluid trapping core component for capturing, retaining and trapping bodily fluid wicked away from the wearer's skin. The fabric insert can wick bodily fluid away from a wearer's skin into a fluid trapping core component of the insert. The fluid wicking component is directly contactable against the wearer's skin when a garment comprising the insert is worn. When used correctly and within its maximum capacity limits, the fabric insert can prevent unwanted leaks of fluid from the fluid trapping core component onto the wearer's clothing. Suitably, the fabric composite comprises a leakproof barrier component. Desirably, the leakproof barrier component comprises a leakproof material and/or may be treated with a leakproof material or waterproofing substance which prevents fluid leaking through sides or a bottom part of the fabric insert onto the wearer's clothing. It will be understood that leakproof means leakproof against bodily fluid retained or trapped within the core of the insert. Leakproof therefore for the purposes of this disclosure can be equated with waterproof.

Various components as described herein may be selected and assembled together in a manner which supports bodily fluid management capability of volumes of greater than 20 mis, or at least 30 mis of the insert and more as described above. Preferably, various components are selected and assembled together to supports bodily fluid management capability of up to and including volumes of: 30mls, 50 mis or 100 mis of the insert.

Fabric Insert Assembly - Suitably, the fabric insert of the invention is a composite of several components, preferably each component being a fabric components associated together in the form of a fabric assembly. Preferably, the fabric components are provided as fabric layers in the assembly. In one embodiment, the fabric insert comprises at least three fabric components. In particular, the core component can have more than one layer of fabric. In one embodiment, the fabric insert comprises at least four fabric components. More components or subcomponents may be provided where higher bodily fluid management capability is required.

Suitably, the fluid trapping core component is sandwiched between a fluid wicking component and a leakproof barrier component for protecting the garment from fluid leaks from the fluid trapping core component. Suitably, the fluid wicking component is contactable against the wearer's skin. Suitably, the fluid wicking component is in direct fluid communication with the fluid trapping core component. Suitably, the fluid trapping core component overlays at least a portion of the leakproof barrier component in the assembly. Desirably, however, the edges of the core component and the barrier component are not aligned together. This is because the core component is smaller in dimension than the barrier layer. On assembly, this leaves a margin of the leakproof barrier to the outside of the stitch free leakproof seam. The margin is seam free. The margin can be used to attach/secure the fluid wicking component to the leakproof barrier component. In this way, the assembly can be fused and attached to a garment without interfering with or without causing damage to the leakproof seam e.g., through attachment means involving piercing or stitching. The margin can also be used to attach the insert to a garment if desired. The leakproof barrier component underlies or supports the fluid trapping core component in the assembly. Desirably, the outer edges or periphery of the fluid trapping core component are fused to the leakproof barrier component by a stitch free leakproof seam. Preferably, one or more portions of the stitchless seam are in the form of a stripe, that is, in the form of a band or tape shaped seam, preferably a long narrow band of seam. The seam can be uninterrupted in one or more areas, e.g., it can run circumferentially around the entire fabric insert, or it can run uninterrupted along the longitudinal (leg facing) sides of the fabric insert only which are most prone to leaking. The stitch free leakproof seam, in conjunction with leakproof barrier component, serves to retain trapped bodily fluid in the fluid trapping core component away from edges where leaking tendency is highest. The stitch free leakproof seam prevents bodily fluid leak from the periphery of the fluid trapping core component. This is achieved as the seam/barrier arrangement forces pooled or accumulated bodily fluid away from the core/insert edges deeper into the fluid trapping core component. This does not occur with the Modifier product which uses a stitched seam to hold the components together and where required attaches the insert to the garment whereby the stitching pierces the edges of the Modifier core. Fluid pooling or accumulating at core/insert edges of the Modifier insert can leak through the insert where the stitches are located. The improved seam of the invention provides a solution to the problem of side/edge leakage. Desirably, the stitch free leakproof seam is an internal stitch free leakproof seam located internally within the assembly of components. As such, preferably, the stitch free leakproof seam is not visible to the wearer in the final product. Suitably, the stitch free leakproof seam is not a stitched seam or other join type that requires piercing of any part of the fluid trapping core component. Pressure welding, ultrasonic welding, adhesive fusion, heat fusion can be used. In some embodiments, use of adhesive is preferred over pressure welding or ultrasonic welding.

In one embodiment, each of the fluid trapping core component, the fluid wicking component and the leakproof barrier component may have the same general shape. Suitably, the fluid wicking component and the leakproof barrier component may each have identical shape and dimensions as they are mated together in the assembly. Desirably, the fluid trapping core component has a smaller surface area/overall dimension than the leakproof barrier component which ensures the margin described above is formed. As such, the edges of the fluid trapping core component do not align with the peripheral edges of the leakproof barrier component. When the core is centred over the barrier layer, the outer edges of the fluid trapping core component do not extend all the way to match the outer edges of the leakproof barrier component. When the stitchless seam is formed over edges of the core component, this results in a border or a margin of the barrier component located outside/beyond the seam not in contact with the core such that the outer edges/periphery of the leakproof barrier component are devoid of contact with the fluid trapping core component. The border/margin thus formed is preferably in the form of a stripe, at least on each the leg facing sides of the insert, but instead may also be provided circumferentially around the insert. The stitch free leakproof seam includes the edges of the core within the seam. Desirably, at least the side/leg facing longitudinal edges of the core are included in a continuous stripe of seam. Ideally the core edges are centred within the seam for maximum security and leakproofing. Desirably, the seam is compressed whereby the seam compresses the edges of the core to the barrier component thereby smoothing and sealing the core edges to the barrier component.

In one embodiment, where the components are in layer form, preferably, the fluid trapping core component overlays the leakproof barrier component so as to form a stepped structure or configuration, preferably an upwardly stepped structure or configuration, comprising the edge of the fluid trapping core component where it contacts the leakproof barrier component underlying the fluid trapping core component. The upper step is formed from the fluid trapping core component, while the lower step is formed from the leakproof barrier component. Preferably, the stitch free leakproof seam bridges or overlays the stepped structure/configuration formed by centrally positioning the fluid wicking component over the leakproof barrier component. Suitably the stitch free leakproof seam may be substantially centred over the stepped structure. It is preferred that the stitch free leakproof seam does not extend to the outer edge of the leakproof barrier component. This preserves a border or a margin around at least part of the leakproof barrier component that is free of contact of the fluid trapping core component. This border or margin can be used to secure the fluid wicking component and the leakproof barrier component together to form the insert assembly without interfering with the fluid trapping core component. The margin can also be used to sew/fuse or otherwise attach the insert to a garment. Preferably, the stitch free leakproof seam overlays the stepped structure formed at the contacting edge between the fluid trapping core component and the leakproof barrier component. Desirably, the stitch free leakproof seam seals, flattens and smooths the stepped structure formed between the fluid trapping core component and the leakproof barrier component. In some embodiments, the stitch free leakproof seam may downwardly to compress the stepped structure formed between the fluid trapping core component and the leakproof barrier component, thereby flattening the stepped structure, so that the seam cannot be felt by the wearer during use. Preferably the stitch free leakproof seam is substantially centred over the stepped structure. The stitch free leakproof seam simultaneously fuses both component layers together and smooths the stepped structure. The stitch free leakproof seam may smooth the stepped structure by compressing the step structure. As the stitch free leakproof seam is a leakproof seam, bodily fluid in the core portion cannot leak out of the core as the edges are sealed. In the absence of the stitch free leakproof seam, bodily fluid in the core may readily leak out of the core due to structural nature of the unsealed stepped structure. Desirably, the stitch free leakproof seam does not extend to the peripheral edge of the leakproof barrier component, as it is desired that a portion of this margin may be used to stitch the fabric insert to a desired garment without puncturing the fluid trapping core component.

Preferably, the stitch free leakproof seam comprises a waterproof adhesive, preferably a band of waterproof adhesive such as a waterproof hot melt adhesive or a waterproof heat activated adhesive. Suitable waterproof adhesives are waterproof elastomeric thermoplastic adhesives such as those provided under the Bemis brand.

Desirably, fluid trapping core component comprises a single layer of an absorbent fabric or material, preferably an absorbent, quick drying fabric, most preferably an absorbent, quick drying microfibre fabric. Alternatively, the fluid trapping core component may comprise two or more layers of the absorbent fabric or material. Preferably, the two or more layers of absorbent fabric are laminated together, preferably by internal stitching, suitably at one or more locations remote from the stitch free leakproof seam. Desirably, this stitching is internal stitching which is not visible to the wearer in the final product. In one embodiment, the fluid trapping core component comprises two or more layers of absorbent fabric, an upper layer and one or more lower layers. Desirably, the one or more lower layers of the absorbent fabric have a smaller surface area (smaller dimensions) than the upper layer of absorbent fabric. Desirably, in a preferred assembly, only the upper layer of the core fabric is included in the stitch free leakproof seam. When assembled, the smaller dimensioned one or more lower layers are desirably provided between the upper layer of the core fabric and the fluid trapping core component. In other words, the lower layers are encased by the upper layer which alone is included in the stitch free leakproof seam. The lower layers do not form part of the seam itself. In other embodiments, the arrangement may be reversed where the one or more smaller dimensioned layers are provided over the layer of the fluid trapping core component that is included in the stitch free leakproof seam. The former arrangement is preferred as it is believed to lead to high comfort when worn due to an overall smoother feel.

When the insert is used in a bra, the insert adopts a generally bra cup shape. When the insert is used in underwear, the general shape of the fabric insert corresponds to the gusset shape of the underwear garment. In one embodiment, wherein the fabric insert is included in the gusset region of underwear, the fabric insert may adopt a generally longitudinal shape. In this embodiment, the fabric insert preferably has a head portion which, in use, sits at the front crotch area of the wearer, and a tail portion which, in use, sits at the rear crotch area of the wearer. The fabric insert preferably also has a longitudinal body portion between the head and the tail portions, whereby the longitudinal body portion has a left side and a right side which contacts the upper inner thigh of the wearer at the groin area. Preferably in this embodiment, the general shape of the fabric insert, from a top down or overhead view, a central body section which has a generally biconcave shape. Suitably, the biconcave shape may be capped on each straight end of the respective head and tail portions by a further section having an isosceles trapezoid shape. In this embodiment, a long edge of each trapezoid is positioned at each straight end of the biconcave shaped central body section. The biconcave body shape means the fabric inserts curves inwards at each respective concave part of the central body section. This results in a comfortable fit around the junction of the inner thigh and groin of the wearer. The comfort level is further enhanced by the stitch free leakproof seam as described herein, particularly those which are stitch free leakproof compressed seams. Advantageously, a compressed seam may be more comfortable around inner thigh and groin areas of the wearer than a seam which is not a compressed.

Suitably, in the assembly, the fluid wicking component and the leakproof barrier component have a complementary shape and/or overall dimensions to each other. Preferably, the fluid trapping core component may be of the same general shape but smaller in overall dimensions than each of the fluid wicking component and the leakproof barrier component. Each component may be considered as having a centrally disposed alignment point positioned at the intersection of a midway longitudinal line and a midway transverse line through each component. On assembly together, whereby the centrally disposed alignment points of each component are aligned, preferably at least the longitudinal edges of the fluid wicking component and leakproof barrier component align together. When the smaller fluid trapping core component is sandwiched between the fluid wicking component and the leakproof barrier component, the edges of the smaller dimensioned fluid trapping core component do not extend all the way to the edges of the fluid trapping core component and the fluid wicking component. This results in an assembly having border or a margin around the outer/peripheral edges of the fluid wicking component and leakproof barrier component which is free of the fluid trapping core component as desired above. Advantageously, a portion of this margin may be used to stitch the wicking layer to the barrier layer and also stich the assembled fabric insert to a desired garment without piercing, puncturing or otherwise damaging the fluid trapping core component. Since the fluid trapping core component does not comprise any stitches towards its peripheral edge region leakage through stitch holes is avoided. This has found to be a problem with many prior art inserts.

Fluid wicking component - Preferably, the fluid wicking component comprises an absorbent or otherwise moisture wicking fabric, more preferably an absorbent, quick drying fabric. Preferably, the fabric of the fluid wicking component is moisture-wicking, or the fabric is pre-treated to enhance the moisture-absorbing and/or wicking capabilities thereof. A moisture-wicking fabric wicks bodily fluid from the interface between the fluid wicking component and the fluid trapping core component to a location deeper within the fluid trapping core component. Moisture wicking relies on "capillary action," involving the movement of the bodily fluid through tiny spaces within a fabric due to the molecular forces between the liquid and the fabric's internal surfaces. When fluid is absorbed into the fibres of the moisture-wicking fabric, the moisture gets wicked away to drier parts of the fibre of the fluid wicking component, for example, which are in direct fluid contact with the fluid trapping core component. Preferred moisture-wicking fabrics dry rapidly so that the bodily fluid may not easily saturate the fabric.

Preferably, the fluid wicking component comprises a fabric which is derived from a natural fibre or a synthetic fibre. Natural fibres are preferred. Desirably, the fabric of the fluid wicking component may be hydrophilic or may comprise a hydrophilic material. Such materials may aid in wicking away bodily fluid away from the wearer's skin. Desirably, the fabric of the fluid wicking component may comprise keratinous fibres or other moisture-wicking or which are pre-treated to enhance the moisture-absorbing capabilities thereof. Preferred keratinous fibres are stain resistance. Otherwise, is desired, the fibres may be treated to render them stain resistant, with for example, Scotchguard™ or Teflon™.

Preferably, the fluid wicking component comprises a fabric comprising fibres selected from the group consisting of wool, preferably merino wool, or a cellulosic material, which is preferably selected from the group consisting of moisture wicking synthetic materials including moisture wicking polyester, hemp, bamboo, cotton, silk and any combination or organic variation thereof. A preferred cellulose-based fabric is commercially available under the trade names Moda™ orTencel™.

Preferably, the fabric of the fluid wicking component is in the form of a knitted or a woven fabric, preferably knitted.

Preferably, the fluid wicking component includes an antimicrobial material or itself comprises fibres having antimicrobial properties, for example, such as wool, preferably a soft wool such as merino wool. It will be understood that an antimicrobial material is one have antibacterial, antiviral, and/or antifungal properties. The antimicrobial property minimises, and more preferably eliminates, odour arising from the bodily fluid. Suitably antimicrobial materials include silver ions. Most preferably, the fabric of the fluid wicking component is in the form of a merino wool.

Desirably, the fluid wicking component is included in a weight range of 50 gsm to 500 gsm in the fabric insert. However, fluid wicking components in a weight in a range of 100 gsm to 350 gsm are preferred as less dense materials may feel more comfortable for the wearer. Fluid wicking components in a weight in a range of 125 gsm to 300 gsm are particularly preferred. In one embodiment, a fluid wicking component having a weight of 150 gsm to 200 gsm is preferred, and most preferably still, 180 or 190 gsm is preferred.

Desirably, the fluid wicking component has a thickness of between 0.5 mm and 5 mm, preferably of between 0.8 mm and 2 mm, most preferably < 1 mm.

Fluid trapping core component

Suitably, the fabric insert assembly comprises a fluid trapping core component. The fluid trapping core component may comprise a single layer of fabric, dual layers of fabric or even multiple layers of fabric. The fluid trapping core component may include a fabric comprising absorbent fibres and/or an absorbent compounds or materials such as a polymer gel which may be provided in fibre form. Most preferably the absorbent fabric is an absorbent and more preferably an absorbent and quick drying fabric.

The fluid trapping core component may comprise one or more microfibre materials. The fluid trapping core component may comprise one or more layers of an absorbent fabric, preferably an absorbent, quick drying fabric, more preferably an absorbent, quick drying microfibre fabric or woven or knitted fabric, such as SAF™ fabric. A preferred absorbent fabric may include hydrophobic fibres, such as terry or towelling fabric or bamboo or cotton towel. Preferred absorbent, quick drying fabrics may include hydrophobic, synthetic fibres. Absorbent, quick drying microfibre fabrics include a polyester microfiber, such as that commercially available under the trade name Zorb™.

Preferably, the fluid trapping core component comprises one or more layers of an absorbent fabric, preferably an absorbent, quick drying fabric, more preferably an absorbent, quick drying microfibre fabric. Preferably the adsorbent fabric is a wicking fabric such as a microfibre fabric, particularly a synthetic microfibre. Preferred microfibres have, e.g., fibres < 1 denier. Preferred fibres have a diameter of < 10 microns. Suitable microfibre fabrics may comprise polyester or polyamides (nylon, or conjugation of polyester and polyamide). Preferably, the microfibre comprises a synthetic fabric which comprises a mixture of synthetic fibres, such as a polyester/polyamide or polyester/nylon fabric. Alternatively, the fluid trapping core component may be manufactured from a cellulosic material, such as hemp, bamboo, cotton or combination of these fibres. In some embodiments, the fluid trapping core component may be manufactured from a keratinous compound, such as wool.

Desirably, the fluid trapping core component has a thickness of from 0.5 mm to 15 mm, from 1 mm to 10 mm, from 1 mm to 5 mm, from 1 mm to 3 mm, or from 1 mm to 2 mm. Depending on the desired level of bodily fluid management required, one or more fabric layers of the fluid trapping core component may comprise a denser or heavier fabric. For example, the fabric may be provided as a single layer of a fabric having a particular density or weight dictate the maximum bodily fluid absorption capacity of the fluid trapping core component. Alternatively, the core may be in the form of two or more individual layers of a fabric having a particular density or weight which in combination dictate the maximum bodily fluid absorption capacity of the fluid trapping core component. Suitably, where two are more layers of absorbent fabric are included, the two or more layers may be of the same absorbent fabric or material or different absorbent fabrics or materials. In some embodiments, where more than one fabric layer is used in the core, each layer may have the same density or weight or may have a different density or weight. A variety of different absorbent fabric layers which may of the same density or weight may be provided in the core. In a preferred embodiment, two or more layers of absorbent fabric may be provided in the core, particularly where an insert having higher bodily fluid management capability is required. For example, where a single layer of absorbent fabric may accommodate up to 15 mls/cm² of the insert of bodily fluid before saturation and leakage, two layers of that absorbent fabric may accommodate up to 25 mis of the insert of bodily fluid before saturation and leakage. Likewise, three layers of that absorbent fabric may accommodate up to 30 mis of the insert of bodily fluid before saturation and leakage, etc. It should be noted that there is a tradeoff between the higher bodily fluid management capacity and the overall thickness of the fluid trapping core component. It will be understood that the thicker the fluid trapping core component the less comfortable the insert may be to wear. One layer of a wicking fabric of a sufficient density, weight and/or thickness, may be sufficient in terms of bodily fluid management and comfortable fit. In some embodiments, two or more layers of a wicking fabric of a sufficient density, weight and/or thickness, may be sufficient in terms of bodily fluid management and comfortable fit.

Desirably, the fluid trapping core component may comprise one or more layers of absorbent fabric, each layer of absorbent fabric having a weight range of 100 gsm to 500 gsm in the fabric insert. However, a core in which each layer of absorbent fabric has a weight in a range of 100 gsm to 350 gsm are preferred, as less dense materials may be more comfortable for the wearer. In one embodiment, a preferred fluid wicking component has a fabric layer of a density or weight of 125 gsm to 300 gsm, more preferably 150 gsm to 300 gsm, most preferably 200 gsm to 300 gsm. Where higher bodily fluid management capability is required, it is preferred to use two or more layer of absorbent fabric with a lower gsm than a single layer of absorbent fabric with a higher gsm. For example, two fabric layers of 280 gsm would be preferred to a single fabric layer of absorbent fabric of 560 gsm. Most preferably still, a preferred fluid wicking component includes one or two layers of absorbent fabric each layer ideally having a fabric weight or density of 240 gsm, or 280 to 290 gsm. A single 240 gsm layer is favoured where bodily fluid capacity of up to and including 10 mis of the insert is required. Two individual 240 gsm layers are favoured where bodily fluid capacity of up to and including 30 mis is required. A single 280 gsm layer is favoured where higher bodily fluid capacity of up to and including 25 mis of the insert is required. Two individual 280 to 290 gsm layers are favoured where bodily fluid capacity of up to and including 50 mis of the insert is required. Likewise, a single 320 gsm layer is favoured where higher bodily fluid capacity of up to and including 35 mis of the insert is required. Two individual 320 to 350 gsm layers are favoured where bodily fluid capacity of up to and including 70 mis of the insert is required. Two individual 400 to 450 gsm layers are favoured where bodily fluid capacity of up to and including 100 mis of the insert is required. Desirably, in each of the preceding cases, these arrangements and bodily fluid capacity may be achievable with a total fabric insert thickness of about 1 cm.

Leakproof barrier component - Suitably, the fabric composite of the invention comprises a leakproof barrier component. Preferably, the leakproof barrier component comprises a waterproofed fabric which prevents movement of bodily fluids from the fluid trapping core component to outside the insert, particularly leakage at the longitudinal sides of the insert, thereby avoiding leakage of captured bodily fluid onto the wearer's clothing.

Preferably, the leakproof barrier component comprises a fabric which is itself waterproof. Desirably, the fabric may be treated with a waterproofing agent which may assist with waterproofing. In one embodiment, the leakproof barrier component may comprise a fabric which includes a film of waterproof polymer laminated as a backing onto the fabric. The film laminate makes the fabric moisture impenetrable. Suitable fabrics for lamination include polyester, nylon, cotton, bamboo, cellulose fabric such as Tencel, or any knitted or woven fabric. The waterproof polymer laminate renders the fabric of the leakproof barrier component impenetrable to the bodily fluid trapped or captured within the core of the insert assembly. For example, a film of polyurethane may be provided on a polyester fabric to waterproof the polyester fabric. Other polyurethane composites comprising other fabrics can be used. For example, a polyurethane backing can be provided as a backing on nylon or cotton fabric.

Other suitable waterproof polymer laminates include waterproof polymers such as silicon-based polymers including those available under the Huntsman, Rudolph brands. In other embodiments, a waterproof tape or sheet could be used as laminate layer. The outer surface of such fabrics may allow for air penetration, which may assist with drying the middle layers and ameliorating microbial growth and/or odours. Preferably, the barrier layer component is a polyester urethane laminate (PUL) fabric. PUL is a polyester fabric, backed with a waterproof laminate coating, i.e., a polyester/polyurethane laminate fabric. A particularly preferred barrier layer component is in the form of a polyester knit fabric bonded to a polyurethane, breathable and waterproofing film. Typically, a preferred leakproof barrier component have a thickness of about 1 mm.

Desirably, the leakproof barrier component is formed from a breathable fabric. A breathable fabric is one which allows water vapour generated from evaporation of perspiration and water from the trapped bodily fluid to diffuse to the outside of the fabric insert. It will be understood that the water vapour is evaporated by the wearer's body heat.

Suitably, the leakproof barrier component has a thickness in the range of between 0.1 mm and 2 mm, preferably between 0.2 mm and 1.5 mm. Preferably, the leakproof barrier component may have a thickness of between 0.1 mm and 2 mm, preferably between 0.2 mm and 1.5 mm, most preferably no more than 1.0 mm. In a particularly preferred embodiment, the leakproof barrier component comprises a polyester/polyurethane laminate fabric, for example, a 100% polyester knit fabric bonded to polyurethane breathable and waterproofing film, which generally has a thickness of 1 mm or less.

Leak proof seam - The composite fabric insert is provided in the form of an assembly of the fabric layers. Suitably, in the fabric assembly of the invention, the fluid trapping core component may be disposed between the fluid wicking component and the leakproof barrier component. Preferably, a special stitch free leakproof seam is positioned towards the peripheries of one or more component of the assembly of the fabric layers. It will be understood that the peripheries of the assembly are the parts at the assembly's border, fringe, margins, or edges. Suitably, the stitch free leakproof seam forms a leakproof barrier to prevent bodily fluid leaking out from the core of the insert onto the wearer's clothing.

Most preferably, the stitch free leakproof seam is a stitch free leakproof compressed seam. Thus, the stitch free leakproof seam is free of stitching or other join that requires piercing of any part of the fluid trapping core component. Suitably, the stitch free leakproof seam compresses, flattens, seals and/or smooths the edges of the fluid trapping core component to the leakproof barrier component. Desirably, the stitch free leakproof seam compresses the fluid trapping core component onto the leakproof barrier component. Suitably, the stitch free leakproof seam comprises a waterproof adhesive as a band or stripe of waterproof adhesive, e.g, a waterproof elastomeric adhesive film or tape.

In one preferred embodiment, the stitch free leakproof seam fuses the edges of the fluid trapping core component directly to the leakproof barrier component. "Fused" means the components are welded, bonded or otherwise joined together at an area having a stitch free leakproof seam. Desirably, at least one or more portions of fluid trapping core component and the leakproof barrier component, particular at the leg facing portions of the insert, are fused together by the stitch free leakproof seam. Preferably, the stitch free leakproof seam is positioned at, or towards, the peripheral edge of the fluid trapping core component which is the component of smallest dimension in the assembly.

In other embodiment, if desired, a further stitch free leakproof seam may fuse the fluid wicking component directly to the leakproof barrier component. Desirably, one or more portions of fluid trapping core component and the fluid wicking component are fused together by the stitch free leakproof seam. Preferably, the stitch free leakproof seam is positioned at, or towards, the peripheral edge of the fluid trapping core component which is the component of smallest dimension in the assembly. Desirably, the stitch free leakproof seam is provided at the edge of the smaller dimensioned fluid trapping core component where the fluid trapping core component contacts the larger dimensioned fluid wicking component, at the periphery of the fluid trapping core component where its edge contacts the leakproof barrier component. In this embodiment, the stitch free leakproof seams may simultaneously unite all of the fabric components together in the assembly.

Without being bound by any theory, it is believed that the stitch free leakproof seam used in the insert of the invention may enhance the comfort perceived by the wearer compared to inserts without the stitch free leakproof seam. This is because compared to an equivalent fabric assembly without the stitch free leakproof seam, for example, one having a stitched seam, the stitch free leakproof seam, particularly a stitch free leakproof compressed seam is thinner in the vertical dimension. In the case of underwear comprising the insert, this physically results in less bulk at the anatomical juncture between the wearer's inner thigh and groin area. Advantageously, this makes the inserts of the invention more desirable in terms of wearability than at least the Modifier inserts described herein without the stitch free leakproof seam described herein which has stitching instead. Further, it is believed that the stitch free leakproof seam enhances the bodily fluid management capabilities of the fabric insert compared to prior art inserts not having a stitch free leakproof seam. Without being bound by any theory, it is believed that the stitch free leakproof seam, particularly when provided at the longitudinal sides/edges of the fabric insert forces bodily fluid wicked away from the edge and preferentially deeper into the core, for example, towards the head and tail of the fabric insert in preference to an outwardly to the side directions. Therefore, it is believed that bodily fluid trapped in the core does not accumulate at the longitudinal sides/edges of the fabric insert as may occur in prior art inserts without the stitch free leakproof seam. This is believed to assist in superior bodily fluid management capabilities of the fabric insert of the invention.

The term "leakproof" may be used interchangeably with the terms waterproof, moisture proof, bodily fluid proof, etc., and means that bodily fluid trapped in the fluid trapping core component does not traverse the stitch free leakproof seam during normal use. "Normal use" means where the fabric insert is used for bodily fluid management of typical volumes of at least 35 mis of the insert, and in some embodiments, up to 500 mis of the insert as described above.

As described above, the fluid trapping core component is of smaller overall dimensions than the fluid wicking component and the leakproof barrier component. On assembly together, the peripheral edges of the fluid wicking component and leakproof barrier component align together. However, as the fluid trapping core component is smaller, the edges of the smaller dimensioned fluid trapping core component do not extend all the way to the edges of the leakproof barrier component and the fluid wicking component, resulting in a border or a margin around the peripheral edges of the fluid wicking component and leakproof barrier component which does not directly contact edge of the fluid trapping core component. Overlaying the fluid trapping core component on the leakproof barrier component results in formation of a stepped structure where the edges of the fluid trapping core component contacts the leakproof barrier component.

The stitch free leakproof seam may be circumferentially positioned at the peripheral edges of the fluid trapping core component where the edges of that component meets the leakproof barrier component of the insert. In other words, the stitch free leakproof seam may run uninterruptedly around the entire periphery of the fluid trapping core component at its edges which contact the leakproof barrier component of the fabric assembly. Alternatively, the leakproof seam can be provided interruptedly around only certain portions or parts of the peripheral edges of the fluid trapping core component, where its edges contact the leakproof barrier component. For example, where the insert is used in the gusset region of underpants, for example, in one such embodiment, the stitch free leakproof seam may be provided only towards the peripheral edges of the fabric assembly which are contactable against the upper inner thigh in the crotch region of the wearer, that is, the longitudinal edges of the fabric insert. In some embodiments, the stitch free leakproof seam may also run along the areas of the insert which contact the buttock area of the wearer during use. In preferred embodiment, the stitch free leakproof seam comprises at least one waterproof adhesive, preferably at least one waterproof hot melt adhesive or at least one waterproof heat activated adhesive. Desirable adhesives comprise at least one thermoplastic, preferably an elastomeric thermoplastic such as polyurethane.

A band of waterproof hot melt adhesive may have any desired width, for example, 12 mm or 16 mm width as long as it is positionable such that a seam free margin around the leakproof barrier component is retained. In one embodiment, the strip or a band of waterproof adhesive can be derived from a band of sealing adhesive tape, such as Bemis™ adhesive tape available from Bemis Associates inc. Desirably, Bemis 3415 tape is used.

"Fused" means the component parts are joined together via a join or seal. The join or seal may arise after initial assembly of the components to be joined with the adhesive sandwiched between the various fabric components, thereafter formation of the seal or weld at those areas through activation of the adhesive by appropriate activation means. For example, the seal or weld can be formed by heating desired areas of the assembled components to which adhesive has been applied, whereby applied heat melts the adhesive which softens or liquifies to penetrate into the fibres of the various fabric components.

Therefore, during manufacture, the leakproof seam may be formed from activation of the waterproof adhesive, preferably through heat activation of a waterproof hot melt adhesive or waterproof heat activated adhesive, for example, by a hot press or hot rollers or combinations thereof. In this embodiment, heating melts the adhesive to a more liquid state where the adhesive may interpenetrate between at least a portion of the fibres of the fabric components of the assembly. Before activation, such adhesives may be sandwiched in a desired location, for example, between each of the fluid trapping core component and the fluid wicking component, and the fluid trapping core component and leakproof barrier component in the assembly. On cooling, the adhesive between and around the fibres of the fabric solidly thereby forming a welded seal in which the various components are effectively fused together. Preferably, the adhesive interpenetrates between fibres of the assembled fluid trapping core component, the fluid wicking component and the leakproof barrier components. The interpenetration occurs when the adhesive is heat activated to melt. Heat activation results in the adhesive softening and/or liquifying to the degree that the adhesive interpenetrates between fibres of the assembled fluid trapping core component, the fluid wicking component and the leakproof barrier components. On cooling, the adhesive solidifies, binding the fibres and fabrics together in the form of the welded seal. If heat is applied in combination with pressure, for example, by passing the fabric and adhesive through a hot press or a hot roller, a leakproof welded compression seam may be formed. As the seal is a leakproof seal, it forms a barrier to passage to liquid from the bodily fluid.

While hot melt adhesive or heat activated adhesive have been used previous in garment manufacture, they are traditionally used for waterproofing seams for outer garments, e.g., rain coats or pants or trousers, for example. In such applications, the hot melt adhesive or heat activated adhesive is applied as a band or tape positioned directly over a stitched seam. This adhesive is activated by heat to waterproof the stitched seam which would otherwise result in water ingress through the stitched seam. In contrast, in the present invention, the adhesive is used to fuse components of the insert together in a manner that joins the components together but provides a leakproof seal at the edges of the components without using stitching to attempt to leakproof a seam. To the inventor's best knowledge, hot melt adhesive or heat activated adhesive have not been used to fuse components together into an assembly. Similarly, compressed seams whereby the edges of the thickness of the components after sealing to a degree that is not achievable through prior art assembly methods, such as stitching.

Single layer core - In one embodiment, the fluid trapping core component may comprise a single layer of an absorbent fabric, preferably an absorbent, quick drying fabric, most preferably an absorbent, quick drying microfibre fabric. In embodiments comprising a fluid trapping core component comprising a single layer of an absorbent fabric, preferred core component fabric layers have a weight/density from 280 gsm to 350 gsm and a thickness of from about 1 mm to 2 mm. In such embodiments, preferred fabric inserts have a maximum thickness of from 2 to 20 mm through a midline of the insert. In such embodiments, preferred fabric inserts have a maximum thickness of 5 to 15 mm through a midline of the insert. Preferred sealed thickness at the peripheral edge of the insert range from 1 mm to 15mm, preferably, 3 mm to 10 mm.

Multilayer core - In a particularly preferred embodiment, the fluid trapping core component comprises a laminate structure including two or more layers of an absorbent fabric, preferably an absorbent, quick drying fabric, most preferably an absorbent, quick drying microfibre fabric. For example, where two layers of absorbent fabric are used, that is, a lower layer and an upper layer of absorbent fabric, it is preferably that the upper layer has a smaller surface area than the lower layer. Preferably, the lower layer of the fluid trapping core component, the fluid wicking component and the leakproof barrier component each have identical shape and dimensions, however, the upper layer of the fluid trapping core component has a smaller surface area than the lower layer. In this arrangement, the peripheral edges of the upper layer of the fluid trapping core component having the smaller surface area than the lower layer are not included in the leakproof seam.

Inclusion of more than one layer of absorbent fabric in the fluid trapping core component dramatically increases the moisture management capabilities of the fabric insert compared to inserts having a single layer of absorbent fabric in the fluid trapping core component. By including at least one smaller surface area layer in the fluid trapping core component, this layer does not form part of the leakproof seam as the peripheral edges do not match the peripheral edges of the other components.

The one or more additional layers of absorbent fabric in the fluid trapping core component do not contribute to the thickness of the leakproof seam as they are not included in the seam due to their smaller surface area. Advantageously, in these embodiments, the moisture management capabilities of the fabric insert are significantly enhanced but at no cost to the comfort perceived by the wearer as there is no additional thickness to the seam at the peripheral edges of the fabric assembly which are contactable against the upper inner thigh in the crotch region of the wearer.

In embodiments involving a fluid trapping core component comprise a laminate structure comprising two or more layers of absorbent fabric, the two or more layer of absorbent fabric may be attached or joined together in one or more locations remote from the leakproof seam, preferably by stitching. Remote from the leakproof seam means the attachment or join does not overlap with the leakproof seam between the assembled components. For example, where two layers of absorbent fabric are provided in the core, the first layer and the second layer of the core component may be joined together, preferably by stitching. Suitably said stitching may be provided alone the centre line of the fluid trapping core component. Such attachment or joining may stabilise the fabric layers of the fluid trapping core component. Such attachment or joining may prevent undesirable disruption or separation of the fabric layers of the laminate structure during use or during laundering which could lead to reduced performance or comfort.

In preferred embodiments, a fluid trapping core component, which may have a single layer, two layers or multiple layers as described herein of absorbent fabric, preferred fabric inserts have a fluid absorbency, measured as a water absorbency in terms of ml/g of core component, of up to: 0.5 ml/g, 0.65 ml/g, 0.85 ml/g, 1 ml/g, 1.5 ml/g, 2.0 ml/g, or up to 5.0 ml/g of the core fabric component.

In preferred embodiments, preferred fabric inserts have a maximum central point thickness of up to 10 mm, up to 9 mm, up to 8 mm, up to 7 mm, up to 6 mm, up to 5 mm, up to 4 mm, up to 3 mm, up to 2 mm, up to 1 mm. In such embodiments, preferred fabric inserts have a maximum edge point thickness of up to 7 mm, up to 6 mm, up to 5 mm, up to 4 mm, up to 3 mm, up to 2 mm, up to 1 mm.

In a particularly preferred embodiment, there is provided a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the fabric insert comprising as an assembly: the fluid trapping core component being at least one layer of a polyester microfibre sandwiched between a fluid wicking component being merino wool contactable against the wearer's skin and a leakproof barrier component being a polyester polyurethane laminate for protecting the garment from fluid leaks from the fluid trapping core component, wherein edges of the fluid trapping core component are fused to the leakproof barrier component by stitch free leakproof heat activated adhesive seam, which in conjunction with leakproof barrier component retains trapped bodily fluid the fluid trapping core component.

The invention provides for use of a fluid trapping core component which is fused to a leakproof barrier component by a stitch free leakproof seam, in a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin. In another embodiment there is provided a launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a polyester microfibre fabric fluid trapping core component of the insert, the fabric insert comprising as an assembly: the polyester microfibre fabric fluid trapping core component being at least one layer of a polyester microfibre fabric sandwiched between a merino wool fluid wicking component contactable against the wearer's skin and a polyester polyurethane laminate leakproof barrier component for protecting the garment from fluid leaks from the polyester microfibre fabric fluid trapping core component, wherein edges of the polyester microfibre fabric are fused to the polyester polyurethane laminate leakproof barrier component by stitch free leakproof heat activated adhesive seam, which in conjunction with the polyester polyurethane laminate leakproof barrier component retains trapped bodily fluid the polyester microfibre fabric fluid trapping core component; characterised in that edges of the polyester microfibre fabric fluid trapping core component do not align with the peripheral edges of the polyester polyurethane laminate leakproof barrier component thereby providing a margin around the outer edges of the polyester polyurethane laminate leakproof barrier component which is devoid of contact with the polyester microfibre fabric fluid trapping core component, wherein the fluid trapping core component is fused to the polyester polyurethane laminate leakproof barrier component by a stitch free leakproof seam which includes the edges of the core component therein and is positioned at peripheral edges of the polyester microfibre fabric fluid trapping core component where the edges of the core meet the polyester polyurethane laminate leakproof barrier component, whereby the fluid wicking component is secured to the margin without interference with the polyester microfibre fabric fluid trapping core component in the seam, and whereby the stitch free leakproof seam in conjunction with polyester polyurethane laminate leakproof barrier component retains trapped bodily fluid in the polyester microfibre fabric fluid trapping core component and forces wicked bodily fluid away from the edges deeper into the polyester microfibre fabric fluid trapping core component to prevent accumulation or pooling of trapped fluid at the edges of the fabric insert.

Exemplary garments - Preferably, the fabric insert forms part of a garment, for example, briefs, underwear, pantyhose, leggings, gym shorts, a bra, a maternity bra, a singlet, a t-shirt, a sports bra, or toilet-training garments for children. Advantageously, the fabric insert of the invention may be included in the gusset region of underwear or may be included in the cup region of a bra (e.g., a sports bra or a maternity bra). Suitably, the fabric insert may be non-removably attached to the garment, preferably wherein the protective insert is sewn or fused to the garment. For example, an assembled insert may be fused or sewn into the outer fabric to make the garment, e.g., gusset in underpants, or breast pad for bra or materiality tops.

Alternatively, the fabric insert may be removably attached to the garment, preferably wherein the protective insert retained in the garment by, for example, Velcro™ or studs. Suitably, the fabric insert may be affixed or attached to the garment in, proximal to, substantially covering, or extending over, at least part of a bodily fluid discharge zone. It will be understood that, in use, the fluid wicking component is proximal to the body of a wearer, while the leakproof barrier component is distal from a wearer.

In use, the fabric insert may be fixed or attached to the garment in, proximal to, substantially covering, or extending over, at least part of a bodily discharge zone. The fabric insert may form part of a garment, particularly an undergarment, and as such may be non-removably attached to the undergarment. As such, the protective insert may be sewn or fused to the garment. The garment may be in the form of briefs, pantyhose, leggings, gym shorts, a brassiere, a singlet, a t-shirt, a sports bra, or toilet-training garments for children.

According to another aspect of the invention, there is provided a garment having included therein a fabric insert of the invention. The article of clothing may be an undergarment. When in the form of briefs, pantyhose, or leggings, the protective insert may be attached to the clothing in the general crotch area of a user. When in the form of a brassiere, singlet, sports bra, or T-shirt, the protective insert may be attached to the clothing in the general chest area of a user, the underarm area, or both.

In use, fluid wicking component may be proximal to the body of a wearer, while the leakproof barrier component is then distal from a wearer. During use (meaning when worn against a wearer's skin), the fluid wicking component is directly contactable against a wearer's body when the garment is worn. The wicking layer component comprises a moisture-wicking fabric which wicks bodily fluid away from the wearer's skin to the fluid trapping core component which traps the body fluid within the insert thereby keeping the fluid wicking component dry to touch, at least until the maximum volume capacity of the insert of reached. At least the skin contacting surface of the wicking layer component is kept dry to the touch at least when the insert is used as intended, i.e., to supports bodily fluid management capability of greater than 20 mis, more preferably greater than 25 mis, more preferably greater than 30 mis and most preferably greater than 50 mis of bodily fluid.

Manufacture - \n another aspect, the invention provides a method of manufacturing a moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin, the method comprising overlaying a fluid trapping core component on a provided leakproof barrier component, wherein outer edges of the fluid trapping core component do not extend to the outer edges of the leakproof barrier component; forming a stitch free leakproof seam between the outer edges of the fluid trapping core component and the leakproof barrier component to form a fused component construct; overlaying a fluid wicking component over the fused component construct and bonding the outer edges of the fluid wicking component to the outer edges of the leakproof barrier component to form a component assembly. In a related aspect, the invention provides a method of manufacturing a launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the method comprising providing a margin around the outer edges of the leakproof barrier component which is devoid of contact with the fluid trapping core component by overlaying a smaller fluid trapping core component on a provided larger leakproof barrier component, such that outer edges of the fluid trapping core component do not extend to the outer edges of the leakproof barrier component; forming a stitch free leakproof seam between the outer edges of the fluid trapping core component and the leakproof barrier component to form a fused component construct, wherein the stitch free leakproof seam includes the edges of the core therein; overlaying a fluid wicking component over the fused component construct and bonding the outer edges of the fluid wicking component to the margin of the leakproof barrier component to form a component assembly.

Desirably, the moisture management fabric insert manufacture is an insert according to the first aspect of the invention.

In a preferred method, a fluid wicking component and leakproof barrier component of the same shape and dimensions are provided. A fluid trapping core component is provided. Depending on the bodily fluid management capacity desired, the fluid trapping core component may comprise a single layer of absorbent fabric or it may comprise two or more layers of absorbent fabric. Where two are more layer of absorbent fabric are required, one support layer is provided and one or more additional layers which have smaller dimensions that the support layer are provided. The support layer has smaller dimensions than the fluid wicking component and leakproof barrier component. Each of the support layer and the one or more additional layers may be considered as having a centrally disposed alignment point positioned at the intersection of a midway longitudinal line and a midway transverse line through each component. The support layer and the one or more additional layers are positioned such that the centrally disposed alignment points of each component are aligned. When the smaller one or more additional layers are associated with the support layer of the fluid trapping core component, the edges of the smaller dimensioned additional layers do not extend all the way to the edges of the support layer of the fluid trapping core component. The smaller one or more additional layers and the support layer are fixed in this position, for example by stitching that can be provided at various parts of the fluid trapping core component or around the entire perimeter of the fluid trapping core component.

The fluid trapping core component is then brought into contact with the leakproof barrier component and centrally positioned thereon by aligning the centrally disposed alignment points of the fluid trapping core component and the leakproof barrier component. As the fluid trapping core component is smaller in dimensions than the leakproof barrier component, the arrangements results in a border or margin on the leakproof barrier component which is free of the fluid trapping core component. Heat activated adhesive, preferably in the form of a band of adhesive tape, is then overlayed in position where the peripheral edge of the fluid trapping core component meets the leakproof barrier component. A preferred adhesive tape has one adhesive side which is positioned adhesive side down over the contact point of the peripheral edge of the fluid trapping core component and the leakproof barrier component. The arrangement gives rise to a tiered fabric assembly. The heat adhesive may be activated, for example, by application of heat from a hot press, which activates the adhesive, effectively fusing the fluid trapping core component and the leakproof barrier component together in the area provided with adhesive. The fluid wicking component is then brought into alignment with the assembly by overlaying the fluid wicking component over the assembly by aligning the centrally disposed alignment points of the fluid wicking component with the assembled fluid trapping core component and the leakproof barrier components. The fluid wicking component is then fused to the assembled fluid trapping core component and the leakproof barrier components. Suitably, the parts may be fused by stitching the fluid wicking component to the fluid trapping core component free margin of the leakproof barrier component. Care is to be taken to ensure that stitching does not pierce the adhesive seal between the support layer of the fluid trapping core component and the leakproof barrier components. As the smaller fluid trapping core component is sandwiched between the fluid wicking component and the leakproof barrier component, the edges of the smaller dimensioned fluid trapping core component do not extend all the way to the edges of the fluid trapping core component and the fluid wicking component. This results in an assembly having border or a margin around the peripheral edges of the fluid wicking component and leakproof barrier component which is free of the fluid trapping core component. Advantageously, this margin may be used to stitch the fabric insert to a desired garment without puncturing the fluid trapping core component. This avoids needles holes which may cause leaks.

Description of preferred embodiments - Figure 1 shows a first example of an insert of the invention broken into component parts of the insert fabric assembly. Fluid trapping core component 4, a two-layer laminate of microfibre terry fabric, overlays leakproof barrier component 2 which is a PUL material in this example. In this embodiment, stitching 6 holds the laminate of microfibre fabric together. A single band of adhesive 8 is centred over the meeting point of the edge of the fluid trapping core component and the leakproof barrier component 2. An adhesive and stitch free margin about the outer edges of the leakproof barrier component 2 can be seen. Fluid wicking component 1 is provided on top of the subassembly and can be stitched to the leakproof barrier component 2 at the adhesive and stitch free margin.

Figure 2 shows a second example of an insert of the invention broken into component parts of the insert fabric assembly. Fluid trapping core component 4, a two-layer laminate of microfibre terry fabric, overlays leakproof barrier component 2 which is a PUL material in this example. In this embodiment, stitching 6 holds the laminate of microfibre fabric together. A first band of adhesive 8" is centred over the meeting point of the edge of the fluid trapping core component and the leakproof barrier component 2. An adhesive and stitch free margin about the outer edges of the leakproof barrier component 2 can be seen. A first band of adhesive 8' is centred over the meeting point of the edge of the fluid trapping core component and the fluid wicking component 1, which on assembly is provided on top of the subassembly and can be stitched to the leakproof barrier component 2 at the adhesive and stitch free margin.

Fluid Capacity Examples - To compare the fluid capacity advantages provided by the leakproof seam of the invention, the following study was carried out.

The core component of size 12 underwear samples in the "light/moderate", "moderate/heavy" and "ultra" ranges were removed from each sample and weighed. The average weight of each type of core from 6 samples from each range was determined. The "light/moderate" core comprises a single layer of fabric in the core and involves a stitched seam joining the core component to the leakproof barrier component.

The "moderate/heavy" core comprises two layers of fabric in the core and involves a stitched seam joining the core component to the leakproof barrier component. The "ultra" core also comprises two layers of fabric in the core, however, the rather than a stitched seam, in the "ultra" product, the core is joined to the leakproof barrier component through a preferred leakproof seam as described herein, that is, using Bemis tape.

On average, a single layer of core fabric had a weight of 15.8g. On average fabric from a two layer core had a weight of 27.8g. The maximum fluid capacity of 6 size 12 underwear samples was measured as follows: Room temperature water was applied to the gusset of intact size 12 underwater from light/moderate", "moderate/heavy" and "ultra" ranges. The test were performed in replicates of 6 for each range.

The water was carefully applied to the centre area of the gusset at the narrowest width to correspond to the area of heaviest wetting in actual use. The water was applied in an amount of 2.5 mis at a time and left for 15 minutes before repeating. Maximum capacity was taken as the amount of water which did not result in leakage at the sides of the underwear. Once leakage from the sides of the underwear was detected, the test was considered as a fail and no further water was added. The amount of water retained is shown in the table below. It is evident that the leakproof seam dramatically increases the fluid capacity before leaking without requiring an increase in the bulk of the core. The leakproof seam substantially increases the capacity without sacrificing comfort and wearability for the users.

Claims

27 Claims

1. A launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the fabric insert comprising as an assembly: the fluid trapping core component sandwiched between a fluid wicking component contactable against the wearer's skin and a leakproof barrier component for protecting the garment from fluid leaks from the fluid trapping core component, characterised in that edges of the fluid trapping core component do not align with the peripheral edges of the leakproof barrier component thereby providing a margin around the outer edges of the leakproof barrier component which is devoid of contact with the fluid trapping core component, wherein the fluid trapping core component is fused to the leakproof barrier component by a stitch free leakproof seam which includes the edges of the core therein and is positioned at peripheral edges of the fluid trapping core component where the edges of the core meet the leakproof barrier component, whereby the fluid wicking component is secured to the margin without interference with the fluid trapping core component in the seam, and whereby the stitch free leakproof seam in conjunction with leakproof barrier component retains trapped bodily fluid in the fluid trapping core component and forces wicked bodily fluid away from the edges deeper into the fluid trapping core component to prevent accumulation or pooling of trapped fluid at the edges of the fabric insert.

2. The fabric insert of claim 1, wherein the fluid wicking component and the leakproof barrier component each have identical shape and dimensions, and wherein the fluid trapping core component has a smaller surface area than the leakproof barrier component.

3. The fabric insert claim 1 or claim 2, wherein the stitch free leakproof seam is free of stitching or other join that requires piercing of any part of the fluid trapping core component.

4. The fabric insert of any one of claims 1 to 3, wherein the stitch free leakproof seam seals and smooths the edges of the fluid trapping core component to the leakproof barrier component.

5. The fabric insert of any one of the preceding claims, wherein the stitch free leakproof seam compresses the fluid trapping core component onto the leakproof barrier component.

6. The fabric insert of any one of the preceding claims, wherein the stitch free leakproof seam comprises a waterproof adhesive as a band or stripe of waterproof adhesive, e.g, a waterproof elastomeric adhesive film or tape.

7. The fabric insert of any one of the preceding claims, wherein the fluid trapping core component comprises a single layer of an absorbent, quick drying fabric, preferably an absorbent, quick drying microfibre fabric.

8. The fabric insert of any one of claims 1 to 6, wherein the fluid trapping core component comprises two or more layers of an absorbent, quick drying fabric, preferably an absorbent, quick drying microfibre fabric.

9. The fabric insert of claim 8, where the two or more layers of absorbent fabric are laminated together, preferably by internal stitching at one or more locations remote from the stitch free leakproof seam.

10. The fabric insert of any one of the preceding claims, wherein the fluid trapping core component comprises two or more layers of microfibre fabric, an upper layer and one or more lower layers and, wherein the one or more lower layers have a smaller surface area than the upper layer.

11. The fabric insert of claims 10, wherein only the upper layer is included in the stitch free leakproof seam.

12. The fabric insert of any one of the preceding claims, wherein the fabric of the wicking layer component is wool, preferably merino wool, or comprises cellulosic fibres, such as bamboo, cotton, silk, or any combination or organic variation thereof.

13. The protective insert of any one of the preceding claims, wherein the fluid trapping core component comprises an absorbent, quick drying fabric manufactured from a cellulosic material, preferably hemp, bamboo, or cotton.

14. The fabric insert of any one of the preceding claims, wherein the barrier layer component includes a waterproof film laminate, such as a polyester/polyurethane laminate fabric.

15. A launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a polyester microfibre fabric fluid trapping core component of the insert, the fabric insert comprising as an assembly: the polyester microfibre fabric fluid trapping core component being at least one layer of a polyester microfibre fabric sandwiched between a merino wool fluid wicking component contactable against the wearer's skin and a polyester polyurethane laminate leakproof barrier component for protecting the garment from fluid leaks from the polyester microfibre fabric fluid trapping core component, wherein edges of the polyester microfibre fabric are fused to the polyester polyurethane laminate leakproof barrier component by stitchfree leakproof heat activated adhesive seam, which in conjunction with the polyester polyurethane laminate leakproof barrier component retains trapped bodily fluid the polyester microfibre fabric fluid trapping core component; characterised in that edges of the polyester microfibre fabric fluid trapping core component do not align with the peripheral edges of the polyester polyurethane laminate leakproof barrier component thereby providing a margin around the outer edges of the polyester polyurethane laminate leakproof barrier component which is devoid of contact with the polyester microfibre fabric fluid trapping core component, wherein the fluid trapping core component is fused to the polyester polyurethane laminate leakproof barrier component by a stitch free leakproof seam which includes the edges of the core component therein and is positioned at peripheral edges of the polyester microfibre fabric fluid trapping core component where the edges of the core meet the polyester polyurethane laminate leakproof barrier component, whereby the fluid wicking component is secured to the margin without interference with the polyester microfibre fabric fluid trapping core component in the seam, and whereby the stitch free leakproof seam in conjunction with polyester polyurethane laminate leakproof barrier component retains trapped bodily fluid in the polyester microfibre fabric fluid trapping core component and forces wicked bodily fluid away from the edges deeper into the polyester microfibre fabric fluid trapping core component to prevent accumulation or pooling of trapped fluid at the edges of the fabric insert.

16. The fabric insert of any one of the preceding claims, wherein the protective insert forms part of a garment, preferably briefs, underwear, pantyhose, leggings, gym shorts, a bra, a maternity bra, a singlet, a t-shirt, a sports bra, or toilet-training garments for children.

17. The fabric insert of any one of the preceding claims, wherein being non-removably attached to the garment, preferably wherein the protective insert is sewn or fused to the garment.

18. The fabric insert of any one of the preceding claims, wherein the fluid trapping core component has a fluid absorbency capacity of up to 5.0 ml/g of the core fabric component.

19. A launderable garment having included therein a fabric insert as claimed in any one of the preceding claims, preferably a launderable underwear garment.

20. A method of manufacturing a launderable moisture management fabric insert for a garment for wicking bodily fluid away from a wearer's skin into a fluid trapping core component of the insert, the method comprising providing a margin around the outer edges of the leakproof barrier component which is devoid of contact with the fluid trapping core component by overlaying a smaller fluid trapping core component on a provided larger leakproof barrier component, such that outer edges of the fluid trapping core component do not extend to the outer edges of the leakproof barrier component; forming a stitch free leakproof seam between the outer edges of the fluid trapping core component and the leakproof barrier component to form a fused component construct, wherein the stitch free leakproof seam includes the edges of the core therein; overlaying a fluid wicking component over the fused component construct and bonding the outer edges of the fluid wicking component to the margin of the leakproof barrier component to form a component assembly.