GB2477571A

GB2477571A - Incontinence pad for use in a garment

Info

Publication number: GB2477571A
Application number: GB1002098A
Authority: GB
Inventors: Razak Vayani; John Higgins
Original assignee: CUI INTERNAT Ltd; Cosmopolitan Textile Co Ltd
Current assignee: CUI INTERNAT Ltd; Cosmopolitan Textile Co Ltd
Priority date: 2010-02-09
Filing date: 2010-02-09
Publication date: 2011-08-10
Also published as: GB201002098D0

Abstract

An incontinence pad including an absorbent element and a distribution element for dispersing liquid for use in a garment. (10) wherein the garment (10) is washable. The distribution element may comprise a wicking material. There may also be a hydrophobic element. The elements may comprise a mixture of polyester, viscose or rayon, and bi-component binder fabrics. The incontinence pad may be manufacture by needling the elements together, and calendering. The various fibres may have specific decitex ranges.

Description

Tifle: Garment Decription lpyJon This invention relates to a garment including an incontinence pad, particularly, but not exclusively to a garment suitable for use by "lightly incontinent" males and females, and to a method of providing such a garment.

It is known to provide absorbent pads and garments including an absorbent portion, for use by sufferers of incontinence. Traditionally, incontinence garments include a simple absorbent pad which is sewn into the garment, extending between the front and the rear of the garment, in the region of a gusset of the garment. Such garments are washable and reusable.

Alternatively an absorbent pad may be temporarily attached to a garment, for example by means of an adhesive strip on the garment-side of the pad, or the pad may be inserted into and removed from the garment via an opening in the garment, such that the garment is reusable, whilst the pad itself is disposable.

Of course, such the requirements of absorbent pads for "light" incontinence are very different from those of disposable nappies or diapera Diapers are very thick and bulky, and are disposable. They are not intended to be re-used.

A problem associated with known incontinence garments is that in use, liquid, i.e. urine, tends to flow under gravity towards the lowest region of the garment, which tends to cause saturation of the absorbent pad in that region, and eventual leakage, typically at one or both of the leg openings of the garment.

This can cause discomfort, irritation and embarrassment to the user.

Furthermore, the wet absorbent pad is in contact with the wearer's skin, which can increase irritation and discomfort. To avoid such situations, the user may discard or change the garment/pad frequently, before the whole of the absorbent pad has been used, which is wasteful and uneconomical.

In accordance with a first aspect of the invention, there is provided a garment including an incontinence pad, the incontinence pad including an absorbent eiement and a distribution element for dispersing liquid, wherein the garment is washable.

A washable incontinence garment is economically and environmentally advantageous, since the garment can be worn multiple times, and no part of the garment or the incontinence pad has to be discarded. In addition to these convenient features, the garment is discreet1 because the garment may have a similar appearance and can be worn in a similar way to normal underwear.

The absorbent element stores liquid effectively and inhibits leakage, and the distribution element also inhibits pooling and leakage, by enabling the liquid to disperse, rather than pooling at an in use lower region of the garment.

The distribution element of the incontinence pad may be a wicking layer through which liquid disperses, such that liquid is inhibited from accumulating at an in use lower region of the garment.

The inclusion of a distribution element is also advantageous since the liquid is substantially evenly dispersed through the distribution element. This inhibits accumulation of liquid at an in use low region of the garment, which in turn prolongs the length of time the garment can be worn before having to be replaced, either as a result of discomfort or fear of leakage.

The incontinence pad may also include a hydrophobic element, The hydrophobic element reduces encourages liquid to pass into the absorbent element and inhibits "wet-back".

The hydrophobic element may include polyester and a bicomponent binder fibre. Bicomponent binder fibres are known in the art, and are generally understood to be fibres including two polymers having different physical properties, in particular different melting points. The lower melting point polymer is co-extruded as a sheath around the higher melting point core. The hydrophobic element allows liquid to pass therethrough, maintaining a substantially dry wearer-contacting surface. Polyester is naturally hydrophobic. The bicomponent binder fibre assists in bonding the hydrophobic element to the other elements of the incontinence pad, and provides structural stability of the hydrophobic element and the incontinence pad as a whole during and after washing.

The hydrophobic element may include approximately 90-99% polyester and approximately 1-10% bicomponent binder fibre, and preferably includes approximately 97% polyester and approximately 3% bicomponent binder fibre.

The polyester of the hydrophobic element may have a linear density in the range 1.7 to 7 decitex and the linear density of the bicomponent fibre of the hydrophobic element may be in the range 3.3 to 7 decitex.

The linear density of the polyester of the hydrophobic element may be 3.3 decitex, and the linear density of the bicomponent binder fibre of the hydrophobic element may be 4.4 decitex.

The absorbent element may include viscose, polyester nd a bicomponent binder fibre. Viscose has a high absorbency, whereas the polyester is hydrophobic, which assists in resisting wet compaction of the incontinence pad, and assists in maintaining the volume of the incontinence pad.

in a first embodiment of the invention, the absorbent element may include approximately 75-85% viscose, approximately 5-15% polyester and approximately 5-15% bicomponent binder fibre. Preferably the absorbent element may include approximately 80% viscose, approximately 10% polyester and approximately 10% bicomponent binder fibre. The viscose may have a linear density in the range 1.7 to 7 decitex, preferably 3.3 decitex, the polyester may have a linear density in the range 7 to 17 decitex, preferably 12 decitex, and the bicomponent binder fibre may have a linear density in the range 3.3 to 7 decitex, preferably 4.4 decitex.

In a second embodiment of the invention, the absorbent element may include approximately 45-55% viscose, approximately 35-45% polyester and approximately 5-15% bicomponent binder fibre. The absorbent element preferably includes approximately 50% viscose, approximately 40% polyester and approximately 10% bicomponent binder fibre. The polyester fibre of the absorbent element of the second embodiment of the invention may include approximately 20-30% (by total weight of the absorbent element) 17 to 40 decitex polyester, preferably 28 decitex polyester, and approximately 10-20% (by total weight of the absorbent element) 3.3 to 7 decitex hydrophilic polyester, preferably 5.1 decitex hydrophilic polyester. Preferably the polyester fibre of the absorbent element includes 25% (by total weight of the absorbent element) 28 decitex polyester, and approximately 15% (by total weight of the absorbent element) 5.1 decitex hydrophilic polyester. Hydrophilic polyester being polyester adapted to be durably hydrophilic, for example by the inclusion of a durable hydrophilic additive.

The distribution element of the garment may include approximately 90-99% polyester and 1-10% bicomponent binder fibre, the distribution element preferably including approximately 95% polyester and approximately 5% bicomponent binder fibre.

The linear density of the hydrophilic polyester may be in the range 3.3 to 7 decitex, and is preferably 5.1 decitex. The hydrophilic polyester is a polyester copolymer adapted to be durably hydrophilic, for example by the addition of any additive.

The bicomponent binder fibre of the distribution element may be polyester having a linear density in the range 3.3 to 7 decitex, preferably 4.4 decitex.

The bicomponent binder fibre assists in bonding the distribution element to the other elements of the incontinence pad, and enables the incontinence pad to be calendered to a relatively high density, such that the proximity of the fibres to one another promotes wicking by capillary action.

The distribution element may include a plurality of hydrophilic fibres in close proximity to one another, such that the distribution element is capillary active.

The incontinence pad may be permanently attached to the garment, for example by the pad being sewn into a gusset part of the garment.

According to a second aspect of the invention, there is provided an incontinence pad including an absorbent element and a distribution element for dispersing liquid., for use in a garment according to the first aspect of the invention.

According to a third aspect of the invention, there is provided a method of manufacturing a washable incontinence pad, the method including providing an absorbent element and a distribution element, and bonding the absorbent element and the distributing element together, by needling the elements together.

The method may include providing a hydrophobic element and bonding the hydrophobic element, absorbent element and distribution element together by needling the three elements together such that the absorbent element is sandwiched between the hydrophobic element and the distribution element.

The elements may be needled together over a substantial proportion of the area of each of the elements.

The method may include needling each of the elements separately, to obtain a desired density of each element, and needling the elements together mechanically to bond the elements together.

The method may include needling the distribution element at a higher intensity than the absorbent element to provide openings in the distribution element, such that the distribution element is capillary active.

This difference in the needling intensity allows the absorbent element to retain a relatively low density teservoir" structure, whilst the high density distribution element permits capillary action. This method of manufacture means that a portion of the absorbent element which is adjacent the distribution element is also needled at a high intensity, but the penetration depth is such that the needles do not extend all the way through the absorbent element. Hence the region of the absorbent element which is adjacent the distribution element has a higher density than the remainder of the absorbent element and encourages capillary action, such that liquid is drawn from the absorbent element into the distribution element, where the liquid is substantially evenly distributed through the distribution element.

The method may include thermally bonding the elements of the incontinence pad together by calendering.

The pad may be calendered at a temperature between approximately 165°C and 175°C, preferably approximately 165°C. This melts the bicomponent binder fibre i.n the distribution element, allowing the polyester of the distribution element to be compressed and set into a surface skin" which is capillary active.

The incontinence pad may be washed, prior to use, to recover the thickness of the calendered pad. This increases the absorbency of the incontinence pad.

According to a fourth aspect of the invention, there is provided a method of manufacturing a washable garment including attaching an incontinence pad manufactured in accordance with the third aspect of the invention to a part of a garment.

The invention will now be described, by way of example only, with reference to the accompanying drawings of which: FIGURE 1 is an illustrative side view of a garment in accordance with the invention, FIGURE 2 is a cross-sectional view of a gusset of the garment of Figure 1, and FIGURE 3 is a cross-sectional view of an incontinence pad suitable for use in the garment of Figure 1 Referring to the drawings, there is shown a garment 10, which is an undergarment for wearing around the lower abdomenS The garment 10 has a front panel 12, and a rear panel 14. The garment 10 also includes a gusset 16 which extends between the front panel 12 and the rear panel 14. The garment also includes a pair of leg openings 18 (only one of which is shown in Figure 1), one on each side of the garment 10. The garment 10 also includes a waistband 20 at an in use upper end of the garment 10. The leg openings 18 and waistband 20 are preferably elasticated.

B

The gusset 16 of the garment 10 includes an incontinence pad 21. The incontinence pad 21 includes a plurality of layers.

The incontinence pad 21 includes a hydrophobic element 24. The hydrophobic element 24 forms a first layer of the incontinence pad 21. The hydrophobic layer 24 contains polyester, which is a naturally hydrophobic material. In the present example, the hydrophobic element includes approximately 97% 3.3 decitex polyester, and 3% 4.4 decitex polyester bicomponent binder fibre. The linear density of the polyester may be in the range 1.7 to 7 decitex, and the linear density of the bicomponent binder fibre may be in the range 3.3 to 7 decitex, for example. The bicomponent binder fibre is a sheath which surrounds the core, polyester fibre. The bicomponent binder fibre is preferably a low-melt bicomponent binder fibre, which assists in bonding the hydrophobic element 24 to other elements of the incontinence pad 21 as will be described in more detail below, Furthermore! the bicomponent binder fibre increases the stability of the incontinence pad 21 during and following washing of the garment 10. The target weight of the hydrophobic element 24 is 200 glrn2.

The incontinence pad 21 includes an absorbent element 26, which forms a second layer, or central core, of the incontinence pad 21 of the garment 10. In a first embodiment of the invention, the absorbent element 26 includes approximately 75% to 85%, preferably approximately 80% viscose, approximately 5-15%, preferably approximately 10%, polyester and approximately 5-15%, preferably approximately 10%, polyester bicomponent binder fibre. The linear density of the viscose is in the range 1.7 to 7 decitex, for example, and advantageously is 3.3 decitex. The linear density of the polyester is in the range 7 to 17 decitex, for example, and is preferably 12 decitex. The linear density of the bicomponent binder fibre is in the range 3.3 to 7 decitex and in this example is 4.4 decitex.

The viscose material has a multi-lobal", preferably a "trilobal" cross-section Which increases its specific absorbency. The polyester also has a multi-lobal, preferably trilobal cross-section and is hydrophobic to resist wet compaction, so as to maintain the volume of the absorbent element 26 in use, to counteract the tendency of viscose to collapse when wet This maintains the structure of the incontinence pad 21 during use, to enable further liquid to pass through and be entrapped by the incontinence pad 21 The low-melt bicornponent binder fibre reinforces the structure of the absorbent element and assists in maintaining the integrity and structure of the garment 10 during and following washing of the garment 10 The target weight of the absorbent element 26 is 550g/m2.

The incontinence pad 21 of the garment 10 also includes a distribution element 28. The distribution element 28 includes a layer of hydrophilic material The distribution layer 28 includes approximately 90-99%, preferably 95%, hydrophilic polyester and approximately 1-10%, preferably 5%, polyester bicomponent binder fibre. The linear density of the polyester is in the range 3 3 to 7 decitex, and advantageously is 5 1 decitex The linear density of the polyester bicomponent binder fibre Is in the range 3 3 to 7 decitex, and in this example is 4 4 decitex The target weight of the distribution element 28 is approximately I 50g/m.

Since polyester is naturally hydrophobic, the 5 1 decitex polyester is adapted so as to be hydrophilic This adaption may involve a chemical modification of the polyester, for example by the inclusion of an additive within the polymer The adapted polyester is durably hydrophilic, i e is permanently hydrophilic, even after the garment 10. including the incontinence pad 21, has been washed. The bicomponent binder fibre assists in bonding the distribution element 28 to the absorbent element 26, and also allows the distribution element to be "calendered" he, hot compressed down to a much higher density than if the bicomponent binder fibre were not included. The proximity of the fibres in a denser material increases the wicking capability of the material.

A layer of waterproof fabric 30 is positioned on the outside of the incontinence pad 21, such that liquid is inhibited from soaking through the garment 10, and from causing other garments, such as outerwear from becoming wet. The waterproof fabric 30 may be added to the incontinence pad 21 before the pad is attached to the garment 101 or may be a part of the garment 10.

An outer layer of fabric 32, is provided adjacent the waterproof fabric 30. The outer layer of fabric 32 may be the same as the fabric forming the front and rear panels 12, 14. This increases the aesthetic qualities of the garment 10, such that the garment 10 resembles ordinary underwear as far as possible.

The incontinence pad 21 is covered by a topsheet 22, which is provided on an inside, i.e. wearer-facing side of the gusset 16. The topsheet 22 includes a fabric which is comfortable to wear next to the skin, such as polyester or a polyester mix fabric.

In a second embodiment of the invention, the material of the absorbent element 26 is replaced by a material which includes approximately 45-55%, preferably approximately 50%, viscose, approximately 20-30%, preferably approximately 25%, polyester, approximately 10-20%, preferably approximately 15%, hydrophilic polyester, and approximately 5-15%, preferably approximately 10%, polyester bicomponent binder fibre.

The linear density of the viscose is preferably in the range 1.7 to 7 decitex, and advantageously is 3.3 decitex. The linear density of the polyester is preferably in the range 17 to 40 decitex, and advantageously is 28 decitex. The linear density of the hydrophilic polyester is in the range 3.3 to 7 decitex and is preferably 5.1 decitex. The linear density of the polyester bicomponent binder fibre is in the range 3.3 to 7 decitex and is preferably 4.4 decitex.

The remaining features of the garment 10 are identical to those described above. The higher proportion of approximately 28 decitex polyester and the inclusion of the approximately 5.1 decitex hydrophilic polyester improves resilience of the incontinence pad 21 and internal wicking capability.

In use, the garment 10 is worn in the same way as normal underwear, around the lower abdomen. The topsheet 22 is positioned adjacent the skin for comfort. In the event of incontinence, urine passes through the hydrophobic element 24 towards the absorbent element 26. The fact that the element 24 of the incontinence pad 21 which is closest to the skin (excluding the topsheet) is hydrophobic means that the element 24 avoids retention of liquid, thus maintaining a substantially dry wearer-contacting surface, and inhibiting "wet-back" from a saturated absorbent element 26, in the event of compression of the incontinence pad 21, for example during sitting.

The first and second embodiments of the incontinence pad 21 are manufactured as follows. The hydrophobic element 24, the absorbent element 26 and the distribution element 28 are manufactured separately, without activation of the respective bicomponent binder fibres, i.e. without thermally treating the elements. Staple (cut) fibres in bale form are "opened", i.e. reduced from bale form into relatively small tufts, and blended, in the proportions described above to form each of the elements 24, 26, 28 of the incontinence pad 21 of the garment 10. The blended fibres are "carded" into a thin web. Carding involves passing tufts of fibre between a series of finely-toothed cylinders, which rotate in opposite directions relative to one another The carding process further blends and opens the tufts into individual fibres.

The resultant web is passed through a "cross-lapper", in which reciprocating conveyors fold the web into a plurality of layers. The web is folded onto a further, lower conveyor which moves in a direction which is transverse to the direction in which the web extends. The weight of the fabric is a function of the number of layers of fibre provided by the folded web.

The folded (layered) web is moved through one or more "needleloonis". Each loom contains a plurality, generally several thousands, of needles each of which includes a plurality of barbs which face forwards, i.e. towards the point of the needle. The loom is operable to punch the needles through the web, which entangles and compacts the fibres of the web, to create a densified, mechanically bonded fabric. The frequency and direction of punching, the degree of needle penetration and the form of the needles of the needleloom are variable, in order to control the physical characteristics of the resultant fabric. Additional fabrics, scrims and/or yarns can be added to and combined with the web fibres during this process.

The inclusion of the bicomponent binder fibres in each of the elements 24, 26, 28 of the incontinence pad 21 enables the elements 24, 26, 28 to be thermally bonded together, locking the structure of the incontinence pad 21 of the garment 10 together, The bicomponent binder fibres of the elements 24, 26, 28 fuse together to form a three dimensional network of fibres which connect together around the non-melting or "matrix" fibres of the elements, 24, 26, 28.

The bicornponent binder fibres can be activated, i.e. thermally bonded, in two ways. The first method is to use a through air oven. Such ovens include at least one conveyor for carrying the fabric through the oven. As the fabric passes through the oven, hot air is forced or drawn through the thickness of the fabric. Such an oven may include an upper and a lower conveyor to control the pressure exerted on the fabric, and hence to calibrate the thickness of the fabric as the fabric passes through the oven. This is particularly advantageous for fabrics which have not been subjected to the needling process mentioned above.

The second method is "calendering", which involves passing the fabric to be activated through paired, heated rollers. The temperature of the rollers is controllable, as are the dwell time (i.e. the time the fabric spends in the vicinity of the rollers), and the spacing between the rollers. The smaller the gap between the rollers, the higher the pressure experienced by the fabric passing between the rollers. Increasing the pressure experienced by the fabric, produces denser fabrics.

The hydrophobic element 24 is relatively highly needled, to achieve a dense fabric having a pile on at least one side. The pile is on the side which is adjacent the topsheet.

The hydrophobic element 24 and the distribution element 28 are both needled as follows: Loom Stroke Stitches per unit Penetration depth area (st/cm2) (mm) I Downstroke 80 10.0 2 Upstroke 90 -7.5 3 Downstroke 90 -6.0 4 Downstroke -240 6.0 The reference to "stitches per unit area" above refers to the number of needle punches per unit area, and the penetration depth is the distance by which the needle exits the fabric when punched.

The absorbent element 26 of the incontinence pad 21 is needled as follows: Loom l Stroke Stitches per unit Penetration depth area (st/cm2) (mm) 1 Downstroke -40 -140 The hydrophobic element 24 and the distilbution element 28 are fed alongside the absorbent element, adjacent a lower and an upper side of the absorbent element 26, respectively, such that the absorbent element 26 is sandwiched between the hydrophobic element 24 and the distribution element 28.

The three elements 24, 26, 28 are then needled together, as follows: Loom Stroke -Stitches per unit Penetration depth area (st/cm2) (mm) 2 Upstroke 40 14.0 3 Downstroke -Off - 4 Downstroke j 400 3.0 The mechanicafly bonded elements 24, 26, 28 are then fed through a through-air oven at a temperature of between approximately 170°C and approximately 190°C, preferably at a temperature of approximately 180°C. The temperature should be selected to correspond with the typical activation temperature of the bicomponent binder fibre. Typical activation temperatures for polyester bicomponent binder fibres are generally between approximately 170°C and approximately 190°C.

A principle of this method of combining the elements of the incontinence pad 21 of the garment is that the full thickness of the absorbent element 26 is tacked° by the needles of the first loom. The second loom punches through *the hydrophobic element 24, through the absorbent element 26, and finally into the distribution element 28, which in this example is an "upstroke", to provide structural integrity to the underside (the side on which the hydrophobic element 24 is positioned) of the incontinence pad 21, and mechanically bonding the elements 24, 26, 28 together. The thickness of the incontinence pad 21 is between approximately 7mm and approximately 10mm.

The relatively high needle density of the fourth loom further attaches the distribution element 28, and densifies the distribution element 28 only, and provides openings or "channels" which form a capillary active region, to provide the wicking capability of the distribution element 28. The region of the absorbent eLement 26 which is adjacent the distribution element 28 is included in the capillary active region.

The difference in the needle densities of the looms, and thus the difference between the number of stitches or punches per unit area of each element 24, 26, 28 allows the absorbent element 26 to retain a relatively low density reservoir" structure, whilst the higher density distribution element 28 enables wicking of liquid through the distribution element 28, to transfer liquid away from an in use lower region of the incontinence pad 21, against gravity, to an in use higher region of the incontinence pad 21, so as to inhibit pooling of liquid and subsequent leakage. The higher region(s) of the incontinence pad 21 are likely to be towards the front and rear of the pad 21. Liquid is absorbed from an in use lower region of the absorbent element 26 by an adjacent region of the distribution element 28. Liquid is distributed through the distribution element 28 and can be re-absorbed from the distribution element 28 by an in use higher region of the absorbent element 26, which is not saturated The wicking capability of the distribution element 28 means that liquid can be substantially evenly distributed across a substantial proportion of the incontinence pad 21. This inhibits saturation of one region of the incontinence pad 21 whilst another region of the incontinence pad 21 remains dry, or relatively dry. Thus the effective absorbent area of the incontinence pad 21 is increased and the garment 10 can potentially be worn for longer without fear of discomfort or embarrassment.

The incontinence pad 21, including the three mechanically bonded elements 24, 26, 28 is then calendered through a cotton/heated steel bowl combination at a temperature between approximately 155°C and 175°C, preferably approximately 165°C and at approximately lOObar pressure, with the distribution element 28 adjacent the heated steel bowl. The temperature is selected to correspond to the melting point of the bicomponent binder fibre of the distribution element 28, which is typically approximately 165°C. This re-melts the bicomponent binder fibre of the distribution element 28, permitting the polyester fibre of the distribution element 28 to be compressed and set into a surface "skin" of the incontinence pad 21 which is approximately 0.3mm thick, and is capillary active. The resulting fabric of the incontinence pad 21 of the garment 10 is flexible and is between approximately 4mm and approximately 5mm thick.

The finished incontinence pad 21 fabric is cut to the required size, rolled, and may be packaged or converted into sheets or narrower rolls, for inclusion in the garment 10.

The incontinence pad 21 is shaped and sewn into the garment 10, between the topsheet 22 and the waterproof layer 30. The garment 10 is washed before use, and the thickness of the incontinence pad 21 recovers to approximately 8mm. The retention and recovery of thickness of the incontinence pad 21 contributes to the efficacy of the incontinence pad 21, since the absorbency of the incontinence pad 21 is directly related to its volume.

Therefore, the garment can be worn and washed multiple times, in the same way as normal underwear, without losing its absorbent properties, which is more economical and environmentally friendly than disposable incontinence products. The garment is particularly effective for "lightly incontinent" males and females, although it will be appreciated that the composition of the incontinence pad 21 can be used, or adapted as required for use in other applications) The hydrophobic element 24 may be omitted from the incontinence pad 21. In this case liquid is received by the absorbent element 26 of the incontinence pad 21, and the distribution element 28 is operable in the same manner as in the three-layered embodiment of the pad 21 i.e. to distribute liquid so as to inhibit localised saturation of the absorbent element 26. Liquid is absorbable from the absorbent element 26 by the distribution element 28 which wicks the liquid against gravity, towards an in use higher region of the pad 21, liquid being absorbable from the distribution element 28 by an unsaturated region of the absorbent element 26.

The incontinence pad 21 is not limited to use in incontinence garments and may be used furniture, such as chairs, or beds and/or in soft furnishings and bedding. For example, the incontinence pad may be incorporated into a part of a piece of furniture, for example, a seat pad or cushion. The part of the piece of furniture can be removed from the piece of furniture for washing, and then replaced. In the case of bedding, the incontinence pad 21 can be used as or incorporated into a mattress protector, for example. Where the incontinence pad 21 is incorporated into furniture, bedding or soft furnishings, a top sheet or outer layer layer may be positioned adjacent the hydrophobic element 24 or the absorbent element 26 in the case that the incontinence pad does not include a hydrophobic element 24. This top sheet or outer layer may be a decorative fabric, such as a seat fabric, or a fabric suitable for bedding, such as cotton.

The incontinence pad 21 may be backed by a waterproof layer for inhibiting liquid from contacting and being absorbed by furniture fillings/padding or by mattresses to which the incontinence pad 21 has been applied. The incontinence pad 21 is removeable from the furniture/bedding/furnishings and washable. Alternatively, the whole item may be washable.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims

CLAIMS1. A garment including an incontinence pad, the incontinence pad including an absorbent element and a distribution element for dispersing liquid, wherein the garment is washable.
2. A garment according to claim 1 wherein the distribution element of the incontinence pad is a wicking layer through which liquid disperses, such that liquid is inhibited from accumulating at an in use lower region of the garment
3. A garment according to claim 1 or claim 2 wherein the incontinence pad includes a hydrophobic element.
4. A garment according to claim 3 wherein the hydrophobic element includes polyester and a bicomponent binder fibre.
5. A garment according to claim 4 wherein the hydrophobic element includes approximately 90-99% polyester and approximately 1-10% bicomponent binder fibre.6 A garment according to claim 5 wherein the hydrophobic element includes approximately 97% polyester and approximately 3% bicomponent binder fibre.7. A garment according to any one of claims 4 to 6 wherein the linear density of the polyester of the hydrophobic element is in the range of 17 to 7 decitex.8. A garment according to claim 7 wherein the linear density of the polyester of the hydrophobic element is 3.3 decitex.9. A garment according to any one of claims 4 to 8 wherein the linear density of the bicomponent binder fibre is in the range 3.3 to 7 decitex.10. A garment according to any one of claims 4 to 9 wherein the bicomponent binder fibre of the hydrophobic element is polyester having a linear density of 4.4 decitex.II. A garment according to any one of the preceding claims wherein the absorbent element includes viscose, polyester and a bicomponent binder fibre.12. A garment according to claim 11 wherein the absorbent element includes approximately 75-85% viscose, approximately 5-15% polyester and approximately 5-15% bicomponent binder fibre.13. A garment according to claim 12 wherein the absorbent element includes approximately 80% viscose, approximately 10% polyester and approximately 10% bicomponent binder fibre.14. A garment according to any one of claims 11 to 13 wherein the linear density of the viscose is in the range 1.7 to 7 decitex.15. A garment according to claim 14 wherein the linear density of the viscose is 3,3 decitex.16. A garment according to any one of claims 11 to 15 wherein the polyester has a linear density in the range 7 to 17 decitex.17. A garment according to claim 16 wherein the polyester has a linear density of 12 decitex.18. A garment according to any one of claims 11 to 17 wherein the bicomponent binder fibre has a linear density in the range 1.7 to 7 decitex.19. A garment according to claim 18 wherein the linear density of the bicomponent binder fibre is 4.4 decitex.20. A garment according to claim 11 wherein the absorbent element includes approximately 45-55% viscose, approximately 35-45% polyester and approximately 5-15% bicomponent binder fibre.21. A garment according to claim 20 wherein the absorbent element includes approximately 50% viscose, approximately 40% polyester and approximately 10% bicomponent binder fibre.22. A garment according to claim 21 wherein the absorbent element includes approximately 20-30% polyester having a linear density in the range 17 to 40 decitex and approximately 10 to 20% hydrophilic polyester having a linear density in the range 3.3 to 7 decitex.23. A garment according to claim 22 wherein the absorbent element includes approximately 25% 28 decitex polyester and approximately 15% 5.1 decitex hydrophiHc polyester.24. A garment according to any one of the preceding claims wherein the distribution element includes approximately 90-99% polyester and approximately 1-10% bicom ponent binder fibre.25. A garment according claim 24 wherein the distribution element includes approximately 95% hydrophilic polyester and approximately 5% bicomponent binder fibre.26. A garment according to claim 24 or claim 25 wherein the linear density of the hydrophilic polyester is in the range 3.3 to 7 decitex.27. A garment according to claim 26 wherein the linear density of the hydrophilic polyester of the distribution element is 5.1 decitex hydrophilic polyester.28. A garment according to any one of claims 24 to 27 wherein the bicomponent binder fibre is polyester having a linear density in the range 3.3 to 7 decitex.29. A garment according to any one of the preceding claims wherein the distribution element includes a plurality of hydrophilic fibres in close proximity to one another, such that the distribution element is capillary active.30. A garment according to any one of the preceding claims wherein the incontinence pad is permanently attached to the garment.31. A garment substantially as described herein and/or as shown in the accompanying drawings.32. An incontinence pad including an absorbent element and a distribution element for dispersing liquid, for use in a garment according to any one of claims 1 to 30.33. A method of manufacturing a washable incontinence pad, the method including providing an absorbent element and a distribution element, bonding the absorbent element and distribution element together, by needling the elements together.34. A method according to claim 33 including providing a hydrophobic element and bonding the hydrophobic element, absorbent element and distribution element together by needling the three elements together such that the absorbent element is sandwiched between the hydrophobic element and the distribution element.35. A method according to claim 33 or claim 34 wherein the elements are needled together over a substantial proportion of the area of each of the elements.36. A method according to any one of claims 33 to 35 including needling each of the elements separately to obtain a desired density of each element, and needling the elements together to mechanically bond the elements together.37, A method according to any one of claims 33 to 36 including needling the distribution element at a higher intensity than the absorbent element to provide openings in the distribution element, such that the distribution element is capillary active.38. A method according to any one of claims 33 to 37 including thermally bonding the elements together by calendaring.39. A method according to claim 38 wherein the pad is calendered at approximately 165°C.40. A method according to any one of claims 33 to 39 wherein the incontinence pad is washed, prior to use, to recover the thickness of the calendered pad.41. A method of manufacturing a washable incontinence pad substantially as described herein and/or as shown in the accompanying drawings.42. A method of manufacturing a washable garment including attaching an incontinence pad manufactured in accordance with any one of claims 33 to 41 to a part of a garment.43. A method of manufacturing a washable garment substantially as described herein and/or as shown in the accompanying drawings.44. Any novel feature or novel combination of features substantially as described herein and/or as shown in the accompanying drawings.