GB2607000A

GB2607000A - Garment and method of manufacture

Info

Publication number: GB2607000A
Application number: GB2106290.6A
Authority: GB
Inventors: Fashoni Paige
Original assignee: Flux Undies Ltd
Current assignee: Flux Undies Ltd
Priority date: 2021-04-30
Filing date: 2021-04-30
Publication date: 2022-11-30
Also published as: GB202106290D0

Abstract

A garment 100 for absorbing blood or urinary leaks, comprising a fabric body 101 having a waist opening 102 and two leg openings 103L,R, and a gusset 104 on the fabric body between leg openings. The gusset comprises a base layer and an absorbent layer thereon, wherein the fabric body of the garment is stretchable by at least 40% to allow conforming to the body shape of the wearer over multiple clothing sizes. The garment may be formed of a composite high stretch material, comprising polyester, spandex, nylon and/or elastane. The garment may be formed by forming a fabric body net, folding the net, and bonding the seams to form the fabric body, and attaching a gusset to the fabric body. The garment may stretch by at least 10cm, and may be formed of two layers of material with a seam located at each respective hip portion.

Description

GARMENT AND METHOD OF MANUFACTURE

Technical Field

The present disclosure relates to a garment having an absorbent gusset. In particular, but not exclusively, the present disclosure relates to a one-size fits all stretch underwear garment having an absorbent gusset for absorbing liquid such as blood. Aspects of the present invention relate to a garment and to a method of manufacturing a garment.

Background

The problem of menstrual leaks, urinary leaks, and leaks from other bodily fluids affects many women and there are a number of options available, including underwear that is designed to absorb blood and leaks. Reusable undergarments designed to absorb blood/leaks that can be worn by the wearer are available in different absorbencies, but an average absorbent garment of a moderate absorbency can usually be worn for up to 8 hours, replacing disposable products such as sanitary towels and tampons. This has a huge environmental benefit.

However, there is a problem when it comes to finding underwear of the right size and fit.

Menstruating women's bodies are known to fluctuate in size due to hormonal changes and other contributing factors such as bloating, meaning that current underwear designed to absorb menstrual flow and leaks can be uncomfortable for the wearer. Aside from this, due to the nature of the product, current absorbent undergarments do not easily adapt to suit a wide variety of shapes and sizes of the user making it difficult for women to find something that is suited to their shape. Moreover, current absorbent undergarments do not adapt to the wearer's fluctuating body when they are, for example, bloating due to menstruation and their stomach size has increased.

Women are known (as all people are) to change shape and size due to weight loss or weight gain. Reusable absorbent undergarments have a lifespan of at least three years and during this time, if a woman loses or gains weight, she is forced to dispose of her absorbent undergarment and purchase a new absorbent undergarment in a different size. This causes a loss to the user financially, and it also means that a perfectly good product goes to waste which is bad for the environment.

Another drawback of current absorbent undergarments is that when manufacturing a number of different underwear sizes, patterns have to be cut out of the fabric, and when there are multiple different patterns needing to be cut because of the multiple sizes, fabric is not able to be used as effectively and ultimately leads to fabric wastage which can cause a loss economically and environmentally.

There is therefore a need to address the problems and disadvantages associated with the prior art.

Summary

According to an aspect of the present invention there is provided a garment comprising: a fabric body having a waist opening and two leg openings, and a gusset on the fabric body between the leg openings, the gusset comprising a base layer and an absorbent layer on the base layer, wherein the fabric body is stretchable to conform to the wearer's body shape.

The fabric body may, for example, be stretchable by at least 40%, 50%, 60% or more. For example, it may be stretchable by at least 80% or 100% or more.

This garment may be an item of underwear that is able to absorb liquid due to the absorbent and waterproof layers of the gusset and to adapt to the wearer's body shape and size due to the stretchability of the fabric body. So, the product will remain comfortable to the wearer through the changes in body shape that occur through a menstrual cycle and/or through weight gain or loss. This increases the lifetime of the product, thereby decreasing waste and environmental damage.

Furthermore, the garment is suitable to fit a wide range of wearers, thereby improving accessibility for all shapes and sizes of women without discriminating women outside the "typical" range of sizes. The garment is washable and reusable, making it an environmentally friendly alternative to disposable pads and tampons. The garment may be a one-size fits all garment that is stretchable to fit three or more clothing sizes. For example, the garment may be stretchable to fit a S, M and L. Furthermore, the underwear garment may be stretchable to fit women sized UK 8 to UK 18.

The fabric body may comprise a layer of thin breathable fabric. When the garment is unstretched, the size of the fabric body may be smaller than a UK size 8. The waist diameter of the garment may be about 26cm (half-folded) or about 50cm circumference when unstretched. When fully stretched the waist diameter of the garment may be about 50cm to 52cm (half-folded) or 100cm to 104cm circumference. The fabric body of the garment may conform to the shape of the wearer at sizes between the aforementioned unstretched and fully stretched dimensions. This is beneficial as the garment may be a one size fits all underwear garment.

The fabric body of the garment may configured to stretch to conform to the shape of a wearer's body across a range of three or more sizes. For example, the garment may cover XS to XL or UK 8 to UK 18. The fabric body may also be dimensioned to cover a plus size range. For example, the fabric body may over sizes 2XL -5XL.

The fabric body may comprise a composite material formed of polyester, spandex, nylon, and/or elastane. The composite material may comprise a high content of high stretch material such as elastane or spandex. The content of elastane and/or spandex may be higher than is normally seen in underwear to allow for stretch of the fabric body. The composite material may comprise a high percentage of high stretch materials such as Elastane or Spandex. For example, the composite material may comprise at least 10% high stretch material such as Elastane or Spandex. In another embodiment the composite material may comprise at least 15%, 20% or more high stretch material.

The composite material may comprise a non-stretch in combination with a high-stretch material like, but not limited to, Nylon and Elastane or may comprise Polyester and Elastane, or Modal and Elastane, or Cotton and Elastane or any other combination of high stretch material such as elastane or spandex and a non-high stretch materials such as nylon, modal and polyester. It is envisaged that the composite material comprises a higher percentage of a high-stretch material like, or similar to, Elastane or Spandex, than is seen in current underwear that is not designed to stretch across multiple sizes.

The fabric body may be stretchable such that a diameter of the waist opening may be increased by at least 15cm diameter (half fold, or 30cm increase in total circumference) when the garment is in a stretched configuration. Typically, the size difference between two consecutive UK dress sizes (e.g., Size 8 to Size 10) is 2cm (half fold, or 4cm of total circumference) which means that the garment allows coverage of at least three sizes or more, for example five sizes. (e.g., size 8 to size 16). The fabric body may be 4 way stretchable. The fabric body may be stretchable such that a circumference of the waist opening may be increased by at least 30cm, for example 40cm.

The fabric body may be lightweight and/or breathable. The fabric body may be formed of one or two layers of material. For example, if the stretch of the material forming the fabric body is high, two layers of the material may be used to offer more stability and support to the gusset whilst retaining a good stretch. If the stretch of the material is lower, one layer of the material may be used for the fabric garment body. Using one layer, may help to retain breathability and comfort for the wearer.

The fabric body may comprise seams which may be located at two hip portions of the garment. The seams may be folded over. This may create a seam-free leg line and may allow for further stretch. The seams may be glue bonded. The fabric body may comprise elastic around the leg opening. The elastic may have a high stretch percentage. The elastic may comprise polyester and/or elastane. The seams may comprise stitches, the stitches comprising a high stretch low tension thread, for example elastic. This will allow the stretch of the fabric body to reach its full capacity without becoming restrictive at the legs.

The fabric body may further comprise a waistband extending around the waist opening.

The waistband may comprise a double layer of material. The waistband may increase the strength of the garment around the waist meaning that the gusset may be better supported.

S

This is especially important when the gusset has absorbed liquid as it will then become heavier.

The gusset may be bonded to the fabric body, optionally around an outside edge of the gusset. The gusset may be glue-bonded to the fabric body. Glue bonding may provide better attachment of the relatively non-stretchable gusset to the stretchable fabric body than other methods.

The gusset may be attached to the fabric body by stitches, optionally around an outside edge of the gusset. The stitches may comprise a high stretch low tension thread. This may overcome difficulties with attaching the relatively non-stretchable gusset to the stretchable fabric body.

The base layer of the gusset may lay on an inside of the fabric body. The inside of the fabric body will face the wearer's skin when the garment is worn. The gusset base layer may be attached to a crotch region of the fabric body.

The gusset of the garment may have a length of between 10 and 30 cm and may be 20cm. The length may be measured in a direction from the front of the garment to the back. The gusset may have a width (measured at the narrowest part of the gusset) of between 5 and 10cm, and may be between 7 and 9cm, and may be 8cm. The width is measured in a direction from a left side to a right side of the garment. This size allows ample coverage and protection for all wearers across the different sizes that the garment will stretch to cover. The required coverage of the gusset does not increase or decrease according to weight loss or gain or bloating so the gusset need not stretch. A length between about 10cm to 30cm will suit wearers of the smallest size or largest size ensuring any wearer receives ample coverage and protection. Dimensions of the gusset are measured through a centre point of the garment.

The gusset may comprise three or four layers of material. The gusset may be breathable.

The gusset may further comprise a top layer, on the absorbent layer. The absorbent layer may comprise two layers of material. The base layer may be a waterproof layer. The gusset may measure between 2mm and Smm in thickness. This allows the user to feel protected without the garment feeling bulky or uncomfortable. Thickness may be measured from a top surface for contacting a wearer's skin to a bottom surface of the base layer, which lies against the fabric body.

The absorbent layer may have a capacity of 20m1. This is equivalent to the capacity of around four regular tampons' and so is suitable for all day wear for many women. Alternative versions may have a capacity higher than 20m, for example 30m1, or a capacity of lower than 20m1, for example 10m1 or 15ml. A lower capacity may be preferable to limit the weight of the gusset in use. This may ensure that the stretchable fabric body is capable of holding the gusset in its position against the user's skin.

The absorbent layer of the gusset may comprise cotton, modal, bamboo, microfibre, and/or terry towelling. These materials are all highly absorbent. Modal is advantageous as it is stretchable and so can conform to the shape of the wearer. Modal is also lightweight and absorbent which reduces the chance that the gusset could become too heavy to be supported by the fabric body. Modal is also thin, making it easy to bond to the base layer/fabric body. The absorbent layer may comprise two layers of modal material. Microfibre and terry towelling are very absorbent materials making them advantageous for use in the absorbent layer. They are both thicker than modal but will in turn absorb more liquid.

The base layer of the gusset may comprise a waterproof material. The base layer may comprise polyurethane laminate. The waterproof base layer prevents leaks from going through the gusset to the fabric body of the garment by beading up liquid and pushing it back into the absorbent layer.

The top layer of the gusset may comprise a moisture-wicking material such as modal, microfibre or polyester. These soft fabrics are comfortable against the skin of the wearer and also wick moisture quickly to keep the wearer feeling dry. These fabrics also hold their shape over time, giving the garment stability and retaining the shape of the garment in the gusset area. This is advantageous in combination with the stretchable fabric body as these fabrics can stop the gusset area of the garment stretching with the fabric body, thereby providing gusset stability which is especially important when the gusset is holding liquid. Polyester is also thin and so easy to bond to the fabric body. If the gusset becomes too heavy to be properly supported by the stretchable fabric body, this may cause the garment to become misshapen and/or the gusset to move away from the wearers skin resulting in discomfort for the wearer. Utilising a polyester top layer helps keep the gusset thin and lightweight to reduce the chance of the garment becoming too heavy. The top layer may comprise cotton. Cotton is also comfortable for the wearer.

In use, moisture is immediately wicked through the top layer to the absorbent layer where it is absorbed, and leaks are then prevented from going through to the fabric body by the waterproof base layer. The top layer allows liquid to be absorbed and dry out allowing further liquid to do the same until the gusset reaches full saturation. The wicking top layer and the waterproof base layer work together to trap liquid in the gusset, predominantly in the absorbent layer.

The garment may be a garment for pelvic, crotch and/or groin coverage. This includes garments which only partially cover these region(s) of the wearer, such as thongs, underpants, knickers, bikini bottoms and swimwear. The garment may be an intimate garment. An intimate garment is any garment that is configured to be worn against the skin.

The garment may be underwear, for example, underpants or knickers. The knickers may have a hipster shape. In this style, the fabric body will be shaped such that, when the knickers are worn, the waist opening is configured to sit on the wearer's waistline and a rear part of the fabric body is shaped to cover the buttocks of the wearer. Alternatively, the knickers may be a high-waisted style, or a thong or other style of knickers, in which case the shape of the fabric body will be modified to adapt to the style. The differing shapes/styles of the knickers still offer the same functionality in combining a high-stretch underwear with a multi-layer absorbent gusset but will differ in the coverage design and style, and fit offered to the wearer.

The garment may be swimwear, such as bikini bottoms, a swimming costume or swim shorts. The garment may be nightwear such as night shorts or pyjama bottoms. The garment may be sportswear, such as cycling shorts, running shorts or leggings. The swimwear may comprise a thinner gusset than used in conventional underwear. For example, the gusset in swimwear may only comprise a single layer of absorbent material.

Furthermore, the leg openings on the garment may comprise elasticated seams extending around the leg openings to create a waterproof seal between the garment and the wearer's legs. Furthermore, the fabric body may be made from nylon or elastane to create a waterproof outer layer. This is beneficial as it prevents the ingress of water to the gusset when the wearer is submerged.

The garment may be shorts, such as cycling shorts, swim shorts or running shorts. In this case, the fabric body has the shape of shorts. The garment may further comprise a fabric outer short, attached to the fabric body at an edge of the waist opening. In this way, the fabric body may be worn against the skin and the outer short may be worn over the fabric body which may be advantageous when the wearer takes part in sport, for example, running.

There is further provided a method of manufacture of a garment, the method comprising: forming a fabric body having a waist opening and two leg openings, the fabric body being stretchable enough to fit across multiple sizes, by at least 40%, attaching a gusset to the fabric body between the two leg openings, the gusset comprising gusset absorbent layers and waterproof layer on a gusset base layer. The fabric body may stretch by at least 50%, at least 60%, at least 80% or at least 100%.

Forming the fabric body may comprise forming a fabric body net, folding the net and bonding seams of the fabric body. The seams may be at hip regions of the garment. Two seams may be bonded, each seam being between the waist opening and a respective leg opening.

The fabric body net may have a rounded I shape, with a central column and a pair of wings at each end of the column. Folding the net may comprise folding the column in half so that opposing ends of the column meet Two seams may be formed, the first between a left edge of a left wing of one end of the column and a left edge of a left wing of the other end of the column and the second seam between a right edge of a right wing of one end of the column and a right edge of a right wing of the other end of the column. The wings form hip regions of the fabric body. The central column forms a crotch region of the fabric body. A waist opening is formed by an upper (front) and lower (back) edge of the I shape and right and left leg openings are formed between the seams and the column.

Bonding the seams may comprise glue bonding. Bonding the seams may comprise folding the seams over. This may create a seam-free leg line and may allow for further stretch.

Bonding the seams may comprise stitching the seams optionally with a high stretch, low tension thread such as elastic thread.

The gusset may be attached to a crotch region of the fabric body. The gusset may be attached to the fabric body net before it is folded. The gusset may be attached to the central column of the fabric body net The gusset may be bonded to the fabric body, optionally around an outside edge of the gusset The gusset may be glue-bonded to the fabric body. Glue bonding may provide better attachment of the relatively non-stretchable gusset to the stretchable fabric body than other methods.

The gusset may be attached to the fabric body by stitching optionally around an outside edge of the gusset. The stitching may use a high stretch, low tension thread, for example elastic. This may overcome difficulties with attaching the relatively non-stretchable gusset to the stretchable fabric body.

The method may further comprise placing the gusset absorbent layer on the gusset base layer to form a gusset. The method may further comprise placing a gusset top layer on the gusset absorbent layer to form the gusset. Attaching the gusset to the fabric body may comprise attaching the layers of the gusset to one another. In other words, attaching the gusset to the fabric body may include attaching all of the gusset layers to the fabric body, thereby attaching the gusset layers to each other as well as to the fabric body.

Alternatively, the method may further comprise attaching the gusset absorbent and waterproof layers and optionally the gusset top layer to the base layer. Attaching may comprise glue-bonding and/or stitching, optionally around an edge of the layers of the gusset.

The optional features described above are equally applicable to all of the described garments and methods of manufacture and are not limited to the particular garment/method with which they are described above. Further, the method of manufacture described above may be a method of manufacture of a garment described above.

Further features and advantages of the aspects of the present disclosure will become apparent from the claims and the following description.

Brief Description of Drawings

Embodiments of The present disclosure will now be described by way of example only, with reference to the following diagrams, in which:-Fig. 1A is a front view of a garment; Fig. 1B is a back view of the garment of Fig. 1A; Fig. 2A is a front view of a garment in use on a wearer; Fig. 2B is a back view of the garment of Fig. 2A in use on a wearer; Fig. 3 is a plan view of a gusset; Fig. 4 is a schematic diagram of layers of the gusset of Fig. 3; and Fig. 5 is a plan view of a fabric body net and a gusset.

Detailed Description

A number of different embodiments of the disclosure are described subsequently. In order to minimise repetition, similar features of the different embodiments are numbered with a common two-digit reference numeral and are differentiated by a third digit placed before the two common digits. Such features are structured similarly, operate similarly, and/or have similar functions unless otherwise indicated.

Figs. 1A and 1B show a garment 100 having a fabric body 101 having a waist opening 102 and two leg openings 103L, 103R. The garment 100 partially covers the pelvic and crotch areas of a wearer. The garment 100 of Figs. 1A and 1B is a pair of knickers with a hipster shape. The fabric body 101 shape means that, when the knickers are worn, the waist opening 102 sits on the wearer's waistline and the rear of the fabric body 102 covers the buttocks of the wearer.

The garment 100 also has a gusset, the gusset being between the leg openings 103L,103R and attached to the inside of the fabric body 101. The gusset is not visible from the outside of the garment 100, however, in Figs. 1A and 1B the position of the gusset is indicated by the region 104. The gusset is attached to a crotch region of the fabric body 101 and the gusset has a length 20cm and a width of 8cm. The fabric body 101 is formed of a fabric that is stretchable to conform to multiple sizes of wearer's body thereby making the garment one size fits all. For example, the fabric body may stretch by at least 40% or more to conform to the shape of the wearer. For example, the fabric body may stretch by at least 60% or greater.

The gusset has a base layer and an absorbent layer on the base layer. The garment is absorbent by virtue of the absorbent layer(s) of the gusset, and adapts to the user's body shape and size by stretching across multiple sizes, offering comfort when their body may be fluctuating in size (e.g. due to bloating) and also making this environmentally friendly product accessible to a wider range of users. The garment is reusable and washable, making it an environmentally friendly alternative to disposable pads and tampons.

The fabric body 101 is formed of a single layer of fabric having a high percentage of a stretch material, such as Elastane and/or Spandex, comprised with another material such as Nylon, Polyester, Modal or Cotton. The fabric body 101 may be formed of a single layer of fabric having about 80% non-stretch material such as, but not limited to, Nylon, Polyester, Cotton or Modal and 20% Elastane or about 90% Nylon and 10% Elastane. For example, the fabric body 101 may comprise between about 75% to 90% Nylon and 10% to 25% high stretch material such as elastane or spandex. The fabric body is stretchable such that a diameter of the waist opening 102 can increase elastically by over 10cm. This means that the garment allows coverage of at least five sizes. The fabric body has seams 105L and 105R located at the hip portions of the garment 100. The seams are folded over to create a seam-free leg line and allow for stretch. The seams are glue bonded.

Figs. 2A and 2B show a garment 200 being worn by a wearer. The garment has a fabric body 201 having a waist opening 202 and two leg openings 203L, 203R. The garment partially covers the pelvic and crotch areas of a wearer. The garment of Figs. 2A and 2B is a pair of knickers with a hipster shape. The fabric body shape means that, when the knickers are worn, the waist opening sits on the wearer's waistline as shown in Figs. 2A and 2B and the rear of the fabric body covers the buttocks of the wearer as can be seen in Fig. 2B.

The garment 200 also has a gusset, the gusset being between the leg openings and attached to the inside of the fabric body. The gusset is not visible in Figs. 2A and 2B, but is attached to a crotch region on the inside of the fabric body and has a length of 20cm and a width of 8cm.

The garment is absorbent by virtue of an absorbent layer of the gusset, and adapts to the user's body shape and size by stretching across multiple sizes, offering comfort when their body may be fluctuating in size (e.g. due to bloating) and also making this environmentally friendly product accessible to a wider range of users. The garment is reusable and washable, making it an environmentally friendly alternative to disposable pads and tampons.

The fabric body 201 is formed of two layers of fabric, each having a high percentage of a stretch material, such as Elastane and/or Spandex, comprised with another material such as Nylon, Polyester, Modal or Cotton. The fabric body 201 may be formed of two or more layers of fabric having between about 75% to 90% Polyester and 10% to 25%Elastane. The fabric body is stretchable such that a diameter of the waist opening 202 can increase elastically by over 15cm. This beneficially allows the garment to stretch to cover at least three clothing sizes. The fabric body 201 has elastic around the leg openings 203R and 203L. The fabric body has seams 205L and 205R located at the hip portions of the garment 100. The seams are stitched with a high stretch low tension thread of elastic. This allows the stretch of the fabric body 201 to reach its full capacity without becoming restrictive to the legs of the wearer.

Fig. 3 shows a plan view of gusset 304 with a width 306 and a length 307. The width and length of the gusset are measured through the centre 308 of the gusset as shown by the dashed lines. The length 307 is 20cm and may be between 10cm and 30cm in other examples. The length is measured in a direction from the front of the garment to the back through centre 308. The gusset width 306 is 8cm, and may be between Scm and 10cm in other examples. The width is measured in a direction from a left side to a right side of the garment through centre 308. This size allows ample coverage and protection for all wearers across the different sizes that the garment will stretch to cover.

The side edges 309L and 309R of the gusset are concave and the end edges 309F and 3098 are convex which allows the gusset to conform comfortably to a crotch region of the wearer.

Fig. 4 shows the layers used in the gusset 304 of Fig. 3. The gusset 304 has three layers: a base layer 411, an absorbent layer(s) 412 and a top layer 413.

The base layer 411 is waterproof and is made of one layer of polyurethane laminate material.

The absorbent layer 412 is on the base layer 411. The absorbent layer 412 is formed of one layer of modal material. Modal is advantageous as it is stretchable, thin, lightweight and highly absorbent The absorbent layer has a capacity of 20m1. This is equivalent to the capacity of around four regular tampons' and so is suitable for all day wear for many women. The absorbent layer may comprise two layers of material in other examples. Other material that may be used for the absorbent layer(s) are, but not limited to, terry towelling, S microfibre, cotton, or bamboo.

The top layer 413 is on the absorbent layer 412. The top layer 413 is formed of one layer of polyester material. This is advantageous in combination with the stretchable fabric body as polyester is quick-wicking and thin, so easy to bond to the fabric body. The polyester top layer 413 is thin and lightweight which helps to reduce the chance of the garment becoming too heavy. Other material that may be used for the top layer is, but not limited to, cotton, and modal.

The thickness of all of the layers 411,412 and 413 measured from a top surface of the top layer to a bottom surface of the base layer through centre of gusset 308 is between 2mm and Smm. This allows the user to feel protected without wearing a garment that is bulky or uncomfortable.

In use, moisture is immediately wicked through the top layer 413 to the absorbent layer 412 where it is absorbed, and leaks are then prevented from going through to the fabric body by the waterproof base layer 411. The top layer 413 allows liquid to be absorbed and dry out allowing further liquid to do the same until the gusset reaches full saturation. The wicking top layer 413 and the waterproof base layer 411 work together to trap liquid in the gusset, predominantly in the absorbent layer 412.

Fig. 5 shows a plan view of a fabric body net 501 and a gusset 504. Fig. S shows a stage in the manufacture of a garment.

The fabric body net 501 may be formed into a fabric body for the garment shown in Fig. 1 by attaching edges 505L to form a left hip seam and attaching the edges 505R to form a right hip seam. Front edge 502F and back edge 502B will then form a waist opening of the garment Edge 503L will form a left leg opening and edge 503R will form a right leg opening.

Gusset 504 is on the fabric body net 501 between the leg opening edges 503L and 503R. The gusset 504 is as illustrated and described in relation to Figs. 3 and 4 above. The fabric body 501 is stretchable enough to fit across multiple sizes. For example, by at least 40% or more or by at least 50% or more. The fabric body may stretch by at least 60% or more.

The fabric body net 501 is formed of a single layer of fabric having a high percentage of a stretch material, such as Elastane and/or Spandex, comprised with another material such as Nylon, Polyester, Modal or Cotton. The fabric body 501 may be formed of a single layer of fabric having between about 75% to 90% Nylon and 10% to 25% Elastane. The fabric body is stretchable such that a length of edges 502F and 502B can increase elastically by over 15cm. The gusset 504 is bonded to the fabric body net 501 around an outside edge of the gusset The gusset SO4 is glue-bonded to the fabric body net.

In alternative embodiments, the gusset may be attached to the fabric body by stitches, optionally around an outside edge of the gusset. The stitches may comprise a high stretch low tension thread, for example elastic.

The gusset SO4 lays against an inside of the fabric body net 501. The inside of the fabric body net 501 will face the wearer's skin when the garment is worn. The gusset is attached to a crotch region of the fabric body which will lie against the wearer's crotch when the garment is worn. The size and composition of the gusset is as described above in relation to Figs. 3 and 4.

The garment formed by the fabric body net 501 when the seams are formed partially covers the pelvic and crotch areas of a wearer. The garment is a pair of knickers A method of manufacture of a garment will now be described in relation to Fig. 5.

A fabric body net 501 is formed having a rounded I shape, with a central column having a front end 502F and a back end 502B, and a pair of wings at each end of the column. Each pair of wings having a left and a right wing each wing extending from the column and terminating in a left SOSL and a right edge SOSR respectively. The fabric body net 501 is formed of a single layer of material having a high percentage of a stretch material, such as Elastane and/or Spandex comprised with another material such as nylon, polyester, modal or cotton.. The fabric body net is stretchable such that a length of edges 502F and 502B can increase elastically by over 10cm.

Gusset 504 is formed by placing a gusset top layer 413 on the gusset absorbent layer 412 and placing the absorbent layer 412 on the gusset base layer 411. The gusset layers 411, 412, 413 may be attached together at this stage as is the case in this example, or may be attached to each other via the same mechanism as attaching the gusset to the fabric body 501. The gusset layers are attached to one another by glue-bonding around the edge of the gusset 504. The gusset 504 is then attached to the fabric body net 501 by glue-bonding around the edge of the gusset 504.

The gusset 504 is attached to the fabric body between the two leg openings defined by edges 503L and 503R. The leg openings will be completed later when the hip seams 505L and 505R are bonded to one another. The gusset 504 is attached to the central column of the fabric body net 501.

The fabric body net 501 is then folded in half so that opposing ends 502F and 502B of the column meet. Two seams are formed between the left edge of the left wing of one end of the column and a left edge of a left wing of the other end of the column at 505L and the second seam between a right edge of a right wing of one end of the column and a right edge of a right wing of the other end of the column at 505R. The wings form hip regions of the fabric body. The central column forms a crotch region of the fabric body. A waist opening is formed by a front edge 502F and a back edge 502B of the I shape and right and left leg openings are formed between the seams and the column, by side edges 5031 and 503R. The seams are glue-bonded and folded over. This creates a seam-free leg line and may allow for further stretch.

Forming the seams completes the forming of the fabric body which has a waist opening and two leg openings.

Although particular embodiments of the disclosure have been disclosed herein in detail, this has been done by way of example and for the purposes of illustration only. The aforementioned embodiments are not intended to be limiting with respect to the scope of S the invention. It is contemplated by the inventors that various substitutions, alterations, and modifications may be made to the invention without departing from the scope of the invention as defined by the claims.

Claims

CLAIMS1. A garment for absorbing blood or urinary leaks, the garment comprising: a fabric body having a waist opening and two leg openings, and a gusset on the fabric body between the leg openings, the gusset comprising a base layer and an absorbent layer on the base layer for absorbing the blood or urinary leaks, wherein the fabric body is stretchable by at least 40% to allow the garment to stretch across multiple clothing sizes to conform to the body shape of a wearer.
2. A garment according to claim 1, wherein the fabric body comprises a composite material formed of a high stretch material wherein the high stretch material comprises one or more of: polyester, spandex, nylon, and/or elastane.
3. A garment according to claim 2, wherein the composite material comprises at least 10% high stretch material.
4. A garment according to claim 3 wherein the composite material comprises between 75% and 90% Nylon and between 10% and 25% Elastane.
5. A garment according to claim 3 wherein the composite material comprises between 75% and 90% Polyester and between 10% and 25% Elastane.
6. A garment according to any preceding claim wherein the fabric body is stretchable such that a diameter of the waist opening increases by at least 10cm when the garment is in a stretched configuration.
7. A garment according to any preceding claim wherein, the fabric body is formed of two layers of material.
8. A garment according to any preceding claim wherein the fabric body comprises two seams, each seam located at a respective hip portion of the garment
9. A garment according to claim 8, wherein the seams are folded over.
10. A garment according to claim 8 or claim 9, wherein the seams are glue bonded.
11. A garment according to any preceding claim, wherein the gusset is glue-bonded to the fabric body.
12. A garment according to any one of claims 1 to 10, wherein the gusset is attached to the fabric body by stitches.
13. A garment according to claim 12, wherein the stitches are formed of high stretch thread.
14. A garment according to any preceding claim wherein the gusset has a length of between 10 and 30 cm.
15. A garment according to any preceding claim, wherein the gusset has a width of between 5 and 10cm at a narrowest point of the gusset.
16. A garment according to any preceding claim wherein the base layer is a waterproof 20 layer.
17. A garment according to any preceding claim wherein the absorbent layer of the gusset comprises modal.
18. A garment according to any preceding claim wherein the absorbent layer comprises two layers of material.
19. A garment according to any preceding claim, wherein the gusset further comprises a top layer, on the absorbent layer.
20. A garment according to claim 19, wherein the top layer of the gusset comprises a moisture-wicking material.
21. A garment according to claim 20, wherein the top layer comprises polyester.
22. A method of manufacture of a garment, the method comprising: forming a fabric body having a waist opening and two leg openings, the fabric body being stretchable by at least 40%, attaching a gusset to the fabric body between the two leg openings, the gusset comprising a gusset absorbent layer on a gusset base layer.
23. A method of manufacture according to claim 22, wherein forming the fabric body comprises: forming a fabric body net, folding the net, and bonding seams to form the fabric body.
24. A method of manufacture according to claim 23, wherein bonding seams comprises glue bonding two seams, each seam being between the waist opening and a respective leg opening.
25. A method of manufacture according to claim 23 or 24, wherein attaching the gusset occurs before folding the fabric body net.
26. A method of manufacture according to any of claims 22 to 25, wherein attaching the gusset to the fabric body comprises glue-bonding the gusset to the fabric body.
27. A method of manufacture according to any of claims 22 to 25, wherein attaching the gusset to the fabric body comprises stitching the gusset to the fabric body using elastic thread.
28. A method of manufacture according to any of claims 22 to 27, wherein the garment is a garment according to any one of claims 1 to 21.