WO2007073506A2

WO2007073506A2 - Moisture management garment and fabric composite

Info

Publication number: WO2007073506A2
Application number: PCT/US2006/049283
Authority: WO
Inventors: Mark Miskie
Original assignee: Arcus Medical, Llc
Priority date: 2005-12-22
Filing date: 2006-12-22
Publication date: 2007-06-28
Also published as: WO2007073506A3

Abstract

A multi-layer moisture management fabric composite incorporates a three- dimensional fabric spacer and a liquid impermeable barrier. The fabric spacer forms an inside layer of the fabric composite, and has a first facing adapted for residing near the skin, a second facing adapted for residing away from the skin, and an intermediate spacer yam interconnecting the first and second facings. The liquid impermeable barrier forms an outside layer of the fabric composite. The fabric spacer and liquid impermeable barrier cooperate to form a pocket adapted for holding at least one absorbent pad designed to receive and disperse moisture entering the fabric composite through the spacer.

Description

MOISTURE MANAGEMENT GARMENT AND FABRIC COMPOSITE

Technical Field and Background of the Invention

[0001] This invention relates generally to incontinence, and more specifically to a moisture management garment and fabric composite. The invention includes features designed to manage moisture in cases of light to heavy incontinence. In one exemplary implementation, urine is collected in disposable and/or reusable pads stored in the crotch pockets and which can be conveniently exchanged as needed.

Objects of the Invention

[ooo2] Therefore, it is an object of the invention to provide a moisture management fabric composite which may incorporate one or more pockets for receiving absorbent material (reusable or disposable).

[ooo3] It is an object of the invention to provide a moisture management fabric composite which is applicable for use in bed pads, chair pads, body wraps, and other products intended for managing moisture.

[ooo4] It is an object of the invention to provide a moisture management garment which incorporates a moisture management fabric composite.

[ooo5] It is an object of the invention to provide a moisture management garment which may incorporate wicking and absorbing cloth layers, as opposed to cotton fiber- filling elements commonly used in disposable diapers.

[ooo6] It is another object of the invention to provide a moisture management garment and fabric composite which may comfortably handle multiple instances of wetting. [0007] These and other objects of the present invention are achieved in the exemplary embodiments disclosed below by providing a multi-layer moisture management fabric composite incorporating a three-dimensional fabric spacer and a liquid impermeable barrier. The fabric spacer forms an inside layer of the fabric composite, and has a first facing adapted for residing nearest the skin, a second facing adapted for residing away from the skin, and an intermediate spacer yarn interconnecting the first and second facings. The fabric spacer may or may not comprise the innermost layer of the composite, and may occupy only a portion of the inside layer. The liquid impermeable barrier forms an outside layer of the fabric composite. The liquid impermeable barrier may or may not form the outermost layer of the composite, and may also form a portion of the inside layer of the composite adjacent the spacer. The fabric spacer and liquid impermeable barrier define a pocket adapted for holding at least one absorbent pad designed to receive and disperse moisture entering the fabric composite through the spacer. The term "liquid impermeable" is defined broadly herein to mean capable of substantially preventing the movement or leakage of liquid (e.g., urine) through the barrier from one side thereof to the other.

[0008] According to another exemplary embodiment of the invention, the fabric spacer has a loft greater than 0.06 inches.

[ooo9] According to another exemplary embodiment of the invention, the first facing of the spacer comprises a fine mesh fabric.

[0010] According to another exemplary embodiment of the invention, the fine mesh fabric comprises at least 400 uniform, mesh openings per square inch. [ooii] According to another exemplary embodiment of the invention, the first facing of the spacer comprises moisture wicking fibers adapted for promoting moisture flow by capillary wicking.

[o6i2] According to another exemplary embodiment of the invention, the second facing of the spacer comprises an open mesh fabric.

[ooi3] According to another exemplary embodiment of the invention, the open mesh fabric comprises less than 50 uniform, mesh openings per square inch.

[0014]¹ According to another exemplary embodiment of the invention, the second facing of the spacer comprises moisture-absorbent fibers adapted for drawing moisture from the first facing of the spacer through the spacer yarn.

[ooi5] According to another exemplary embodiment of the invention, the intermediate spacer yarn of the spacer comprises moisture wicking fibers adapted for promoting moisture flow from the first facing to the second facing by capillary wicking.

[ooi6] According to another exemplary embodiment of the invention, a drain , valve is operatively connected to the liquid impermeable barrier and adapted for discharging moisture collected within the fabric composite.

[ooi7] According to another exemplary embodiment of the invention, at least one moisture absorbent pad resides within the pocket and is designed to receive and disperse moisture entering the fabric composite through the spacer.

[ooi8] According to another exemplary embodiment of the invention, a sewing thread permanently attaches the moisture absorbent pad to the fabric spacer.

[ooi9] According to another exemplary embodiment of the invention, a removable and exchangeable second moisture absorbent pad is also located within the pocket.

[0020] In yet another exemplary embodiment, the invention comprises a moisture management garment incorporating a shell fabric defining a waist opening, a crotch region, and first and second leg openings. A multi-layer moisture management fabric composite resides in the crotch region adjacent the shell fabric. The fabric composite comprises a three-dimensional fabric spacer and a liquid impermeable barrier. The fabric spacer forms an inside layer of the fabric composite, and has a first facing adapted for residing nearest the skin, a second facing adapted for residing nearest the shell fabric, and an intermediate spacer yarn interconnecting the first and second facings. The liquid impermeable barrier forms an outside layer of the fabric composite. The fabric spacer and liquid impermeable barrier define a pocket adapted for holding at least one moisture absorbent pad designed to receive and disperse moisture entering the fabric composite through the spacer.

[0021] According to another exemplary embodiment of the invention, the fabric composite and garment shell fabric define a second pocket adapted for receiving and storing a further absorbent pad.

[0022] According to another exemplary embodiment of the invention, a removable and exchangeable third moisture absorbent pad is located within the second pocket.

Brief Description of the Drawings

[0023] Figure 1 is a perspective view of a moisture management undergarment according to one exemplary embodiment of the present invention; [oo24] Figure 2 is a top view looking inside the undergarment;

[0025] Figure 3 is a cross-sectional view of the fabric composite showing a sewn- in flip-out absorbent pad residing within the inside pocket formed between the fabric spacer and moisture barrier, and showing the outside pocket formed between the moisture barrier and shell fabric of the undergarment; [0026] Figure 4 is a further top view looking inside the undergarment, and showing the sewn-in flip-out pad removed from the inside pocket;

[00271 Figure 5 is a top view of the undergarment, and demonstrating insertion of a separately formed moisture-absorbent pad into the inside pocket of the fabric composite;

[0028] Figure 6 is a top view of the undergarment, and demonstrating insertion of a second pad into the outside pocket formed between the moisture barrier and garment shell fabric;

[0029] Figure 7 is an enlarged fragmentary view of the fabric composite illustrating the double seam joining the fabric spacer to the moisture barrier, and the moisture barrier to the garment shell fabric, respectively;

[0030] Figure 8 an enlarged fragmentary view of a base portion of the fabric composite with the fluid discharge valve shown in phantom;

[0031] Figure 9 is a cross-sectional view showing the fluid discharge valve located at the base of the fabric composite and projecting through the garment shell fabric; and

[0032] Figures 10, 1 1 , and 12 show a disposable absorbent pad applicable in one exemplary embodiment of the invention.

Description of Exemplary Embodiments and Best Mode

[0033] The present invention is described more fully hereinafter with reference to the accompanying drawings, in which one or more exemplary embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be operative, enabling, and complete. Like numbers refer to like elements throughout. As used herein, the article "a" is intended to include one or more items. Where only one item is intended, the term "one" or similar language is used. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad ordinary and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. Any references to advantages, benefits, unexpected results, or operability of the present invention are not intended as an affirmation that the invention has been previously reduced to practice or that anytesting has been performed.

[0034] Referring now specifically to the drawings, a moisture management garment according to the present invention is illustrated in Figure 1 , and shown generally at reference numeral 10. In the embodiment shown, the garment 10 comprises an undergarment constructed of a common shell fabric 1 1 , and resembling a conventional sport brief including an elastic waistline 12, a front and rear joined to the waistline 12, a crotch region 14, and first and second leg segments 15 and 16 defining respective leg openings. The garment 10 may be constructed in any desired form, including women's panty and men's boxer styles, and is especially useful in managing multiple instances of moderate to heavy urine leakage.

[0035] As best shown in Figures 2 and 3, the garment 10 incorporates a multilayer moisture management fabric composite 20 located in the crotch region 14. The fabric composite 20 may be permanently attached to (or integrally formed with) the garment 10, as described below, or may be separately formed and attached using releasable fasteners, such as mating hook and loops. In alternative applications, the fabric composite 20 may be fabricated in larger dimensions and used by itself as, for example, a bed pad or chair pad. In one exemplary embodiment, the fabric composite 20 incorporates a three-dimensional fabric spacer 21 which resides nearest the body of the user/wearer, and a liquid impermeable barrier 22 forming an outside layer of the composite 20 adjacent the garment shell fabric 11. Both the fabric spacer 21 and moisture barrier 22 are described separately below. The fabric spacer 21 forms at least part of an inside layer of the composite 20, and defines a strategically placed window for entry of moisture into the composite 20. The spacer 21 cooperates with the moisture barrier 22 to create a pocket 25 designed for receiving an absorbent pad 26. The pocket 25 is accessed through a horizontal opening 28 formed along a top inside margin of the composite 20.

[0036] The absorbent pad 26 may be permanently attached at its top edge to the spacer 21 using sewing thread 29 indicated in Figure 3, or by other suitable means, and unattached along its bottom edge and sides. The absorbent pad 26 operates to receive and disperse urine entering the fabric composite 20 through the spacer 21-, and to quickly draw the urine away from the user/wearer. In one exemplary embodiment, the pad 26 comprises one or more layers of hydrophilic fibers such as cotton, felt, and wool. To promote effective and efficient laundering, the pad 26 may be conveniently flipped out of the pocket 25 through the opening 28 and extended away from the composite 20, as demonstrated in Figure 4.

[0037] For added moisture control, a second (disposable or reusable) moisture absorbent pad 31 may be inserted in the pocket 25, as indicated in Figure 5, to reside between the first pad/spacer 26, 21 and moisture barrier 22. A folded top edge 32 of the moisture barrier 22 may extend over the top edge of the fabric spacer 21 and first pad 26 at the pocket opening 28 to further secure and contain the second pad 31 in the pocket 25. The second pad 31 is separately formed and otherwise unattached to the first pad 26 and fabric composite 20. Depending on the level of incontinence, one or more additional pads (not shown) may be located within the pocket 25 for increased absorption.

[0038] As best shown in Figures 3 and 6, an outside pocket 35 may be formed between the moisture barrier 22 and garment shell fabric 11 for receiving and storing additional moisture absorbent pads 36 (See Figure 6) through pocket opening 38. The moisture barrier 22 completely overlies and protects the pad 36 to maintain its freshness prior to use. In one implementation, a user/wearer may conveniently remove a pad 31 from the inside pocket 25 when soiled, and replace it with a fresh pad 36 stored in the outside pocket 35. The absorbent pads are described further below.

Fabric Spacer 21

[0039] Referring to Figure 3, in one exemplary embodiment, the three- dimensional fabric spacer 21 consists of two independently constructed fabric facings 41 and 42 integrally formed with a system of intermediate spacer yarns 43. Examples of this construction are described in U.S. Patent Nos. 6,103,641 and 6,627,562 incorporated herein by reference. The spacer 21 may be produced on a two needle bar Raschel machine, and may have a loft ranging from 0.06 inches to more than 0.6 inches. According to one embodiment, the loft is approximately 0.1875 inches and is greater than 25% of the total composite thickness. The first facing 41 which resides nearest the skin of the user/wearer may comprise a relatively fine mesh fabric consisting substantially of low moisture-absorbent fibers, such as acrylic, or non- absorbent hydrophobic fibers, such as polypropylene. These fibers resist swelling and compression when wet, and promote the rapid transport of moisture away from the inner layer of the fabric composite 20 and the skin of the user/wearer. In one embodiment, the quantity of low and/or non-absorbent fibers is preferably greater than 50% of the total fiber incorporated in the facing 41 , and more preferably, between 85% and100%. A "low absorbent" fiber is defined as one with less than 10% swell when wet. A "non-absorbent" fiber has less than 5% swell when wet. The mesh fabric may have at least 400 uniform, generally round, mesh openings per square inch. To deter the growth of fungus and bacteria, the first facing 41 may also include antimicrobial fibers comprising silver. Suitable antimicrobial fibers are disclosed in prior U.S. Patent No. 6,723,428 incorporated herein by reference.

[0040] The spacer yarns 43 may comprise moisture-wicking fibers, such as acrylic and polyester, which are made to promote the transport of moisture by capillary wicking. Examples of commercially available wicking fibers include Isolfil® by Di Borio Fiorino, Dacron® by E. I. du Pont de Nemours and Company, and Coolmax® by Invista. The mechanical structure and compressibility of the fiber determine its overall wicking potential. CoolMax® fibers, for example, have four longitudinal channels built into their cross-sectional geometry giving a 20% higher perimeter area than traditional round fibers. The result is higher water/vapor transport through enhanced surface exposure for capillary action. Capillary action attracts water from the first facing 41 of the spacer 21 where it is abundant and rapidly transports it to the second facing 42 of the spacer 21 where it is less abundant. In one exemplary embodiment, the spacer yarns 43 consist of between 85% and 100% wicking fibers. [0041] The second fabric facing 42 adjacent the spacer yarns 43 may be constructed of high moisture-absorbent fibers, such as cotton and wool, and/or wicking fibers, such as polyester and acrylic, which operate to draw moisture inwardly from the first facing 41 and spacer yarns 43, and disperse it over the entire surface area of the outside facing 42. In the exemplary embodiment shown, the second facing 42 comprises a highly breathable, open mesh fabric which promotes air circulation within and through the spacer 21. The mesh fabric may have less than 50 uniform, generally oval, mesh openings per square inch. A "high" moisture-absorbent fiber is defined herein as one which swells in excess of 20% when wet.

Moisture Barrier 22

[0042] The moisture barrier 22 resides directly adjacent the garment shell fabric

11, and forms a breathable vapor-permeable, liquid impermeable jacket designed to substantially contain any wetness (urine) passing into the fabric composite 20 through the spacer 21. As indicated above, the fabric spacer 21 defines a window for entry of moisture into the fabric composite 20.

[0043] Referring to Figures 2, 7, and 8, the moisture barrier 22 is attached to the shell fabric 11 along side and end edges 22A, 22B, and 22C, and to the fabric spacer 21 along its side and end edges 21 A, 21 B, and 21 C. The top edge of the spacer 21 is unattached to the moisture barrier 22, and the top edge of the moisture barrier 22 is unattached to the shell fabric 11 in order to provide respective openings 28, 38 for the inside and outside pockets 25, 35 discussed above. In one exemplary embodiment, the inside seams joining edges 21A-21C of the spacer 21 and moisture barrier 22 are created using a substantially liquid-tight, single or double fluid seam weld construction. These seams may also be stitchless and glued, glued and blind-stitched, taped, heat sealed, or formed in any other suitable manner creating a substantially liquid-tight connection. The outer seams joining the edges 22A-22C of the moisture barrier 22 to the shell fabric 1 1 may be formed in an identical manner or using more conventional sewing techniques. foo44] The moisture barrier 22 serves to substantially contain moisture within the fabric composite 20. As best shown in Figure 3, any urine passing through the fabric spacer 21 (and not entirely absorbed by the pad 26) may gravitate towards a sealed collection reservoir 60 at the base of the composite 20. In this embodiment, a one-way self-sealing flapper type valve 61 , best shown in Figures 1 , 3, and 9, is operatively connected to the moisture barrier 22 and designed to project outwardly from the shell fabric 11. The valve 61 communicates with the collection reservoir 60 to conveniently drain urine from the garment 10. A one-way, pressure-responsive, internal entry valve (not shown) may also be located at a controlled inlet of the collection reservoir 60. This internal valve would allow urine to enter the reservoir 60 via gravity, and then capture and store it prior to discharge through the secondary valve 61. The secondary valve 61 may be connected to a drain tube or collection bag. Other exemplary valve types include duckbill and reed valves, and user-actuated "pinch" valves.

Absorbent Pads

[0045] As previously discussed, the absorbent pads 26, 31 , and 36 may be either permanently, releasably, or loosely contained within the inside and/or outside pockets 28, 38, respectively. In the embodiment shown, the pad 26 is sewn-in and has a convenient flip-out design intended to facilitate laundering. This pad 26 may be constructed of one or more layers of hydrophillic fibers including, for example, cotton, felt, and wool. [0046] Any additional exchangeable pads 31 , 36 used in the garment may be either launderable and reusable, or disposable. Like built-in pad 26, a launderabie pad (such as 31 or 36) may also comprise one or more layers of absorbent hydrophilic fibers.

[0047] An exemplary embodiment of a disposable pad (such as 31 or 36) is illustrated in Figures 10-12, and shown generally at reference numeral 70. This pad 70 comprises a moisture permeable "filter paper" type shell 71 with a slow absorbing interior gel 72. The absorbent gel 72 is initially dry and powdery. The pad 70 may be stored in either or both pockets 25 and 35 of the garment 10. As urine enters the fabric composite 20 through the spacer 21 and transfers to the pad 70 located in the inside pocket 25, the powdery gel 72 absorbs the moisture and begins to swell at a relatively slow and controlled rate. Once fully saturated, the soiled pad 70 may be removed from the garment 10 and flushed in a toilet. The pad 70 may be biodegradable and/or sewage treatable.

[0048] Exemplary embodiments of the present invention are described above.

No element, act, or instruction used in this description should be construed as critical or essential to the invention unless explicitly described as such. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the exemplary embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation — the invention being defined by the claims and their equivalents.

Claims

I Claim:

1. A multi-layer moisture management fabric composite, comprising: a three-dimensional fabric spacer forming an inside layer of said fabric composite, and having a first facing adapted for residing nearest the skin, a second facing adapted for residing away from the skin, and an intermediate spacer yarn interconnecting the first and second facings; and a liquid impermeable barrier forming an outside layer of said fabric composite; and wherein said fabric spacer and said liquid impermeable barrier cooperate to form a pocket therebetween adapted for holding at least one absorbent pad designed to receive and disperse moisture entering said fabric composite through said spacer.

2. A moisture management fabric composite according to claim 1 , wherein said fabric spacer has a loft greater than 0.06 inches.

3. A moisture management fabric composite according to claim 1 , wherein the first facing of said spacer comprises a fine mesh fabric.

4. A moisture management fabric composite according to claim 3, wherein said fine mesh fabric comprises at least 400 uniform, mesh openings per square inch.

5. A moisture management fabric composite according to claim 1 , wherein the first facing of said spacer comprises moisture wicking fibers adapted for promoting moisture flow by capillary wicking.

6. A moisture management fabric composite according to claim 1 , wherein the second facing of said spacer comprises an open mesh fabric.

7. A moisture management fabric composite according to claim 6, wherein said open mesh fabric comprises less than 50 uniform, mesh openings per square inch.

8. A moisture management fabric composite according to claim 1, wherein the second facing of said spacer comprises moisture-absorbent fibers adapted for drawing moisture from the first facing of said spacer through said spacer yarn.

9. A moisture management fabric composite according to claim 1 , wherein the intermediate spacer yarn of said spacer comprises moisture wicking fibers adapted for promoting moisture flow from the first facing to the second facing by capillary wicking.

10. A moisture management fabric composite according to claim 1 , and comprising a drain vaive operatively connected to said liquid impermeable barrier and adapted for discharging moisture collected within said fabric composite.

11. A multi-layer moisture management fabric composite, comprising: a three-dimensional fabric spacer forming an inside layer of said fabric composite, and having a first facing adapted for residing nearest the skin, a second facing adapted for residing away from the skin, and an intermediate spacer yarn interconnecting the first and second facings; a liquid impermeable barrier forming an outside layer of said fabric composite; and wherein said fabric spacer and said liquid impermeable barrier cooperate to form a pocket therebetween; and at least one moisture absorbent pad residing within said pocket and designed to receive and disperse moisture entering said fabric composite through said spacer.

12. A moisture management fabric composite according to claim 11 , and comprising a sewing thread permanently attaching said moisture absorbent pad to said fabric spacer.

13. A moisture management fabric composite according to claim 11 , and comprising a removable and exchangeable second moisture absorbent pad located within said pocket.

14. In a moisture management garment comprising a shell fabric defining a waist opening, a crotch region, and first and second leg openings, a multi-layer moisture management fabric composite residing in the crotch region adjacent the shell fabric, said fabric composite comprising: a three-dimensional fabric spacer forming an inside layer of said fabric composite, and having a first facing adapted for residing nearest the skin, a second facing adapted for residing nearest the shell fabric, and an intermediate spacer yarn interconnecting the first and second facings; a liquid impermeable barrier forming an outside layer of said fabric composite; and wherein said fabric spacer and said liquid impermeable barrier cooperate to form a pocket therebetween adapted for holding at least one moisture absorbent pad designed to receive and disperse moisture entering said fabric composite through said spacer.

15. A moisture management garment according to claim 14, and comprising a moisture absorbent pad residing within said pocket.

16. A moisture management garment according to claim 15, and comprising a sewing thread permanently attaching said moisture absorbent pad to said fabric spacer.

17. A moisture management garment according to claim 15, and comprising a removable and exchangeable second moisture absorbent pad located within said pocket adjacent said first pad.

18. A moisture management garment according to claim 14, wherein said fabric composite and said garment shell fabric define a second pocket therebetween adapted for receiving and storing a further absorbent pad.

19. A moisture management garment according to claim 18, and comprising a removable and exchangeable third moisture absorbent pad located within said second pocket.

20. A moisture management garment according to claim 14, and comprising a drain valve operatively connected to said liquid impermeable barrier and extending through said garment shell fabric to discharge moisture collected within said fabric composite.