Patent Application
20120131733
The present invention relates generally to a method of manufacturing an article of clothing, and more particularly to superficially embedding a protective covering made of a thermoplastic material into the article of clothing or garment to be worn by either children or adults. The permanently embedded thermoplastic protective covering may be made from the application of a single layer (monolayer) of lead-free plastisol. The protective covering embedded into the garment of the present invention is functional, flexible and non-absorbent and can be clear or colored with a smooth or slightly textured surface.
Numerous patents disclose a variety of garments, including gloves, aprons, bibs and gowns, providing a protected region on said garments by use of a plurality of chemicals and methods. Many of these methods require complex assembly of a multi-layer protective covering. For example, U.S. Pat. No. 4,526,828 [Fogt et al.] discloses a protective material for use in garments such as gloves, leggings, sleeves, and aprons. This protective material comprises a base layer composed of textile material, an intermediate layer composed of a cut-resistant material having intermeshing strands, and an outer layer composed of solid, elastomeric material that retards penetration by liquids. The multi-step and complex process used to generate this protective covering also results in limited flexibility of the underlying garment.
U.S. Pat. No. 3,608,092 [Taranto] and U.S. Pat. No. 5,153,940 [Bergquist] both disclose a children's garment comprising a multi-layer protective bib attached to the underlying garment. The protective bib disclosed in U.S. Pat. No. 3,608,092 [Taranto] is composed of at least two layers of material superimposed upon one another. One layer comprises synthetic plastic sheet material overlying the front side of the garment portion, and this layer is bonded to a second layer constituting a padding material of foam or fibrous silver. Additionally, this disclosure provides for a decorative picture on the outer layer of the bib region. U.S. Pat. No. 5,153,940 [Bergquist] discloses a children's sleeper garment with an attached bib comprising two layers of protective materials. One layer is a moisture impervious layer, and it is attached to a moisture absorbent layer.
Several patents disclose elastomer coated garments, whereby the preferred embodiments of the inventions result in a “wrinkled”, “textured” or “rough” outer layer of the garment. For example, U.S. Pat. No. 4,174,542 [Vistins] discloses an elastomer coated textile apron characterized by a textured or “wrinkle” finish. This disclosure focuses on the method of manufacturing these garments to produce a “wrinkle” finish. The garment is either dipped in or sprayed with the elastomeric resin resulting in a ‘saturated’ underlying garment with a “wrinkled” finish. Another example of elastomer coated garments with a “textured” surface is disclosed in U.S. Pat. No. 4,359,783 [Andrews]. The methods disclosed include joining a non-woven fibrous web, such as needled felt to a knitted web, and utilizing a needled staple fiber preferably from the non-woven web to join the two webs together into a formed laminate. The joining procedure is such that the finished laminate includes the needled staple fiber extending form one surface of the web to form a base surface for a subsequent application of an elastomeric coating. The methods described in the aforementioned patents provide for a “textured” protective coating on the desired garments at the cost of significantly limiting the flexibility of the underlying garment.
U.S. Patent Application Publication US2004/0123367A1 [Schorr et al.] discloses a structure developed to reduce the likelihood that low surface tension liquids, such as blood, will wick along the outside surfaces of a non-woven material. Such a structure includes a non-woven garment that is treated to include a continuous line, band or path of low surface tension liquid blocking material deposited at least along an outside surface portion of a sleeve, waist, leg, or neck opening of a body garment. The structure is placed on a garment that goes on/or around the body extremities, such as on an ankle portion of a boot, hood portion of a protective outerwear, side edges of facemasks, or wrist portions of hand coverings. The disclosure describes the manufacture of said structure from a breathable multi-layer “film”.
Other patents have described protective coverings resembling aprons for adults, which are put on over the user's clothing to protect the clothing. For example, U.S. Pat. No. 3,984,876 [Sutton] discloses a blouse cover, which fastens to the user's body and has a detachable and replaceable bib fastened to the blouse cover. Thus, a need exists for a permanently embedded protective covering that co-mingles with the fibers of a garment, and one that will not detach from the garment.
The present invention can be clearly distinguished from the aforementioned disclosures, and consequently occupies a niche that fulfills an unmet need in the field. It satisfies a need for a permanently embedded protective covering that does not consist of multiple layers, and maintains the flexible characteristics of the underlying garment. Moreover, the present invention does not have to be attached over, or temporarily to the underlying garment. Specifically, unlike the disclosures outlined in U.S. Pat. No. 4,526,828 [Fogt et al.], U.S. Pat. No. 3,608,092 [Taranto], U.S. Pat. No. 5,153,940 [Bergquist], and U.S. Patent Application Publication US2004/0123367A1 [Schorr et al.], the present invention provides for a simple method to manufacture a superficially and permanently embedded protective coating comprising only a monolayer deposited on the outer fibers of the underlying garment. There are several benefits to this invention when compared to the prior disclosures. Importantly, the inner portion of the region of the garment corresponding to the protective coating (portion in contact with the wearer) will maintain the characteristics of the underlying garment. This will maintain the inherent flexibility and comfort of the underlying garment. Another benefit of this method is that it is easier and more cost effective to embed the protective coating superficially in the form of a monolayer. Additionally, unlike U.S. Pat. No. 4,174,542 [Vistins] and U.S. Pat. No. 4,359,783 [Andrews] that disclose a “texture” or “wrinkled” finish, which can limit flexibility, the present invention puts forth an embodiment having a smooth outer surface of the coating that can maintain the desired flexibility. The current invention can also be distinguished from U.S. Patent Application Publication US2004/0123367A1 [Schorr et al.] that discloses a protective structure circumscribing the wrists, ankles and neck region of the body. In contrast, the present invention discloses a method of superficially and permanently embedding a monolayer of a protective coating on multiple regions of a plurality of garments, including bibs, gowns, overalls, ties, blouses, t-shirts, and children's sleepers.
Unlike the present invention that results in a non-porous surface that is substantially impermeable to liquids, several patents describe coating of fabric that leaves the fabric porous. U.S. Pat. No. 3,503,821 [Conklin] describes a coating process that specifically retains the porosity of the fabric of the garment after the application and heat transfer of the covering. Also, U.S. Pat. No. 4,654,256 [Doree, et al.] speaks of a mechanical bond between the covering and the underlying fabric. More particularly, there is a description of the heated and flowing thermoplastic material flowing into the voids of the porous fabric to achieve the mechanical bond. However, there is no description of the resulting surface properties of the covering or whether there is a resulting impermeability. The only reported result is that the fabric is not adversely affected by the heat and pressure process for embedding the covering into the fabric. Thus, even those descriptions that provide a basis for the thermal embedding of the vinyl chloride compound into fabric still lack any description of the anti-porosity and liquid impermeability as in the monolayer protective coating of the present invention.
The present invention describes a method for manufacturing an article of clothing with a permanently embedded non-porous protective covering directly set or embedded into the fibers of the garment. The permanently and superficially embedded protective covering is made from a plastisol, which is embedded into the fabric by the use of a combination of high temperature and high pressure, and then immediately cooled before the plastisol material can penetrate through all of the layers of the fabric. The cooling process ensures that the plastisol co-mingles only within the top garment fibers and interweaves with the fabric fibers of the garment, where it remains, so that it will not penetrate through all the layers of the fabric, avoiding direct contact with the skin of the user. The plastisol will thermally bond to the underlying fabric of the garment in a temperature range between 150° F. to 200° F. ideally; however the temperature may be increased as high as 330° F.
The permanently embedded protective covering utilized in this invention may be made from the application of a single layer (monolayer) of lead-free plastisol. Plastisol is a polyvinyl chloride (PVC) or liquid vinyl dispersion or thermoplastic, which is fused by heating to form a solidified end product. The plastisol will fuse rapidly to the fabric of a garment because of its fine particle structure. The temperature at which plastisol cures and, by such curing process, is impregnated (or partially impregnated) into a fabric material ranges ideally between 150° F. to 200° F., but can increase up to 330° F.
The plastisol is embedded into the fabric by the use of a process for applying the plastisol material at a temperature sufficient to change the state of the material to a liquid and at higher pressures, such that in combination the liquid plastisol is forced between the fibers of the material of the fabric to which it is being applied. The process then immediately requires a cool-down of the plastisol before it penetrates through all the layers of the fabric. The cooling process ensures that the plastisol embeds only within the outermost garment fibers, interweaving with the fibers of the garment where it remains. In this fashion the plastisol material will not penetrate through all of the layers of the fabric, avoiding direct contact with the skin of the user. Alternatively a heat transfer may be made by screen-printing plastisol on a special release paper. The “transfer” is then applied to a garment or fabric using a heat press that applies pressure and melts the material so it will bond with the fabric, as it is pressed into the garment fibers by the heat press. The heat applied by the heat press liquefies the plastisol material so that it can penetrate the upper layers of the fabric and, once the heat source is removed, the plastisol not only cures or hardens around the garment fibers, but also produces a surface coating that is non-porous which is impermeable to liquids.
The plastisol material is self-extinguishing, non-toxic and water resistant. Plastisol has a good natural bond to most porous surfaces such as paper, fabrics, pile, rope or any material that will allow some superficial penetration by the plastisol material. Since plastisol is a thermoplastic, some softening occurs above room temperature; however it can withstand exposure to temperatures of 180° F. without actual deterioration. Plastisol will not decompose or change significantly in acids, alkalines, detergents, foodstuffs, water or other natural substances. The permanently embedded protective covering does not hold or retain substances very easily. The protective covering is non-absorbent with a smooth or slightly textured surface so that if a particular substance holds temporarily it can easily be wiped away with soap and water.
The present invention provides a permanently embedded protective covering that can be used on garments for both adults and children, which covering does not require fastening means, and which provides protection to the overall garment by resisting penetration of liquids through the covering. The present invention does not have to be worn over a garment, because it already exists on the garment as it is embedded into and co-mingles with the fibers of the garment giving the protective covering the same flexibility as the garment. The present invention is non-toxic and flame retardant, and as easy to clean as the garment itself.
The permanently embedded non-porous protective covering preferably covers the top portion of the garment and extends downward to the mid torso. However, the protective covering can be placed across or extended over a lower portion of the garment, if the lower portion of the garment is prone to attracting particles and dirt. The permanently embedded protective covering surrounds the underlying fiber layers of the fabric so that it becomes one with the fabric and attains the same flexibility as the fabric of the garment, thereby making it a solid portion that cannot be broken easily, while maintaining a liquid impermeability against seepage of most liquids through the protective covering.
The garment, in one preferred embodiment, can be an infant's sleeper or shirt, preferably of a soft woven material. The permanently embedded protective covering begins at the top or neckline of the sleeper or shirt and extends to approximately the mid torso. A different embodiment of the invention can be on a young child's shirt. The permanently embedded protective covering could begin at the neck portion of the shirt and extend to approximately the mid torso.
Yet another embodiment is envisioned to be a permanently embedded protective covering on an adult sized shirt, gown or coat for use in a hospital, nursing home, restaurant, or other institution or facility where clothing would be getting fluids or foods on them and need to be easily wiped away or cleaned. A permanently embedded non-porous protective covering in accordance with the present invention, that resists the inward passage of liquids through the garment, would be particularly useful and convenient as it is easy to clean, non-toxic and flame retardant.
For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
Referring now to the drawings in detail, where like numerals refer to like parts or elements, there are shown in
The protective covering 42 is preferred to be of a thermoplastic material, such as plastisol ink, which is considerably thicker than most graphic inks. The plastisol material will fuse rapidly into the garment fibers 44, 46 due to its fine particle structure. The temperature at which the plastisol material will attain a fluid state so that it will flow into the fabric of the garment is in the range of 150° F. to 200° F., but the temperature may be increased up to 330° F. The plastisol material is embedded into and between the fibers of the fabric by the use of a combination of the higher temperature and a high-pressure application. Once applied and following a time period sufficient for dispersion through the outer layer of the fabric of the garment and into an intermediate layer of the fabric, the thermoplastic material and the garment are cooled before the thermoplastic material can flow into and through all the layers of the fabric. The cooling process ensures that the plastisol material penetrates and embeds only within the outermost fabric fibers of the garment by flowing under and through the outer fibers 44 and under the cross-weave fibers 46, but not onto the inner surface of the garment shown by fibers 48. When cooled below the threshold temperature of 150° F., the plastisol material remains within the outer layers of fiber of the garment. In this manner, the thermoplastic material creates a non-porous liquid shedding covering (monolayer) along the outer surface of the garment and does not penetrate through all the layers of the fabric, such that direct contact with the skin of the user is avoided.
Alternatively, a heat transfer may be made by screen-printing plastisol ink on a special release paper. The “transfer” is then applied to the garment using a heat press that applies pressure and changes the state of the plastisol ink from solid to fluid so that it will flow and bond with the fibers of the garment, as it is pressed into the garment fibers 44 and cross-weave fibers 46 by the heat press. The heat applied by the heat press is maintained for a time period sufficient for the plastisol ink to liquefy and flow into and around the outer fibers 44, 46 of the fabric of the garment and is then removed to allow the plastisol material to cure by forming a permanent bond with the fabric fibers 44, 46, but the innermost fibers 48 of the garment. The permanently embedded protective covering 42 can be seen to entirely surround the outermost layer of the fabric, which consist of the individual fibers 44, and be seen to impregnate the individual cross-weave fibers 46, so that protective covering becomes one with the fabric and attains the same flexibility as the fabric of the garment. In this way the plastisol coating produces a non-porous covering that sheds liquids and prevents the penetration of liquids through the area of the covering on the garment.
Referring now to
Referring to
In
Another garment utilizing the protective covering of the invention is illustrated in
Another garment is illustrated in
Another article of clothing utilizing the method of the present invention, as illustrated in
A garment 90 shown in
Garment 110, as illustrated in
As in the cases of the previously described garments, the protective coverings 12, 22, 32, 52, 62, 72, 82, 92, 102, 112 and 112a are each positioned to extend over and protect that area or portion of the garment or article of clothing that is most likely to be spilled on, or to receive splatter or some other form of deposit of a foodstuff, or the deposit of a human bodily fluid that would normally dampen, in the case of infant saliva, or create an area of contact with the garment leaving on the garment some form of material that has splattered or spilled during eating or using the garment during the course of regular workplace routine. In each case the protective covering resists the adherence of solids and prevents the inward penetration of liquids by the non-porosity of the covering embedded in the garment, while allowing the easy wiping away of the majority of the spillage or spatter, and then the easier washing of the article of clothing to remove any remainder of the deposit. The impermeability to liquids of the coverings 12, 22, 32, 52, 62, 72, 82, 92, 102, 112 and 112a through the non-porosity of the covering material as set into the fabric is believed to be unique to this invention.
The invention has been described as producing a single (monolayer) of a protective covering or coating not only on the top surface of a garment, but extending through to wrap around the garments fibers and to fill the voids between the fibers as presented on the topmost surface. The resulting covering or coating is non-porous such that liquids do not penetrate into the fabric of the garment. This liquid impermeable layer lies atop the fabric and extends into the fabric only a distance sufficient to wrap around the outer fiber layers, but not all the way through the fabric. In this way, the fabric, as well as the overall garment, and the covering remain flexible so that movement by the garment wearer is not impeded. The protective coating functions to shed liquids away from the garment and to be easily cleaned if any liquid or liquid-borne solids remain attached to the protective coating.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.
The present application is a continuation-in-part of U.S. application Ser. No. 12/386,947 filed on Apr. 24, 2009, which application was a continuation-in-part of U.S. application Ser. No. 11/811,410 filed on Jun. 5, 2007, now abandoned.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12386947 | Apr 2009 | US |
| Child | 13365315 | US | |
| Parent | 11810410 | Jun 2007 | US |
| Child | 12386947 | US |
