SUPPORT GARMENT OR TAPE AND METHOD OF MAKING THE SAME

Abstract

A method of producing a variable compression garment. The method includes: identifying, in a base textile having a first elongation and memory characteristic, a first region having a second elongation and memory characteristic; applying to the base textile, in the first region, a first layer of an elastomer; drying the first layer of the elastomer to adhere the first layer of the elastomer to the base textile; applying to the base textile, in the first region, at least a second layer of the elastomer; drying the second layer of the elastomer to adhere the second layer of the elastomer to the first layer on the base textile; and baking the first and second layers of the elastomer to cure the first and second layers of the elastomer.

Description

FIELD OF THE INVENTION

The present invention relates to a compression garment. More particularly, although not exclusively, the present invention relates to a compression support garment arranged to be used in sports and joint support by providing a variable compression to corresponding body part. The invention also relates to support tapes and methods of making support garments and tapes.

BACKGROUND TO THE INVENTION

In our daily lives, many activities pose a heavy burden on our muscles and joints. Examples include sports and exercises such as jogging and cycling, standing and walking, as well as carrying and lifting heavy items for a prolonged period. These physical exertions can cause fatigue, and in excess can lead to damage of muscles and joints.

There are a range of products available to support muscles and joints during exercise or daily activities, including compression garments, sleeves, support braces and tapes. A common feature in such products is an elastic element or characteristic that holds one or more muscles and/or joints firmly in place and/or is designed to stretch with and support muscles and joints as they move. The aim of such products is to prevent injury, improve athletic performance, and/or aid healing or recovery.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a method of producing a variable compression garment or tape, including: applying to a base textile having a first elongation and memory characteristic, in a first region of the base textile, a first layer of an elastomer; drying the first layer of the elastomer to adhere it to the base textile; applying to the base textile in the first region at least a second layer of the elastomer; drying the second layer of the elastomer to adhere it to the first layer or the base textile; and baking the first and second layers of elastomer to cure the first and second layers of elastomer. The method preferably also include identifying, in the base textile, the first region to have a desired second elongation and memory characteristic. The method may additionally or alternatively include providing the base textile prior to the identification step.

The method may also include: determining a number of layers of the elastomer to provide the second elongation and memory characteristic; and after the drying of the second layer of the elastomer, applying an additional number of layers of elastomer and drying each additional layer before applying a next additional layer.

The method may also include: determining a desired direction and/or gradient of the second elongation and memory characteristic; determining a pattern or patterns for the first, second, and optionally the additional, layers of the elastomer to provide the desired direction and/or gradient; and applying the first, second, and optionally the additional, layers of the elastomer includes applying the layers in the determined pattern or patterns. Preferably, the desired direction and/or gradient include two or more directions or gradients. The pattern or patterns may include one or more of: a pattern of interlocking shapes, a pattern of parallel lines and/or a pattern of one or more crossing lines.

The method may also include: identifying a second region of the base textile to have a desired third elongation and memory characteristic; determining a number of layers of elastomer to provide the third elongation and memory characteristic; and before the baking step, applying to the base textile in the second region one or more second-region-layers of the elastomer, and drying each second-region-layer before applying a next second-region-layer.

The method may also include: determining a desired direction and/or gradient of the third elongation and memory characteristic; determining a second-region-pattern or -patterns for the one or more second-region-layers of the elastomer; and applying the one or more second-region-layers of the elastomer may include applying the second-region-layers in the determined second-region-pattern or -patterns.

Preferably, the baking step comprising baking for at least 4 hours, and more preferably at least 8 hours, at a temperature of between 70 and 90 degrees centigrade.

Preferably, the elastomer is silicon or polymer baser elastomer.

In one embodiment, applying the layers or the second-region-layers of the elastomer includes printing the layers, preferably using a capillary film screen printing method.

Preferably, drying the layers or the second-region-layers of the elastomer comprises flash drying the layers at 140 degrees centigrade for at least 6 seconds.

The method may also include: before applying the layers or the second-region-layers of the elastomer, applying a base layer of a primer material to the base textile and drying the primer layer.

One or more patterns or second-region-pattern or -patterns may include 3D patterns for providing the determined desired direction and/or gradient of the second and third elongation and memory characteristics.

Preferably, the material of the base textile includes at least 80% of cotton and/or polyester and/or nylon.

The method may also include: prior to applying to the base textile in the first region a first layer of an elastomer, cutting the base textile to form a panel of a compression garment.

The method may also include: prior to applying to the base textile in the first region a first layer of an elastomer, cutting the base textile form a panel of a compression garment and joining the base textile panel with additional panels to form the compression garment.

The method may also include: after the baking step, cutting the textile form a panel of a compression garment, wherein the panel includes at least one of the first or second regions, and joining the panel with additional panels to form the compression garment.

The method may also include: prior to applying to the base textile in the first region a first layer of an elastomer, cutting the base textile to form a panel of a compression garment, and joining the panel with additional panels to form the compression garment.

In a preferred embodiment of the first aspect, the variable compression garment is any one of: a shirt, shorts, tights, sleeves, socks, underwear, or a joint brace or support.

In a preferred embodiment of the first aspect, the variable compression garment comprises a medical support garment, the medical support garment includes any one of: a joint brace, a knee support, a calf support, an ankle support, a shoulder support, an elbow support, an arm support, a wrist support or a hand and/or figure support.

In accordance with a second aspect of the invention, there is provided a variable compression garment or tape produced using the method of the first aspect. The variable compression garment can be, e.g., a shirt, shorts, tights, sleeves, socks, underwear, or a joint brace or support; or a medical support garment such as a joint brace, a knee support, a calf support, an ankle support, a shoulder support, an elbow support, an arm support, a wrist support or a hand and/or figure support.

In accordance with a third aspect of the invention, there is provided means for applying to a base textile having a first elongation and memory characteristic, in a first region of the base textile, a first layer of an elastomer; means for drying the first layer of the elastomer to adhere it to the base textile; means for applying to the base textile in the first region at least a second layer of the elastomer; means for drying the second layer of the elastomer to adhere it to the first layer or the base textile; and means for baking the first and second layers of elastomer to cure the first and second layers of elastomer.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a front view of a compression vest made according to the invention,

FIG. 2 is a rear view of a compression vest made according to the invention,

FIG. 3 is a front view of a compression leggings made according to the invention,

FIG. 4 is a rear view of a compression leggings made according to the invention,

FIG. 5 is a side view of a compression leggings made according to the invention,

FIG. 6 is a front view of a compression shorts made according to the invention,

FIG. 7 is a rear view of a compression shorts made according to the invention,

FIG. 8 is a side view of a compression shorts made according to the invention,

FIG. 9 is a rear and side view of a brace or support made according to the invention,

FIG. 10 is a rear and side view of a back brace or support made according to the invention,

FIG. 11 is a view of a knee brace or support made according to the invention,

FIG. 12 is a view of an arm brace or support made according to the invention,

FIG. 13 is a view of an elbow brace or support made according to the invention,

FIG. 14 is a view of an ankle brace or support made according to the invention,

FIG. 15 is a view of a wrist brace or support made according to the invention,

FIG. 16 is an illustration of a multi-directional support and/or compression pattern according to the invention,

FIG. 17 is a second illustration of a directional support and/or compression pattern support pattern according to the invention, and

FIG. 18 is a schematic illustration of a method of making a support garment or tape in one embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Unless the context requires otherwise, the term compression garment includes a joint or muscle brace or support which might only provide compression or support to a joint or portion of a limb or torso of a person.

Referring to FIGS. 1 and 2, there is shown a first embodiment of the present invention in the form of a compression garment 10 arranged to provide at least a localized compression effect to a region or body part of a wearer. The compression garment 10 is a shirt, but may in other embodiments be pants or shorts. The compression shirt 10 comprises a base textile 11 consisting of sleeve panels, a front panel 12 and a rear panel 13 sewn or otherwise joined in a known manner. The base textile of the short has a first elongation and memory characteristic. The first elongation and memory characteristic of the base textile 11 is achieved through the use in the textile of a combination of fibres, filaments and/or yarns having different elasticity characteristics such as cotton, polyester, nylon, and various high elasticity fibres generally referred to as SPANDEX, LYCRA, Elastane and their variants. Preferably, the base textile 11 comprises up to 95% cotton, polyester or nylon fibres, with the remaining fibres being SPANDEX, LYCRA or a variant thereof. The first elongation of the base textile 11 may be in any direction. In one setting, it may elongate along a vertical direction. In other settings, it may elongate along a horizontal direction or a slanting/diagonal direction. The base textile 11 further includes a memory characteristic, which allows the base textile to return substantially to its original form before elongation.

The compression shirt 10 further comprises one or more regions 14, 15 with an elongation characteristic different than that of the base textile. The elastomer material is applied to, for example, a first region 14 on the base textile to give the first regions a desired second elongation and memory characteristic different to the elongation characteristic of the base material. The first region 14 is a region for providing a localized compression effect to the wearer, and varies from positions depending on the different targeted body part. In this example, the first region 14 is the whole chest area on the shirt. One or more layer of an elastomer is applied and adhered to the base textile 11 in the first region in a pattern such that the first region has a desired second elongation. Preferably, the second elongation is shorter than the first elongation, for providing the greater localized compression effect. It further has a memory for substantially returning the first region 14 to its original form before elongation.

The one of more layers of elastomer may take different patterns, shapes, and/or forms for providing the desired elongation characteristic. The pattern may be a strip, intersecting lines, a network pattern or any combination of these. Different shapes and forms may be used according to the targeted body part, in order to provide an optimum effect. In FIGS. 1 and 2, the elastomer at the chest region takes a form of a pattern of interlocking shapes having an even elongation in orthogonal directions. Referring to FIG. 16, specifically, the pattern of interlocking shapes is a knuckle lock pattern, which comprises a network of hourglass or dumbbell shapes, distributed uniformly across the chest region. The hourglass or dumbbell shape is closely packed with one another, with the two circular ends 31, 32 of each one fitted in the concave part of another. The knuckle lock pattern can elongate along four directions—vertical, horizontal, 45° and −45° from the vertical. This pattern is advantageous in that it can provide stabilization of chest muscle groups by preventing it from being stretched in random directions and lateral support through the sides.

The compression shirt 10 may further comprise a second region 15 on the base textile 11 having a third elongation and memory characteristic. Similar to the first region, the second region 15 may be positioned at a different location depending on the targeted body part. In this embodiment, the second region 15 may be located at the tricep and bicep area of the upper arm. One or more layer of elastomer is applied and adhered to the base textile 11 in a second pattern, illustrated in FIG. 17, different to that of the first region 14, to provide a different elongation pattern. Within the same region, the number of layers may vary. For example, a first line in the region includes two layers of elastomer and a second line may include three layers of elastomer. The resulting cross-over part of the first and second line has five layers of elastomer.

FIG. 17 shows an enlarged view of the second region 15 of the compression shirt 10 of FIGS. 1 and 2. The second region comprises a cross lock pattern 42 of one or more crossing lines and is formed by contouring the elastomer. Specifically, a pattern of two groups of three parallel lines 44 are contoured and progressed to a crossed-over pattern to form a power up zone 40, the cross lock zone 42, and a lateral support zone. The power up zone 40 covers the triceps; the cross lock zone 42 covers right above the elbows for containing and supporting the muscles and joint. Additionally, a third region may be identified, and a cross lock pattern 15 is provided to support the waist muscles.

Referring to FIGS. 3 to 5, there is shown a pair of compression leggings or tights 20 in one embodiment. Similar to the compression shirt 10, the compression tights 20 comprises a base textile 16 and at least one compression region having a different elongation from the base textile, for providing a localized compression effect. Regions are identified and different patterns are chosen based on the targeted muscle group or joint. For example, a high compression force may be desired for the extremities where main muscles groups and joints are located, and a lower compression force for the core muscles or muscles groups near the core.

Specifically, the compression tights 20 includes four compression regions comprising two cross lock patterns 15 on each leg portion. A first cross lock pattern 15 is positioned at the anterior thigh muscles and a second cross lock pattern 15 is positioned at the calf muscles. Since the thighs and calves are the main muscle groups in the legs, the cross lock pattern 15 can confine and support individual muscle groups and minimize the chance of muscle tearing. The heavy load exerts on the knees can be alleviated through the lateral support of the cross lock zone. The compression force exerted by the cross lock pattern 15 at the anterior thigh muscles may be different from or the same as compression force exerted by the cross lock pattern 15 at the calf muscles. The higher compression force can be achieved by applying additional layers of elastomer.

The compression tights 20 further comprises a knuckle lock pattern 14 covering the hip and posterior thigh region. In this embodiment, the knuckle lock pattern 14 provides an optimum stabilization of hamstring and gluteus muscles by confining the compression region to be stretched in four directions.

Referring to FIGS. 6 to 8 there is shown a pair of compression shorts 21 in one embodiment. In this embodiment, the compression shorts 21 is a thigh or knee-length shorts. Similar to the compression tights, the compression shorts 21 includes a base textile, a cross lock pattern at the anterior thigh on each leg and a knuckle lock pattern at the hip and posterior thigh.

Whilst the above description provide specific examples of the compression garments, it should be noted that the invention can also apply to other types of garments, wearable, clothing (causal or sportswear), or any part of such garment, wearable, or clothing (causal or sportswear). For example, the compression garment may be a pair of tights, a pair of shorts, a sleeve, a sock, underwear, a joint brace or support, or a sports support tape.

Referring to FIGS. 9 to 15, there is shown a medical support garment in one embodiment. In this embodiment, the medical support garment is an arm support. In other embodiments, the medical support garment may be an elbow support, a knee support, a calf support, an ankle support, a shoulder support, a wrist support, or a hand and/or figure support. The arm support in FIG. 12 comprises a base textile having one of more patterns of regions with a different elongation characteristic. Preferably, the base textile is made of neoprene providing a first compression force to a targeted joints and/or muscle groups. The arm support further comprises one or more layers of elastomer for providing an additional, localized compression force. The elastomer layer may be a strip, intersecting lines contoured to compress and support the targeted joints and/or muscles.

FIG. 9 shows a back support in one embodiment of the invention worn on the back. The back support is in the form of a loop, and it is made of a base material that is elastic and includes memory characteristic. Preferably, the base material is, for example neoprene. Multiple layers of base materials may be used or connected together. Elastic strip lines 50 having a second elastic and memory characteristic are bonded, attached, or otherwise connected to the base material. Preferably, the strip lines include elongate portions and cross portions. In this embodiment, the strip lines generally extend around the loop, along the top and bottom edges, and with axial crossings. Preferably, the crossings are provided on the sides that correspond to the back and to the side of the waist. The pattern may be substantially symmetric about the centerline of the base material.

FIG. 10 shows a calf support in one embodiment of the invention. The construction of the calf support is similar to that of back support in FIG. 10, except that the calf support only includes one layer of base material, and strip lines on the side of the support that corresponds to the calf. The strip lines 50 generally extend axially on the base material, with multiple crossings between the top and bottom edges of the base material.

FIG. 11 shows a knee support in one embodiment of the invention. The construction of the knee support is similar to that of calf support in FIG. 10, except that the pattern of the strip lines 50 is arranged differently to provide support for the knee. In this embodiment, crossings of the strip lines are provided on the sides of the knee.

FIGS. 12, 13, 14, and 15 respectively show an arm support, an elbow support, a foot support, and a wrist support. They are of like construction to the supports in FIGS. 9-11, except that they are shaped and sized to fit the corresponding body part, and have different strip line patterns.

Whilst the above description provide specific examples of the compression garments, it should be noted that the invention can also apply to other types of garments, wearable, clothing (causal or sportswear), or any part of such garment, wearable, or clothing (causal or sportswear). The base material may be other flexible material. The base material preferably provides a first elasticity (having an elongation and memory) and the strip lines provide a second elasticity. The first elasticity is preferably different to the second elasticity. The pattern of the strip lines shown is merely exemplary. The strip lines can be different form, shape, width, etc., but preferably they provide cross portions that provide improved support and or compression of the base material. The base material may be formed with one or more openings, preferably at the bending point, to reduce restriction and provide more flexibility during movement. In yet one more embodiments the base material may be an elastic sports tape material with an adhesive for adhering to the skin of a user/wearer. The tape may have applied to it one or more regions of an elastomer to provide the tape with regions having a second elongation characteristic.

A variable compression garment, brace or support as described above can be made of a lower grade textile or fabric having an elongation below that which might otherwise be suitable for such purpose. For example, in a compression garment a lower cost textile comprising, say, up to 95% cotton, Polyester or nylon and less than, say 30% elastane or other highly elastic synthetic fibres such as SPANDEX or LYCRA, can be used. Typical textile combinations include, say, a textile comprising 72% nylon and 28% highly elastic synthetic fibres such as LYCRA with a weight of 210 grams, or a textile comprising 76% polyester and 24% highly elastic synthetic fibres such as SPANDEX with a weight of 200 grams, or a textile comprising 92% polyester and 8% highly elastic synthetic fibres such as SPANDEX with a weight of 190 grams.

In order to provide the textile, or regions of the textile corresponding with a desired compression or support zone, with a suitable elongation and memory, the textile is printed with an elastomer having a high elasticity and resilience. In one embodiment a silicon based elastomer is used. In another embodiment a polymer formula elastomer may be used. Other printable high elasticity and resilient elastomers may be used. The choice of elastomer is based on the perdominent fibres of base material that may be chosen, for example cotton, polyester or nylon, and the desired elasticity of the elastomer. The elastomer is applied to the identified support regions of the textile in two or more layers using a screen printing technique to build up layers of the elastomer in a particular 3D pattern, such as those described previously, to control both the elongation and memory of the support region and the direction of support.

Printing of the textile with the 3D patterns of elastomer in support regions can be done in a nested fashion where several regions of a textile sheet are printed before cutting garment panels from the textile and joining them to form a garment. Alternatively printing can be done after cutting the garment panels but before sewing the garment, or the completed garment can be printed. Another advantage of printing the garment panels with elastomer to control elongation, memory and direction of support of the support region is that it allows fewer panels to be used to construct a garment or support brace/sleeve. Garments relying on the base textile for compression and support require panels to be cut with support regions and direction in mind. Different fabrics must be used in regions requiring different degrees of compression and support. Different panels must be used where different directional support is desired. The present method overcomes or at least ameliorates this requirement because compression, support and directional stability of the support regions is controlled by printing of the textile.

According to a method in one embodiment of the invention, one or more support regions of the textile are identified where the textile is to be provided with an elongation and memory characteristic higher than that of the base textile itself. As aforementioned, such regions can be identified before or after cutting garments panels from the textile, or before or after garment constructions. After the support regions are identified a pattern and a required number of layers of the elastomer are determined or identified that will provided the desired elongation, memory and directional support for each identified support region. A screen printing method is then used to print the identified pattern onto the textile support region in two or more layers. In one embodiment the screen printing may involve use of an emulsion coating method to apply the elastomer to the screens. Such a method, while effective, may require more layers to be printed to achieve the desired elongation characteristic due to inconsistency in thickness of elastomer applied to the screens. The output must also be continually tested to make sure elongation is inside a range of consistency. In a preferred embodiment a capillary film screen printing is used where the elastomer emulsion is applied to the screen from a capillary film. Using a capillary film of, say, between 50 and 125 microns results in an exact and consistent emulsion thickness on the screen and as result more accurate results may be achieved with fewer printed layers.

Referring to FIG. 18, the elastomer in the support regions is built up in layers, including a first, and perhaps optionally, step 50 of applying, via a print screen 52, a primer layer 53 to the target textile 51 in the support region to encourage and enhance adhesion of the elastomer to the base textile. Following each printing step is a flash drying step 54. The flash drying preferably includes introducing the printed textile briefly into a drying tunnel at say 140 degrees centigrade, or thereabouts, for say 6 seconds, or thereabouts. The elastomer pattern is then built up by screen printing successive layers of elastomer and flash drying each layer. Then, in step 55, a first layer 56 of elastomer is applied to the primer layer 55 using a screen printing technique. The first layer 56 of elastomer is the subjected to a flash drying step 54′. Continuing the process a second layer 58 of elastomer is applied to the first layer in a subsequent printing step 57, followed by another flash drying step 54″ of the second layer 58. Further printing steps, each followed by a flash drying step, are undertaken until the necessary thickness and pattern of elastomer is applied to the support region for the desired elongation characteristic to be achieved. In a final, and perhaps optional, printing step 59, a top coat 60 may be printed onto the elastomer to provide an aesthetic or protective top layer. In a preferred embodiment, the top layer may be a suede for both aesthetic and comfort purposes. in step 61, the layers are then dried in a tunnel 62 at say 140 degrees centigrade, or thereabouts, for say 120 seconds, or thereabouts.

After the 3D layered printing and drying steps are completed the various layers of the compression and support patterns of elastomer are set or cured in a final step 63. This is preferably done by baking the printed textile on an oven 62. This baking step greatly increases the durability and effectiveness of the elastomer. The baking requirement may vary depend upon the elastomer used, and is sufficient to fully set or cured the elastomer. In an embodiment with a silicon based elastomer material, the textile or garments may be baked for 4 to 8 hours at 70 to 90 degrees centigrade. The baking time may vary with temperature—at lower baking temperatures the baking time may increase, but the temperature and time should not be so high and long so as to damage the textile. In one embodiment, the curing step 63 is at 70 degrees for 8 hours; in another embodiment, the curing step 63 is at 90 degrees for 4 hours. In other methods according to the invention, highly stretchable and UV curable elastomers can be used and the curing step may include subjecting the printed elastomer pattern to UV curing.

The following summarizes the basic method for making a variable compression garment in the embodiment described above from a lower grade base textile or fabric having a first elongation and memory:

identify a first region of the base textile to have a desired second elongation and memory characteristic,

apply to the textile in the first region a first layer of an elastomer,

dry the first layer of the elastomer to adhere it to the textile,

apply to the textile in the first region at least a second layer of the elastomer,

dry the second layer of the elastomer to adhere it to the first layer or textile, and

cure the elastomer layers, e.g., by baking the elastomer layers to cure the layers.

A further step may include determining a number of layers of the elastomer to provide the second elongation and memory characteristic, and after drying the second layer of the elastomer, applying an additional number of layers of elastomer and drying each additional layer before applying a next additional layer.

Yet a further step may include determining a desired direction and/or gradient of the second elongation and memory characteristic; determining a pattern or patterns for the first, second, and optionally the additional, layers of the elastomer to provide the desired direction and/or gradient; and wherein applying the first, second, and optionally the additional, layers of the elastomer comprises applying the layers in the determined pattern or patterns. The desired direction and/or gradient may comprise two or more directions or gradients. The pattern or patterns comprise, but is/are not limited to one of the patterns discussed above with reference to the drawings, or shown in the drawings.

Another step may include identifying a second region of the base textile to have a desired third elongation and memory characteristic; determining a number of layers of elastomer to provide the third elongation and memory characteristic; and before the curing step, applying to the textile in the second region one or more second-region-layers of the elastomer, and drying each second-region-layer before applying a next second-region-layer. Optionally there may be a step of determining a desired direction and/or gradient of the third elongation and memory characteristic; determining a second-region-pattern or -patterns for the one or more second-region-layers of the elastomer; and wherein applying the one or more second-region-layers of the elastomer comprises applying the second-region-layers in the determined second-region-pattern or -patterns.

Baking the elastomer layers may optionally comprise baking the layers for at least 6 hours, and more preferably at least 8 hours, at a temperature of between 50 and 90 degrees centigrade.

Applying the layers or the second-region-layers of the elastomer may comprise printing the layers.

Drying the layers or the second-region-layers of the elastomer may comprise flashing drying the layers at 140 degrees centigrade.

Optionally, before applying the layers or the second-region-layers of the elastomer, firstly applying a base layer of a primer material to the textile and drying the primer layer.

The one or more patterns or second-region-pattern or -patterns comprise 3D patterns for providing the determined desired direction and/or gradient of the second and third elongation and memory characteristics.

Optionally, prior to applying to the textile in the first region a first layer of an elastomer, the textile is cut to form a panel of a compression garment. Or optionally, prior to applying to the textile in the first region a first layer of an elastomer, the textile is cut to form a panel of a compression garment and the textile panel joined with additional panels to form the compression garment. Or optionally, after the curing/baking step, the textile is cut to form a panel of a compression garment, wherein the panel includes at least one of the first or second regions, and the textile panel is joined with additional panels to form the compression garment. Or optionally, prior to applying to the textile in the first region a first layer of an elastomer, the textile is cut to form a panel of a compression garment and the textile panel is joined with additional panels to form the compression garment.

The method is used to produce a compression garment including but not limited to any one of a shirt, shorts, tights, sleeves, socks, underwear, or a joint brace or support.

The method is also used to produce a medical support garment, including but not limited to any one of a joint brace, a knee support, a calf support, an ankle support, a shoulder support, an elbow support, an arm support, a wrist support or a hand and/or figure support.

The method is also used to produce a medical support garment, such as a brace or support, in which the textile is substituted with a synthetic rubber sheet such as neoprene and 3D printing regions of the synthetic rubber sheet is used to enhance and control directional elongation and memory of regions of the medical support garment.

The method is also used to produce a medical support garment, such as a brace or support, in which the textile is predominately elastane or other highly elastic synthetic fibres such as SPANDEX or LYCRA, and 3D printing regions of the synthetic rubber sheet is used to enhance and control directional elongation and memory of regions of the medical support garment.

The invention also includes a joint or muscle support/brace, and in particular a medical support or brace) made according to the aforementioned method. The invention also includes the aforementioned method used to make a compression garment and/or a joint support or brace including a combination of a textile selected to have a low elongation and memory characteristic, and a elastomer printed to regions of the garment in a pattern selected to have a provide a elongation and memory characteristic.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Any reference to prior art contained herein is not to be taken as an admission that the information is common general knowledge, unless otherwise indicated.

Claims

1. A method of producing a variable compression garment, comprising: identifying, in a base textile having a first elongation and memory characteristic, a first region having a second elongation and memory characteristic,applying to the base textile, in the first region, a first layer of an elastomer, drying the first layer of the elastomer to adhere the first layer of the elastomer to the base textile,applying to the base textile, in the first region, at least a second layer of the elastomer,drying the second layer of the elastomer to adhere the second layer of the elastomer to the first layer of the elastomer on the base textile, andbaking the first and second layers of the elastomer to cure the first and second layers of the elastomer.

2. The method of claim 1, further including: determining number of layers of the elastomer needed to provide the second elongation and memory characteristic, andafter drying the second layer of the elastomer, applying an additional number of layers of the elastomer and drying each additional layer of the elastomer before applying a next additional layer of the elastomer.

3. The method of claim 1, further including: determining a direction and/or gradient of the second elongation and memory characteristic, anddetermining at least one pattern for the first, second, and any additional, layers of the elastomer to provide the direction and/or gradient, wherein applying the first, second, and any additional, layers of the elastomer comprises applying the first, second and any additional layers of the elastomer in the at least one pattern that has been determined.

4. The method of claim 3, wherein the direction and/or gradient comprise at least two directions or gradients

5. The method of claim 3, wherein the at least one pattern comprises at least one pattern chosen from the group consisting of a pattern of interlocking shapes, a pattern of parallel lines, and a pattern of crossing lines.

6. The method of claim 2, further including: identifying a second region of the base textile having a third elongation and memory characteristic,determining number of layers of the elastomer needed to provide the third elongation and memory characteristic, andbefore the baking, applying to the base textile, in the second region, at least one second-region layer of the elastomer, and drying each second-region layer before applying a next second-region layer.

7. The method of claim 6, further including: determining a direction and/or gradient of the third elongation and memory characteristic, anddetermining at least one second-region pattern for the at least one second-region layer of the elastomer, wherein applying the at least one second-region layer of the elastomer comprises applying the sat least one second-region layer in the at least one second-region pattern that has been determined.

8. The method of claim 1, wherein the baking comprises baking for at least 4 hours at a temperature of between 70 and 90 degrees centigrade.

9. The method of claim 1, wherein the elastomer is a silicone-based or a non-silicone-based polymer.

10. The method of claim 6, wherein applying the first, second, and any additional layers of the elastomer, or the at least one second-region layer of the elastomer comprises printing the at least one second-region layer.

11. The method of claim 10 wherein printing comprises capillary film screen printing.

12. The method of claim 6, wherein drying the first, second, and any additional layers of the elastomer, or the at least one second-region layer of the elastomer comprises flash drying at 140 degrees centigrade for at least 6 seconds.

13. The method of claim 7, further comprising, before applying the first, second, and any additional layers of the elastomer, or the at least one second-region layer of the elastomer, applying a base layer of a primer material to the base textile and drying the primer layer.

14. The method of claim 7, wherein the at least one second-region pattern comprises a 3D pattern for providing the direction and/or gradient of the second and third elongation and memory characteristics that have been determined.

15. The method of claim 1, wherein the base textile comprises at least 80% of a material selected from the group consisting of f cotton, polyester, and nylon, and combinations thereof.

16. The method of claim 1, further comprising, prior to applying to the base textile in the first region, a first layer of an elastomer, cutting the base textile to form a panel of a compression garment.

17. The method of claim 1, further comprising, prior to applying to the base textile, in the first region, a first layer of the elastomer, cutting the base textile form a panel of the variable compression garment and joining the base textile panel with additional panels to form the variable compression garment.

18. The method of claim 1, further comprising, after the baking, cutting the has textile form a panel of the variable compression garment, wherein the panel includes at least one of the first and second regions, and joining the panel with additional panels to form the variable compression garment.

19. The method of claim 1, further comprising, prior to applying to the base textile, in the first region, the first layer of the elastomer, cutting the base textile to form a panel of the compression garment, and joining the panel with additional panels to form the variable compression garment.

20. The method of claim 19, wherein the variable compression garment is selected from the group of garments consisting of a shirt, shorts, tights, sleeves, socks, underwear, a joint brace, and a support.

21. The method of claim 19, wherein the compression garment comprises a medical support garment including at least one of a joint brace, a knee support, a calf support, an ankle support, a shoulder support, an elbow support, an arm support, a wrist support, a hand support, and a figure support.

22. A variable compression garment produced using the method of claim 1.