GB2459261A

GB2459261A - A protective insert for an underwear garment

Info

Publication number: GB2459261A
Application number: GB0806765A
Authority: GB
Inventors: Desmond Hatfield; Harvey Jessop; Andrew Tyrer
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-04-15
Filing date: 2008-04-15
Publication date: 2009-10-21
Also published as: GB0806765D0

Abstract

A protective insert 15,20 for use in a protective underwear garment 10 comprising a shaped pad of resilient breathable material that is self supporting, and having a generally convex shape. The insert 15,20 may also comprise perforations 21 , on one or both sides of the pad, to improve breathability and allow for circulation of air. The material may be a foam with a substantially open cell structure, preferably thermoformed open cell polyurethane foam. The pad may comprise a plurality of layers some of which may not be resilient or self supporting, the non- resilient or non-self supporting layers preferably provided on either side of the self-supporting foam. A layer of fabric material may form a covering. Also claimed is a protective underwear garment 10 and a method of manufacturing the garment 10 having the insert 15,20.

Description

IMPROVED CLOTHING

The present invention relates to improvements in underwear, and particularly, but not exclusively, to improvements in protective underwear.

Underwear for use in situations where the user requires protection of their crotch area is known. Typically, such protective underwear comprises a flap or envelope where a rigid plastic cup can be placed and removed from the underwear garment. Such known protective underwear may provide a good degree of protection to the user, but is typically uncomfortable. Additionally, the underwear garment for use with the rigid plastic cup is typically only usable for the purpose of playing sport with the protection, and therefore necessitates the user purchase this underwear garment for this purpose.

The known protective underwear garments are also uncomfortable for the user as the level of breathability of the garment when the rigid plastic cup is in place is usually low. This can lead to the user becoming overly and uncomfortably hot and sweaty in the crotch area particularly during period of physical exertion when playing sport.

Other prior attempts include cycling shorts are available and some have padding which is stitched in to the bottom half of the garment. This padding is usually formed from two-dimensional sheets of constant thickness foam, with the third dimension formed due to folding of the padding around the legs of the wearer. However, this padding is typically uncomfortable for the user and offers limited protection in impact sports.

Additionally, these garments are usable for the purposes of cycling only, and not as normal underwear which could be worn by the user on a day-to-day basis.

Underwear is also known for aesthetic enhancement purposes for males which * -2-comprise pouches of fabric in the crotch portion of the garment. The fabric pouches typically provide little if any protective properties to the user's crotch area from impact.

There is a considerable need to solve the problems associated with prior protective underwear garments as described herein.

The present invention seeks to provide protective underwear garments, and in particular, but not exclusively, protective underwear garments which combine a good level of protection to the user's crotch area during impact sports and which are comfortable for the user to wear. The present invention also seeks to provide protective underwear garments which may be capable of enhancing the user's crotch area.

According to a first aspect of the present invention there is provided a protective underwear garment comprising a protective insert in a front portion of the underwear garment, wherein the protective insert comprises a shaped pad of resilient breathable material that is self-supporting, and said insert having a generally convex shape.

According to a second aspect of the present invention there is provided a method of manufacturing a protective underwear garment of the first aspect, the method comprising the steps of: providing a resilient breathable material that is self-supporting; shaping the said material to provide a shaped pad insert having a generally convex shape; and placing the insert in to a front portion of an underwear garment.

According to a third aspect of the present invention there is provided a protective insert for use in a protective underwear garment according to the first aspect, said insert * -3-comprising a shaped pad of resilient breathable material that is self-supporting, and said insert having a generally convex shape.

It has been found that having an insert being a shaped pad of resilient breathable material that is self-supporting in a front portion of an underwear garment allows for protection to be given to the user's crotch area whilst also providing a comfortable garment. Additionally, the protective properties of the insert are improved due to the insert being resilient and self-supporting, and therefore resistant to changes in shape. The insert resists and protects the user from impacts in the crotch region. The use of resilient self-supporting material to form the insert allows the retention of the shape of the insert during continued use of the underwear garment, therefore allowing retention of the protective properties.

The insert also provides improved breathability of the underwear garment breathability of the material used in its formation which allows wicking of moisture and circulation of air.

It is also found that the protective underwear garment provides support as well as protection, particularly support for the genitals of male users.

The protective underwear garment therefore provides an improved combination of protection and support to the user, whilst also being comfortable due to the improved breathability.

The insert used in the protective underwear garment is a shaped pad of resilient breathable material that is self-supporting, and said insert having a generally convex shape. * -4-

By resilient, it will be understood that the material is capable of absorbing at least some of the impact of an object when placed between an object and a body. The resilient material would reduce the level of impact which would otherwise be experienced by the body.

The level of resilience will be determined by the use to which the insert will be directed such that more resilient materials may be required in sports where the risk of impact is greater.

The insert is also required to have sufficient levels of breathability such that it is comfortable for the user when the insert is worn in the protective underwear garment.

Suitable materials which may be used for forming the shaped pad include foams.

Foam having an open cell structure is preferred.

Inserts formed from polyurethane foams are preferred. In particular, polyurethane foams which are thermoformed open cell polyurethane foams are particularly preferred.

The open-cell polyurethane foam has an open cell structure which is a permeable flexible foam where there are few barriers between individual foam cells due to the rupture of most cell walls during manufacture.

The term "open-cell foams" refer to the cellular structure of the foam as the cellular structure is exposed at the foam surface.

The term "thermoformed" will be understood to refer to a thermoforming processes in which a material is heated (for example using gas or an infrared source) to a known forming temperature. The heated material may then stretched over or in to a single surface mould or a dual surface (closed) mould, in which the temperature is * -5-controlled and where the material is held until cooled. Thermoforming processes are well

known in the field of foam production.

The resilient breathable material that is self-supporting preferably has a density in the range 20 to 50 kg per cm3 prior to formation of the pad. Preferably, the density of material may be in the range 30 to 40 kg per cm3. Most preferably, the density of material may be 35 kg per cm3.

It will be understood that the density values refer to the density of the self-supporting material prior to formation of the pad. During the formation of the pad, the density will vary depending on the parameters used in the process and the level of compression used. It would therefore be possible to use foams of different densities and arrive at final foams with the same density depending on the parameters used in the pad formation process.

It will be understood that the self-supporting material would have sufficient rigidity to provide protection to the user's crotch area and to resist deformation and retain the shape as manufactured.

The pad may be shaped during manufacture using any known method prior to use in the underwear garment. One such method of shaping the pad, by way of example, is skiving, in particular when the pad is formed from foams. The skiving of foam refers to shaping using cutting means, for example a knife.

It is envisaged that the insert would provide sufficient breathability to the user of the protective underwear garment due to the selection of materials used in its formation, for example by using open cell foams for forming the pad. The pad may also comprise * -6-perforations to allow for enhanced or improved levels of breathability.

The pad may therefore comprise a plurality of perforations. The perforations may be arranged on one or both sides of the pad. Additionally, the perforations may pass completely through the pad.

The density of perforations may be in the range 4 to 30 perforations per cm2.

Preferably, the density of perforations may be in the range 8 to 25 perforations per cm2.

Most preferably, the density of perforations may be in the range 8 to 13 perforations per cm2.

The plurality of perforations may be substantially circular in cross-section. The plurality of perforations may each individually have a diameter in the range from 0.8 to 1.6mm.

It is envisaged that the thickness of the pad would be selected to provide the required amount of protection to the pad. The thickness would also be selected to provide strength and relative rigidity so that shape of the pad is retained.

The thickness of the pad may be in the range 0.5mm to 50mm. The thickness may preferably be in the range 0.8mm to 40cm. Most preferably, the thickness of the pad may be in the range 1mm to 30mm.

The profile shape of the pad, and therefore the insert, may be such that the thickness of the insert is consistent across the whole of the insert. Alternatively, the profile shape of the insert may have a variable thickness across its length.

An example of a variable thickness insert is one with a central portion which is thicker than the edge portions of the insert. The variable thickness of the insert is provided for by use of a variable thickness pad. In this embodiment, the degree of protection is enhanced in the central area which is likely to protect the most vulnerable areas of a user's crotch from impact, whilst having reduced thickness and therefore reducing the weight and increasing the breathability of the insert at the edge portions which require less protection.

The ratio of the maximum thickness of the insert, and therefore the pad, to the minimum thickness of the insert may be in the range 200:1 to 1:1. Preferably, the ratio is in the range 150:1 to 10:1. Most preferably, the ratio is in the range 50:1 to 20:1.

The length of the insert may be in the range 10 to 30cm. The length may preferably be in the range 13 to 25cm. Most preferably, the length of the insert may be in therange 18 to 20cm.

The pad may comprise one layer of resilient breathable material that is self-supporting. Alternatively, the pad may comprise a plurality of layers of said material thereby providing a laminate type structure of resilient breathable material.

The layers of resilient breathable material may have the same thickness, or each individual layer may independently have a different thickness.

The pad may also comprise additional material which is not resilient or self-supporting. This additional material may be formed from any suitable material such as foam, and may be formed from polyurethane having a closed cell composition for

example.

The additional material may be in the form of layers, and may be arranged such that a layer is placed on either side of the self-supporting foam thereby providing a * -8- "sandwich" type structure.

The additional material may have a thickness in the range 2 mm to 30 mm.

Preferably, the thickness is in the range 4 mm to 25 mm. Where a plurality of additional foam material layers are present in the insert, all additional foam layers may be of the same thickness. Alternatively, each layer of additional material may have a different thickness.

The insert may comprise a layer of fabric material forming a covering. The fabric layer would therefore form a covering of the pad. The fabric material may be selected from any suitable fabric, such as nylon, polyester. cotton or silk. The fabric material may be selected to prevent dirt from contacting the materials forming the pad.

The fabric layer may also protect the pad when the insert is removed from the protective underwear garment.

The profile shape of the pad is convex. This refers to the pad having a curved profile shape. The curved pad may therefore be adapted to provide an insert which protrudes from the body of the user and form a recess which may receive the genitals of the user which are to be protected.

Examples of particular convex shapes which the pad may have include biconvex, planoconvex, convex with a positive meniscus, or having a concave shape.

The pad may alternatively be formed in a substantially flat shape having a shallow convex profile.

It will be understood that the shape of the pad substantially provides the shape of the insert. * -9-

The choice of profile shape of the pad may be dictated by the end user's sex as typically a protective underwear garment for a female would have a flatter profile shape, and a pad for a male would have a curved shape.

The shape of the pad may also be adapted to provide an insert which aesthetically enhances the user's crotch area. This may be the case especially for a male user whereby a curved insert is used having a greater degree of curvature than necessary, and which would therefore make the user's crotch area appear larger.

The overall shape of the insert may be a v-type shape having a wider top section and narrower bottom section which comes to a point at the bottom. Such a shape would match the profile of the crotch area requiring protection for the user.

The pad, and therefore the insert comprising the pad, is self-supporting. By the term self-supporting it is mean that the pad does not lose its manufactured shape under its own weight. The insert would be readily flexible and deformable in use, but would be disposed to return to its manufactured shape.

The pad is shaped during manufacture such that it substantially retains said shape during use of the underwear garment. This will be understood to mean that pad and therefore the insert is formed in to the desired shape prior to placing in the underwear garment during the process of manufacture. The insert would therefore substantially retain its shape during subsequent use by the user which would include wearing, storage, and washing of the protective underwear garment during the typical lifetime of said garment.

By substantially retains' it will be understood that the pad, and therefore the * -10-insert, is deformable during use on application of a force to it, but once the force is removed the insert would return to the manufactured shape.

It is envisaged that the shape retention properties are a result of the use of the self-supporting material used to form the pad as described herein.

The self-supporting material and additional foam material, if present, may be affixed together using any suitable adhesive. The adhesive may be present as a coating on each or all of the material surfaces, or may be present as discontinuous areas of adhesive covering each or all of the material surfaces.

The protection provided by the insert is due to the shaping and retention of the formed shape such that it approximates the contours of the crotch area for maximum comfort and protection. This is in contrast to other protective garments such as cycle shorts which have padding around all the front and rear of the pants and sometimes in the inner thigh area, but where this padding does not have a retained formed shape.

The insert as described herein is present in a front portion of an underwear garment. By a front portion of the garment it is understood that the insert should be placed in the garment so that it substantially covers the crotch area of the user.

The insert may be integral in the underwear garment, and this will be understood to mean that the insert is not removable during normal use of the garment. Removal of the insert would only be possible by some degree of disassembly of the underwear garment.

In this embodiment, the insert may be present in an internal pocket area of the underwear garment. The internal pocket area may be formed such that there is a layer of * -11-underwear garment material surrounding the insert so that it is completely contained in the underwear garment.

The internal pocket area may be formed such that the underwear material is overlapped and joined by bonding without stitches to give a smooth and flat surface.

The insert may be permanently bonded into the main fabric body of the underwear garment to provide an underwear garment with a smooth profile.

In an alternative embodiment, the insert may be removable from the garment during normal use without disassembly of the garment. The garment may comprise an open pouch for placing the insert within: The pouch may be formed in the front portion of the garment, and may have an opening on either the external or the internal side of the garment.

Use of a removable insert may be advantageous as it would allow removal and replacement of the inserts or different styles or thicknesses. Different styles or thicknesses of insert may be desired depending on the activity the user is undertaking, and therefore the degree of protection from impacts which is desired.

A removable insert would also allow for separate washing of the insert from the garment if required. The open pouch may also receive a secondary moulded insert such as a cricket box if a greater degree of protection was required by the user.

It is envisaged that the type of underwear which is used to form the present invention may be any suitable type, and is not limited.

The underwear garment may be of a typical known type such as athletic-style boxer shorts, traditional briefs (vertical flap), double seat brief or double back brief, * -12-diagonal flap brief, pouch brief, or low-cut/low-rise brief.

The underwear garment may comprise any suitable fabric. Suitable fabrics may be selected from, by way of example, cotton, wool, silk, polyester, aramid fibres, acrylic, nylon, spandex, or olefin fibres.

It is preferred that the underwear garment is formed from a material which is capable for allowing circulation of moisture and air therethrough in order to provide breathability to the garment.

Preferred materials which provide breathability include so called synthetic technical fibres designed to wick moisture away from the skin next to the garment. An example of such a material is polyester such as the material Coolmax.

Clothing made from Coolmax is primarily intended to be worn during exertion and allows sweat to evaporate quickly so the wearer is kept dry. Other useful properties of this material include resistance to fading, shrinking and wriniding.

The pad may be manufactured by cutting the self-supporting material, for example open cell polyurethane foam, along with additional material and fabric if present, to the required shapes. Any suitable cutting means may be used.

The individual components may then be coated in adhesive on any surfaces which adjoin another component. The coated components may then be arranged to form an assembly which is then placed in a mould tool. The mould tool may be hot or cold depending whether the assembly has been pre-heated.

S -13-The hot mould tool may be closed around the assembly for a period of time sufficient to compress the assembly in to the required shape and to ensure the adhesive has set affixing the components in the assembly.

The mould tool will be selected to have an internal and external profile to match that required for the formed insert.

Once the assembly has been subjected to the required heat and compression, the formed insert may be removed from the mould tool and trimmed to remove any excess foam.

The underwear garment may be prepared separately by cutting the various required shapes of material and affixing them together by stitching, or by thermobonding using an adhesive.

The insert may be placed between layers of material forming the crotch portion of the underwear garment such that when the garment material is stitched or bonded together the insert is contained within the garment material.

In an alternative to the above described method of manufacturing the protective underwear garment, the insert may be moulded directly in to the underwear garment rather than being formed separately from the garment.

Alternatively, an open pouch may be formed in the underwear garment which has an opening sufficient to receive the insert, and to allow for removal of the insert during normal use.

It is envisaged that the protective underwear garment may be used by both female and male users, and that the properties of the garment altered for each sex accordingly.

O -14-The garment may be used for protection of a user's crotch area during sport or other activities where there is a significant risk of impact. Additionally, the garment is not restricted to use during such sports or activities, and it is envisaged that it may be worn by the user during non-sports activities.

The protective underwear garment may also have aesthetic enhancement properties for the user's crotch area resulting from the shape of the insert used. These aesthetic enhancement properties would be particularly relevant to male users.

All of the features described herein may be combined with any of the above aspects, in any combination.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which: Figure 1 shows a schematic perspective view of a protective underwear garment of the present invention; Figure 2 shows a schematic perspective view of an insert used in the present invention; and Figure 3 shows a schematic perspective view of a further insert of the present invention; and Figure 4 shows a schematic exploded section view of an insert of the present invention.

* -15-Referring to Figure 1, there is shown a schematic front view of a protective underwear garment 10 of the present invention. The underwear garment 10 is of a typical brief type having an elasticatecl waist band 11, a front portion 12, and a back portion 13.

The underwear garment also comprises leg openings 14. The underwear garment 10 comprises a protective insert 15 which is sandwiched between an outer and inner layer of material forming the underwear garment 10, and is therefore integral in the garment 10.

The pad forming the insert 15 is made from thermoformed open-cell polyurethane foam and is not removable from the garment 10 by the user during normal use. The insert 15 is therefore machine washable so that it can be washed with the underwear whilst remaining in place. The insert 15 is shaped such that it covers most, if not all, of the crotch area of the user.

Referring to Figure 2 there is shown a schematic perspective view of a protective insert 20. The insert 20 is of the type which would be present in the underwear garment of Figure 1. The insert 20 is of a rough v-shape therefore matching the shape of the crotch area to be protected.

The insert 20 also comprises perforations 21 on both surfaces which provide an improved level of breathability for the user. The perforations 21 allow for circulation of air and removal of moisture from the skin surface through an underwear garment in which the insert 20 is contained.

The insert 20 has a constant thickness across its length and therefore has a relatively flat profile. As such, the insert is more suitable for a female user.

Referring to Figure 3 there is shown a schematic perspective view of a further * -16-insert 30. The perspective view shows that the insert 30 has a shallow bowl-type shape which provides both comfort to the user, and protection. The insert 30 has a variable thickness along its length with an area 33 of lower-thickness, and an area 32 of greater thickness of the insert 30. The area 32 of greater thickness is arranged such that it corresponds to the more vulnerable areas of a user's crotch, and therefore providing the greatest level of protection in these areas.

The shape of the insert 30 as shown in Figure 3 is maintained in the underwear, and therefore provides protection to the user's crotch. Additionally, the shape of the insert 30 which is curved is typical of that used for a male underwear garment, whilst an insert for a female underwear garment would most likely be flatter in profile, such as the insert 20 shown in Figure 2.

Referring to Figure 4, there is shown an exploded section view of an insert 40 showing the individual components which form the insert 40. The insert 40 comprises a layer of thermoformed open-cell polyurethane foam 41 arranged in the centre of a laminate structure. The polyurethane foam layer 41 is "skived" to the approximate geometry required to match the required final moulded geometry such that it is pre-shaped during manufacture.

The polyurethane foam layer 41 is sandwiched between two layers of additional foam material 42 and 43. These additional foam layers 42 and 43 are formed from open cell foams but are not shaped or skived. The foam layers 41, 42 and 43 are sandwiched between two layers of outer fabric material 44 and 45. These layers of outer fabric material 44 and 45 are layers of polyester fabric which cover the foam materials and prevent damage and dirt affecting the foam layers 41, 42, and 43.

It is to be understood that the invention is not to be limited to the details of the above embodiments, which are described by way of example only. Many variations are possible. -18-

Claims

CLAIMSI. A protective insert (20) for use in a protective underwear garment (10), wherein said insert (20) comprises a shaped pad (41) of resilient breathable material that is self-supporting, and said insert (20) having a generally convex shape.
2. A protective insert (20) according to claim 1, wherein the resilient breathable material is selected from substantially open cell structure foams.
3. A protective insert (20) according to claim 2, wherein the resilient breathable material is selected from thermoformed open cell polyurethane foams.
4. A protective insert (20) according to any preceding claim, wherein the resilient breathable material has a density in the range 20 to 50 kg per m3 prior to formation of the pad (41).
5. A protective insert (20) according to any preceding claim, wherein the pad (41) comprises a plurality of perforations (21) arranged on one or both sides of said pad (41).
6. A protective insert (20) according to claim 5, wherein the density of said perforations (21) is in the range 4 to 30 perforations per cm2.**::
7. A protective insert (20) according to either claim 5 or claim 6, wherein the *.
S.plurality of perforations (21) each individually have a diameter in the range from S. * * * . * ** 0.8tol.6mm.

S

* S. *** * 20 8. A protective insert (20) according to any preceding claim, wherein the thickness **5 : of the pad (41) is in the range 0.5mm to 50mm.
9. A protective insert (20) according to any preceding claim, wherein the pad (41) comprises a plurality of layers of said resilient breathable material thereby providing a laminate type structure of resilient breathable material.
10. A protective insert (20) according to any preceding claim, wherein the pad (41) comprises additional material which is not resilient or self-supporting.
11. A protective insert (20) according to claim 10, wherein the additional material is in the form of layers (42, 43) and is arranged such that a layer is placed on either side of the self-supporting foam thereby providing a "sandwich" type structure.
12. A protective insert (20) according to any preceding claim, wherein the insert (20) comprises a layer of fabric material (44, 45) forming a covering.
13. A protective underwear garment (10), wherein said garment (10) comprises a protective insert (15) in a front portion (12) of the underwear garment (10), and wherein the protective insert (15) comprises a shaped pad (41) of resilient breathable material that is self-supporting, and said insert (15) having a generally convex shape.
14. A protective underwear garment (10) according to claim 13, wherein the insert (15) is integral in the underwear garment (10) such that said insert (15) is not removable during normal use of the garment (10). S...
15. A protective underwear garment (10) according to claim 13, wherein the insert (15) is removable from the garment (10) during normal use without disassembly *Se..* 20 of the garment (10). S...

*..
16. A method of manufacturing a protective underwear garment (10), the method comprising the steps of: -20 -providing a resilient breathable material that is self-supporting; shaping the said material to provide a shaped pad insert (15) having a generally convex shape; and placing the insert (15) in to a front portion (12) of an underwear garment (10).
17. A method of manufacturing a protective underwear garment (10) according to claim 16, wherein said insert (15) is shaped by skiving in which the resilient breathable material is shaped using cutting means.
18. A method of manufacturing a protective underwear garment (10) according to either claim 16, wherein the resilient breathable material is shaped in a mould tool to form the shaped pad insert (15).
19. A method of manufacturing a protective underwear garment (10) according to claim 18, wherein the mould tool is be selected to have an internal and external profile to match that required for the formed shaped pad insert (15).
20. A method of manufacturing a protective underwear garment (10) according to any of claims 16 to 19, wherein the underwear garment (10) is prepared separately by cutting the various required shapes of material and affixing them together by * .* stitching, or by thermobonding using an adhesive.
21. A protective underwear garment (10) as substantially as hereinbefore described and with reference to the accompanying drawings.* S S *** * 20 **S. *S..