Uncontaminated Garment Packaging

This application is a continuation-in-part of U.S. patent application Ser. No. 11/898,357, entitled “Uncontaminated Garment,” by Stephen S. Trombetta, filed Sep. 11, 2007, the disclosure of which is incorporated herein by reference in its entirety.

The present invention relates to garments. In particular, the present invention relates to the packaging of garments to prevent contamination during donning of the garments.

Garments free of contamination are required in particular situations, such as garments for clean rooms and sterilized procedures. A conventional uncontaminated garment is folded and packaged in a bag. Then, it is irradiated and delivered to the clean room. The bag prevents the garment from becoming contaminated prior to use. The garment is folded with its outer surface facing outward, and thus, the outer surfaces are exposed and subject to becoming contaminated if touched by the hands or body of the person donning the garment. Also, the outer surfaces can become contaminated if the garment contacts the floor or a wall during the donning process.

To don the conventionally packaged garment, the bag must be opened, and the user must look for an exposed inner surface of the garment. Then, the user must carefully grasp the inner surface so as not to touch (and thereby contaminate) the outer surface. This is done by grabbing the garment at a neck portion where a small amount of the inner surface is usually exposed. Next, the user must carefully manipulate the conventional uncontaminated garment to turn it inside out by slowly folding the garment down until the user's legs and arms can be inserted.

Because the donning of conventional uncontaminated garments requires extensive handling while donning, conventional uncontaminated garments are often contaminated during the donning process. Furthermore, to prevent contamination during the donning process, the wearer has to be specially trained in the proper method for donning the garment.

Accordingly, an aspect of the present invention is to provide a packaged uncontaminated garment that facilitates donning and use of the uncontaminated garment.

One embodiment of the present invention provides a packaged garment. The packaged garment includes a torso portion, a sleeve portion connected to the torso portion, and a leg portion connected to the torso portion. The garment has an outer surface and an inner surface opposite the outer surface. The packaged garment also includes a sealed bag containing the garment with the sleeve portion folded onto the torso portion, a portion of the sleeve portion folded at least once underneath the sleeve portion between the sleeve portion and the torso portion, and the leg portion folded onto the torso portion. The folded garment is manipulated so that the inner surface of the torso portion faces outward and the torso portion forms an inner space containing the sleeve portion and the leg portion.

Another embodiment of the present invention provides a method of manufacturing a packaged garment. The packaged garment has an outer surface, an inner surface opposite the outer surface, a torso portion, two sleeve portions connected to the torso portion at respective arm accesses, and two leg portions connected to the torso portion at respective leg accesses. The method of manufacturing includes the steps of: folding the two sleeve portions onto the torso portion; folding a portion of each of the two sleeve portions at least once underneath the sleeve portion between the sleeve portion and the torso portion; folding the two leg portions onto the torso portion; and manipulating the folded garment so that the inner surface of the torso portion faces outward with the two sleeve portions and the two leg portions within.

Yet another embodiment of the present invention provides a method of manufacturing a packaged uncontaminated garment. The garment has an outer surface, an inner surface opposite the outer surface, a torso portion with an opening, sleeve portions connected to the torso portion at respective arm accesses, and leg portions connected to the torso portion at respective leg accesses. The method of manufacturing includes the steps of: folding the sleeve portions onto the torso portion; folding a portion of the sleeve portion at least once underneath the sleeve portion between the sleeve portion and the torso portion; folding the leg portions onto the torso portion over the sleeve portions; manipulating the opening of the torso portion over the folded sleeve portions and leg portions so that the inner surface of the torso portion faces outward with the outer surface of the sleeve portions and the leg portions facing outward within the torso portion; fully extending the leg portions within the torso portion; and arranging arm accesses and leg accesses to lie substantially at an outer peripheral edge of the folded garment.

Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses an exemplary embodiment of the present invention.

Referring to, the present invention provides a packaged garmentand a method of packaging the garmentto prevent contamination while donning the garment.

Referring to, a garmentis shown that is used with the invention. The garment is preferably of the type worn in a clean room and is a coverall that includes an outer surface, a torso portion, sleeve portions, and leg portions. The torso portioncovers, substantially or partially, the torso of a wearer. The torso portionalso has an openingthrough which the wearer dons the garment. The openingis substantially in the center of the torso portionand extends in the longitudinal direction of the garmentfrom the neck to the top of the leg portionsto allow easy access for donning and removal. The openingcan be closed by zipper, Velcro, snap fasteners, clasps, buttons or other similar closing devices. The torso portioncan also include a collar portionthat is worn around the neck of the wearer. The sleeve portionscover the arms of the wearer. The sleeve portionscan have an elastic cuff so that the sleeve portionsstay substantially in place with respect to the wearer's arm. Attached at the end of the sleeve portionmay be a loop that can be placed around the wearer's thumb to prevent the sleeve portionfrom moving away from the wearer's wrist. The leg portionscover the legs of the wearer. The leg portionscan also have an elastic cuff so that the leg portionsstay substantially in place with respect to the wearer's leg. Thus, the garmentsubstantially covers the entire body of the wearer, except the head, feet, and hands. However, the garmentmay also include a hood portion (not shown), a glove portion (not shown), a boot portion (not shown), or any combination thereof. The hood portion, the glove portion, or the boot portion may be provided separately, attached to, or formed integrally with the garment.

Referring to, a method for packaging the garmentfor subsequent use is illustrated. At, the garmentis placed flat on a surface with the openingfacing down. Then, one sleeve portionis folded inward and downward onto the torso portionin the direction of arrow A, as shown in. The folded sleeve portionis shown in. Next, the other sleeve portionis folded inward and downward onto the torso portionin the direction of arrow B, and the folded sleeve portionis shown in. The sleeve portionsfold substantially along a line at which each of the sleeve portionsconnect to the torso portion. After the sleeve portionsare folded, as shown in, the sleeve portionslie substantially parallel to the longitudinal direction of the unfolded garment. The sleeve portionscan also be folded onto the torso portionso that the sleeve portionslie substantially perpendicular to the longitudinal direction of the torso portion.

After the sleeve portionsare folded, the leg portionsare then folded. One leg portionis folded onto the torso portionover the sleeve portionin the direction of arrow C, as shown in. The folded leg portionis shown in. Next, the other leg portionis folded over the other sleeve portionin the direction of arrow D, shown in. In, both of the leg portionsare folded so that the leg portionslie substantially parallel to the longitudinal direction of the torso portion. The leg portionsfold substantially along a line at which each of the leg portionsconnect to the torso portion. Then, the garmentis turned upside down.

Next, as shown in, preparatory folds are made so that the outer surfaceof the torso portionof the garmentfaces inward. In one exemplary embodiment, the garmentis folded in half in the direction of arrow E. Thus, as shown in, the openinglies substantially along an edge of the folded garmentwith the leg portionslying on top and underneath. In further preparation for folding the garmentinside out, the garmentcan be optionally folded substantially in half along a line that is substantially parallel to the openingin the direction of arrow F, as shown in. Then, as shown in, the edges of the openingare separated from each other and the front sides of the torso portionare pulled over the folded garmentin the direction of arrows G. Also, with the garmentfolded as shown in, an exposed part Y in the middle of the back of the torso portioncan be grasped to maintain the sleeve portionsand leg portionsin place while pulling the front sides of the torso portionover the garmentin the direction G. At the same time, the sleeve portionsand the leg portionsare folded within the torso portion.

As a result, the torso portionis inside-out, whereby the inner surfaceof the torso portionfaces outward and the outer surfaceof the torso portionfaces inward, as shown in. The edges of the openingcontinue to be pulled in the direction of arrows H until the sleeve portionsand the leg portionsare folded within the garment, as shown in. At this point, the torso portionessentially forms a satchel with an inner space containing the sleeve portionsand the leg portions. The torso portionhas its inner surfacefacing outward, but the outer surfaceof the sleeve portionsand leg portionscontinue to face outwardly within the torso portion. Preferably, the sleeve portionsand the leg portionsare fully extended within the torso portion. Because the inner surfaceof the garmentfaces outward, the outer surfaceof the garmentis protected from contamination.

As further shown in, the sleeve portionsand the leg portionshave internal openings that receive the arms and legs of the wearer. The arm and leg opening are accessed through arm accessesand leg accesses, respectively. The arm accessesto the sleeve portionsand the leg accessesto the leg portionsare substantially at an outer peripheral edge of the folded garmentso that the wearer has easy access to the arm and leg openings when donning the garment.

Then, the garmentis folded further so that it fits a particular packaging. The garmentalso can optionally be folded so that the inner surfaceof the collar portionprotrudes prominently from the folded garmentso that the wearer can easily find and grasp the inner surfaceof the collar portion. In one exemplary embodiment, the garmentis folded in the direction of arrow I, as shown in; then in the direction of arrow J, as shown in; and finally in the direction of arrow K, as shown in. Consequently, as shown in, the garmentis prepared to be placed in a bag, and the collar portionprotrudes from the folded garmentto provide the wearer with an obvious grasp for handling the folded garmentafter opening the bag.

Although the garmentcan be folded in any environment, to minimize contamination, the garmentis preferably folded in a Classclean room. The garmentis also treated to remove contaminants. The removal of contaminants may be done before or after the garmentis folded. The treatment can be by irradiation, chemical treatment, brushing, wiping, scouring, and other similar methods of removing particulate matter, microorganisms, or chemical contaminants. Preferably, the garmentis treated by irradiation after it is folded and bagged.

Referring to, once the garmentis folded, it is inserted into a bagso that the garmentstays uncontaminated after it is irradiated. The baghas one open end which can be sealed. The bagmay be formed of a plastic composition of the closed cell type and in particular may be formed of a polyethylene composition. Once the garmenthas been placed in the bag, the bagis heat sealed to form a substantially hermetic seal, as shown in. Once the baghas been heat sealed, the bagis then inserted into a lined cartonas shown in. The cartonmay be a cardboard type container adaptable for transportation and associated shipping. Though a sealing layeris not required, one may be provided to line the cartondepending on the application. The sealing layermay be formed of a plastic type composition of the closed cell type which may also be a polyethylene composition. The sealing layerlines the internal walls of the cartonin order to receive one or a plurality of bagstherein. The sealing layermay then be closed through tying or some like closure mechanism and in this manner the one or plurality of bagsis then contained therein. Finally, the cartonmay be closed by flap closures.

Referring to, once the bagshave been inserted into the carton, the cartonis then irradiated. The irradiation may be completed by a gamma irradiation system in accordance with well-known techniques, such as in U.S. Pat. No. 6,123,900 to Vellutato, issued Sep. 26, 2000, the entire disclosure of which is incorporated herewith. In general, the cartonsare brought to an irradiation plant for irradiation. Gamma radiation is generally used for sterilization because gamma radiation has a high penetration capability. This high penetration capability enables products to be processed easily.

The closed cartonsare then prepared for shipping and are transported. When received, the closed cartonsmay be opened and the bagsremoved from the cartonso that the bagscan be stored, for example, in a dressing room located immediately adjacent to a clean room or some other site. If the cartonis lined with the sealing layer, the cartonand the sealing layerwould be opened to remove the bags. Alternatively, the sealing layercan be removed from the carton, and the bagsmaintained within the sealing layerin a closed manner until the sealing layeris moved to the clean room, a room adjacent to the clean room, or some other site. Once removed from the cartonor the sealing layer, the bagencompassing the garmentis available for use.

Accordingly, when the bagis opened, the inner surfaceof the garmentis facing outward and exposed to the wearer, substantially similar to the folded condition shown in. Then, the wearer can grab the garmenteasily by its inner surfacewithout contaminating the outer surfaceof the garment. In addition, because the inner surfaceof the collar portionmay be protruding out beyond the rest of the garment, the wearer can easily grab the garmentby the inner surfaceof the collar portion, if desired.

To don the garment, the wearer removes the garmentfrom the bag. Since the inner surfaceof the garmentis facing outward, the wearer necessarily handles the garmentby the inner surface. After the wearer removes the garmentfrom the bag, the wearer unfolds the garmentuntil the garmentlargely returns to the folded condition shown inin which the arm accessesand the leg accessesare on the outer peripheral edge of the folded garment. At this point, the leg accessesto the openings in the leg portionsare easily accessible. To don the garment, the wearer holds the garmentby its corners X (shown in), and the wearer thrusts one leg into one of leg accessesto one leg portion. Next, while still grasping the corners X (shown in), the wearer thrusts his other leg into the other leg accessfor the other leg portion. Because the leg portionsare fully extended within the torso portion, the wearer's legs can be easily inserted into the leg portions.

Referring to, the wearer has inserted his legs into the leg portionsand the wearer has optionally pulled the garmentup, as shown, by grabbing an interior surface of the garment. Once the wearer's legs are in the leg portions, the sleeve portionshang down behind the wearer. The wearer then reaches down to insert one arm into one of the arm accessesof a sleeve portion. The wearer can simply slide an arm into one of the sleeve portionswhich stays in place by virtue of the leg portionsoperating against the wearer's body. Or, the wearer can grasp the garmentby holding its inner surfaceto further facilitate the arm being inserted into the sleeve portion. After inserting one arm into one of the sleeve portions, the torso portionlargely covers the torso of the wearer, and the other sleeve portionis more reachable. The wearer then inserts his other arm into the other arm accessfor the other sleeve portion, and the wearer finishes pulling the torso portionover his torso. Afterwards, the outer surfaceof the garmentfaces outward, and the wearer can then close the opening.

If hoods, gloves, and boots are required, the hoods, gloves, and boots can be provided in separate bags. Alternatively, the hood, gloves, and boots can be provided in the same bagwith the garment. The hood, gloves, boots, or some combination thereof can be integral with or attached to the garment. If the hood is attached to or integral with the garment, the hood is folded with its inner surface facing outward. If the glove is attached to or integral with the sleeve portion, the sleeve portionis folded as described above. If the boot is attached to or integral with the leg portion, the leg portionis folded as described above.

Turning to, another embodiment of the present invention is shown involving the packaging of a garment. The embodiment shown infurther secures the sleeve portionswhen compared to the embodiment shown in. This may be particularly important when, for example, the garmentis made of a material that is slippery or does not otherwise tend to hold a position or shape.

Referring to, the garmentis shown which is the same construction as the garment. Thus, as described with regard to garment, the garmentincludes an outer surface, a torso portion, sleeve portions, and leg portions. In the embodiment shown in, the garmentis a coverall. The torso portioncovers, substantially or partially, the torso of a wearer. The torso portionalso has an openingthrough which the wearer dons the garment. The openingis substantially in the center of the torso portionand extends in the longitudinal direction of the garmentfrom the neck to the top of the leg portions. The openingcan be closed by zipper, Velcro, snap fasteners, clasps, buttons or other similar closing devices. The torso portioncan also include a collar portionthat is worn around the neck of the wearer. Each sleeve portiongenerally covers an arm of the wearer. The sleeve portionscan have an elastic cuff so that the sleeve portionsstay substantially in place with respect to the wearer's arm. Attached at the end of the sleeve portionmay be a loop that can be placed around the wearer's thumb to prevent the sleeve portionfrom moving away from the wearer's wrist. The leg portionseach substantially cover the legs of the wearer. The leg portionscan also have an elastic cuff so that the leg portionsstay substantially in place with respect to the wearer's leg. Thus, the garmentsubstantially covers the entire body of the wearer, except the head, feet, and hands. However, the garmentmay also include a hood portion (not shown), a glove portion (not shown), a boot portion (not shown), or any combination thereof. The hood portion, the glove portion, or the boot portion may be provided separately, attached to, or formed integrally with the garment.

Referring to, a method for packaging the garmentfor subsequent use is illustrated. At, the garmentis placed flat on a surface with the openingfacing down. Then, one sleeve portionis folded backward (i.e., inward with regard to the figure) and downward onto the torso portionin the direction of arrow A, as shown in. The sleeve portionis folded substantially along a line at which the sleeve portionconnects to the torso portion. After being folded, as shown in, a portion of the sleeve portionis folded under the sleeve portion in the direction of arrow B, as shown in. The folded portion of the sleeve portionis substantially parallel to the longitudinal axis of the sleeve portionand lies underneath the sleeve portionbetween the sleeve portionand the torso portion. The sleeve portionis folded further, in the direction of arrow C at a line formed substantially as the end of the first folded section, so that the sleeve portionis essentially rolled up under itself. The sleeve portionafter being folded again in the direction of arrow C is shown in. In the embodiment shown, the sleeve portionis folded twice, however in other embodiments, the sleeve portioncan be folded once, folded more than twice, or rolled. And, though sleeve portionis shown folded in the direction of arrow A first, the sleeve portioncan be folded in the direction of arrow C before being folded in the direction of arrow A. The sleeve portionrolled under itself, so that it better holds itself in position and is less prone to unrolling.

Next, the other sleeve portionis folded in a similar fashion as the first sleeve portion. The sleeve portionis folded inward and downward onto the torso portionin the direction of arrow D, as shown in. The sleeve portionis folded substantially along a line at which the sleeve portionconnects to the torso portion. After the sleeve portionis folded, as shown in, the sleeve portionlies substantially parallel to the longitudinal direction of the unfolded garment. A portion of the sleeve portionis folded under the sleeve portion in the direction of arrow E, as shown in. The folded portion of the sleeve portionis substantially parallel to the longitudinal axis of the sleeve portionand lies underneath the sleeve portionbetween the sleeve portionand the torso portion. The sleeve portionis folded further, in the direction of arrow F at a line formed substantially at the end of the first folded section, so that the sleeve portionis essentially rolled up under itself. The sleeve portionafter being folded again in the direction of arrow F is shown in. In the embodiment shown, the sleeve portionis folded twice, however in other embodiments, the sleeve portioncan be folded once, folded more than twice, or rolled. And, though the sleeve portionis shown folded in the direction of arrow D first, the sleeve portioncan be folded in the direction of arrow E before being folded in the direction of arrow D. The sleeve portionis rolled under itself, so that it better holds itself in position and is less prone to unrolling. Furthermore, in the embodiment shown, the folded sleeve portionslie substantially parallel to the longitudinal direction of the garment, however, in other embodiments, the sleeve portionscan be folded onto the torso portionso that the sleeve portionslie substantially perpendicular to the longitudinal direction of the torso portion.

After the sleeve portionsare folded, the leg portionsare then folded. One leg portionis folded onto the torso portionand over the sleeve portionin the direction of arrow G, as shown in. The folded leg portionis shown in. Next, the other leg portionis folded over the other sleeve portionin the direction of arrow H, as shown in. The leg portionsare folded over the sleeve portionsto keep the sleeve portionsin place. Also, the leg portionsare not folded so that a portion of each leg portionis between the leg portionand the torso portionbecause such a fold impedes the wearer in donning the garment. In, both of the leg portionsare folded so that the leg portionslie substantially parallel to the longitudinal direction of the torso portion. The leg portionsare folded substantially along a line at which each of the leg portionsconnect to the torso portion. Then, the garmentis turned upside down.

Next, as shown in, preparatory folds are made so that the outer surfaceof the torso portionof the garmentfaces inward. In the embodiment shown, the garmentis folded in half in the direction of arrow I. Thus, as shown in, the openinglies substantially along an edge of the folded garmentwith the leg portionslying on top and underneath. In further preparation for folding the garmentinside out, the garmentcan be optionally folded substantially in half along a line that is substantially parallel to the openingin the direction of arrow J, as shown in. Then, as shown in, the edges of the openingare separated from each other and the front sides of the torso portionare pulled over the folded garmentin the direction of arrows K. Also, with the garmentfolded as shown in, an exposed part Y in the middle of the back of the torso portioncan be grasped to maintain the sleeve portionsand leg portionsin place while pulling the front sides of the torso portionover the garmentin the direction K. At the same time, the sleeve portionsand the leg portionsare folded within the torso portion.

As a result, the torso portionis inside-out, whereby the inner surfaceof the torso portionfaces outward and the outer surfaceof the torso portionfaces inward, as shown in. The edges of the openingcontinue to be pulled in the direction of arrows L until the sleeve portionsand the leg portionsare folded within the garment, as shown in. At this point, the torso portionessentially forms a satchel with an inner space containing the sleeve portionsand the leg portions. The torso portionhas its inner surfacefacing outward, but the outer surfaceof the sleeve portionsand leg portionscontinue to face outwardly within the torso portion. Preferably, the leg portionsare fully extended within the torso portion. Because the inner surfaceof the garmentfaces outward, the outer surfaceof the garmentis protected from contamination.

As further shown in, the sleeve portionsand the leg portionshave internal openings that receive the arms and legs of the wearer. The arm and leg opening are accessed through arm accessesand leg accesses, respectively. The arm accessesto the sleeve portionsand the leg accessesto the leg portionsare substantially at an outer peripheral edge of the folded garmentso that the wearer has easy access to the arm and leg openings when donning the garment.

Then, the garmentis folded further so that it fits a particular packaging. The garmentalso can optionally be folded so that the inner surfaceof the collar portionprotrudes prominently from the folded garmentso that the wearer can easily find and grasp the inner surfaceof the collar portion. In the exemplary shown, the garmentis folded in the direction of arrow M, as shown in; then in the direction of arrow N, as shown in; and finally in the direction of arrow O, as shown in. Consequently, as shown in, the garmentis prepared to be placed in a bag, and the collar portionprotrudes from the folded garmentto provide the wearer with an obvious grasp for handling the folded garmentafter opening the bag.

Accordingly, the embodiment shown inis the same as the embodiment shown in, except the embodiment ofadds extra folds in the direction of arrows B, C, E, and F, as shown in, to prevent the sleeve portionsfrom unfolding during packaging. Also, the leg portionshold the sleeve portionsin place. The fully-folded garmentofis placed in a bag, and the bagis placed in a cartonthat is subsequently irradiated, as shown in.

To don the garment, the wearer removes the garmentfrom the bag. Similar to the garment, because the inner surfaceof the garmentis facing outward, the wearer necessarily handles the garmentby the inner surface. After the wearer removes the garmentfrom the bag, the wearer unfolds the garmentuntil the garmentlargely returns to the folded condition shown inin which the arm accessesand the leg accessesare on the outer peripheral edge of the folded garment, so that the leg accessesto the leg portionsare easily accessible. To don the garment, the wearer holds the garmentby its corners X (shown in) and thrusts one leg into one of leg accesses. Next, while still grasping the corners X (shown in), the wearer thrusts his other leg into the other leg access. Because the leg portionsare fully extended within the torso portion, the wearer's legs can be easily inserted into the leg portions. After the wearer has inserted his legs into the leg portions, the wearer can optionally pull the garmentup, as shown in, by grabbing an inner surfaceof the garment. Once the wearer's legs are in the leg portions, the sleeve portionshang down behind the wearer. The wearer then reaches down to insert one arm into one of the arm accessesof a sleeve portion. The wearer can simply slide an arm into one of the sleeve portionswhich hangs behind the wearer because the wearer has donned the leg portionsand a lower part of the torso portion. Or, the wearer can grasp the garmentby holding its inner surfaceto further facilitate the arm being inserted into the sleeve portion. After inserting one arm into one of the sleeve portions, the torso portionlargely covers the torso of the wearer, and the other sleeve portionis more reachable. The wearer then inserts his other arm into the other arm accessfor the other sleeve portion, and the wearer finishes pulling the torso portionover his torso. Afterwards, the outer surfaceof the garmentfaces outward, and the wearer can then close the opening.

If hoods, gloves, and boots are required, the hoods, gloves, and boots can be provided in separate bags. Alternatively, the hood, gloves, and boots can be provided in the same bagwith the garment. The hood, gloves, boots, or some combination thereof can be integral with or attached to the garment. If the hood is attached to or integral with the garment, the hood is folded with its inner surface facing outward. If the glove is attached to or integral with the sleeve portion, the sleeve portionis folded as described above. If the boot is attached to or integral with the leg portion, the leg portionis folded as described above.

As apparent from the foregoing description, according to an exemplary embodiment of the present invention, the garment is folded so that the wearer handles the garment by its inner surface thus preventing contamination of its outer surface. The garment is also folded to facilitate the donning of the garment while preventing contamination of its outer surface. Furthermore, extensive training for donning the garment is not required. The garment used in the invention is preferably a lightweight disposable garment.

While a particular embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.