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Sweat pad I









Everyone sweats and it could be a problem.

The existing situation: I do buy those underarm sweat pad (single-use) sweat pads in stores, but they lack the absorbency that I am looking for.  These sweat pads has sweat on top when they couldn't absorb anymore.  One would need to change and putting them on could be kind of difficult at times (because the double-sided tape sticks together.  Also I am looking for a more flexible way to use/replace pads instead of having to buy these specially made ones.  Finally, I am looking for a more environmental-friendly solution.  As of today I am writing this blog (Feb 17 2020), I haven't resolved all issues mentioned above, but I did solve most.

In sum, I would like to make a sweat pad that is:
- lightweight
- washable
- instant dry, or very quick dry after washing
- durable
- reduce waste
- easy to apply to clothings
- absorbing material to be replaceable without taking off the whole sweat pad down (unsolved)
- able to wear in sports (unsolved)

This is exciting for me.  This is version one below, completed on December 7, 2019.

**************** VERSION ONE ******************
Version 1: Limb plastic
Completion date: December 7, 2019


Material
- Plastic bag
- Double-sided tape
- Tempo tissue paper

Tool
- Plastic bag heat sealer

Steps
1. Cut 22cm x 7cm from plastic bag.  Need 2 pieces.
2. Fold the long ends up (length: 4cm).
3. Take plastic bag sealer and seal the edges of the folded sides.
4. Cut small slits in the middle of the plastic backing (for a closer fit to clothing's armpit seam)
5. Put Tempo tissue paper between the pockets on the plastic backing.
6. Put double-sided tape to the back of the plastic backing.





Problems:
- Plastic is too noisy.  Most plastics are noisy.  (I think people with me could hear plastic noise, but don't know why.)
- The double-sided tape needs to be replaced everyday


**************** VERSION TWO ******************
Version 2: PVC plastic with 3M removable double-sided tape
Completion date: December 10, 2019



The noise drove me crazy.  It was the fabric that I need to reconsider.  I used another PVC plastic that was thicker (0.5mm) and it was quiet.

Material
- PVC plastic: Purchased from Family House (HK$15/ft)
- 3M Double-sided tape (clear type, 1mm thick, looks like nano tape)
- Tempo tissue paper

Tool
- Plastic heat sealer

Steps
1. Cut 22cm x 8cm from plastic bag.  Need 2 pieces.


2. Fold the long ends up (length: 4cm).


3. Take plastic bag sealer and seal the edges of the folded sides.



4. Put Tempo tissue paper between the pockets on the plastic backing.


5. Put double-sided tape to the back of the plastic backing.


Solved:
- Plastic noisy problem
- Reuse tape.  In order to reuse the tape, the tape is washed with the plastic backing everyday.

Problem:
- The 3M double-sided tape needs to be replaced in every 5 days
- The heat seal worn out in few days.  The heat seal cannot bind this PVC material together
- The plastic material in contact with the skin irritates the skin.  For me, I don't think I am allergic to the plastic, rather it is the sweat on the plastic that is feeding back into the skin that is the problem.


**************** VERSION THREE ******************
Version Three: Using tabs to secure the pockets
Completion date: December 18, 2019

The seals weren't strong enough to hold the pockets.  So, I changed the pocket design with detachable tabs.





Advantage of the detachable-tab design
- Easy washing when the plastic all flat
- Easy to dry

Material
- PVC plastic: Purchased from Family House (HK$15/ft)
- 3M Double-sided tape (clear type, 1mm thick, looks like nano tape)
- Tempo tissue paper

Steps for creating the paper template
1. Cut paper 22cm x 8cm

2. Fold the pockets to be 4cm deep

3. Cut 4 tabs and tape them close to the opening of the pockets


4. Trace the final shape to another piece of paper, and cut it out.



Steps for sweat pad
1. Trace the template to PVC plastic and cut the shape out.



2. Fold the pockets to be 4 cm deep
3. Press a tab down onto the pocket.  The tab looks like a mushroom shape.


4. Use a marker to mark the top of the "mushroom" tab and the beneath of the "mushroom" cap (mark a dot).  Do that for all four "mushroom" tabs.

5. Take a cutter and cut a line between the top mark and the bottom mark.  There are 8 lines in total.



6. Put Tempo tissue paper


7. Put 3M double-sided tape on the backing.

Solved:
- Pocket doesn't come loose even having it operating under armpit all day long.

Problem:
- The 3M double-sided tape needs to be replaced in every 5 days
- The plastic material in contact with the skin irritates the skin.
- The shape of the sweat pad is showing if clothing is lighter in color and thinner in fabric.
- The sweat pad couldn't be effective nor comfortable for me with a knapsack on my back, the shoulder straps got in the way.
- Cannot change the tissue paper easily.  One would have to take down the whole thing in order to change tissue paper.


**************** ATTEMPT 1 ******************
Version Four: Allow tissue paper changing on the sweat pad
Completion date: January 8, 2020

This version was totally a failure.  I am documenting this attempt which was to allow the changing of tissue paper without taking down the whole sweat pad.  At the time the double-sided tapes parallel to bottom of pockets.

Material
- Laundry washing net, fine type (HK$15)
- Sewing thread
- Sweat pad plastic backing (from Version Three)
- Tempo tissue paper

Steps (I don't remember the exact steps)
1. Sandwich the sweat pad (with tissue paper installed) between a folded washing net fabric.  The top layer (in contact with skin) is a bit longer than the sweat pad,  The bottom layer is shorter than the sweat pad, to avoid the double-sided tape area.
2. Narrow the opening (towards inside) about 3 inches with sewing.  When this is done, the opening is 3 inches narrower (back 1.5 inches, front 1.5 inches).  This opening is for tissue replacement to go in.





Problems
- The washing net held up sweat from going down to tissue paper.
- The washing net degrades the performance of the double-sided tape.


**************** VERSION FOUR ******************

Version Four: Sweat pad (full skin contact with the tissue paper)
Completion date: January 11, 2020

In this version I changed the way to install Tempo tissue paper, so that the tissue paper could block the contact between plastic and skin.  The tissue paper would also have full coverage of the armpit.  That would mean to change the sweat pad template once more.  This version is quite good, I have been using it for over a month as of today.

Material
- PVC plastic: Purchased from Family House (HK$15/ft)
- Silverback Nano double-sided tape (Taobao, RMB24.8 for 3cm x 300cm)
- Tempo tissue paper

Steps for creating the paper template
1. Cut paper 22cm x 7cm
2. Fold the pockets to be 4cm deep
3. Cut 4 tabs and tape them close to the end of the plastic
4. Trace the final shape to another piece of paper, and cut it out.



Steps for sweat pad
1. Trace the template to PVC plastic and cut the shape out.
2. Fold the pockets to be 4 cm deep
3. Turn the sweat pad over (backing facing towards you), Press a tab down onto the backing.
4. Use a marker to mark the top of the "mushroom" tab and the beneath of the "mushroom" cap (mark a dot).  Do that for all four "mushroom" tabs.
5. Take a cutter and cut a line between the top mark and the bottom mark.  There are 8 lines in total for each sweat pad.


6.  Apply Silverback Nano double-sided tape on the back of the sweat pad.




Pre-cut of sweat absorbing tissue paper
1. Cut 4 openings on the tissue paper like so.



Remark: I pre-cut them for a week's use.




7. Turn the sweat pad plastic right side up.  Fold the pockets up.
8. With the "mushroom" tabs still loose, spread open tissue paper from step 6 on top of the sweat pad and stick the "mushroom"tabs out from underneath.  Do that for all 4 tabs of a sweat pad.
9. Tuck the left and right flap (tissue paper) under, so that the tissue paper wraps around the pockets.
10. Turn the sweat pad over and insert the tabs in the pre-cut lines from step 5.
11. The tissue paper length is longer than the folded sweat pad.  Tuck the excess tissue paper in one of the pockets.

Installation of tissue paper
1.  After washing and that the sweat pad is air-dried, take a piece of plastic to cover the tape.



2. With the "mushroom" tabs still loose, spread open tissue paper on top of the sweat pad and stick the "mushroom"tabs out from underneath.  Do that for all 4 tabs of a sweat pad.


3. Tuck the left and right flap (tissue paper) under, so that the tissue paper wraps around the pockets.


4. The tissue paper length is longer than the folded sweat pad.  Fold the excess tissue paper under one of the pockets.


5. Turn the sweat pad over and insert the tabs into the pre-cut lines.



6. Store the sweat pads away in a pouch for next day's use.





After thought:
The Silverback nano tape I found from Taobao and installed to this version on January 22, 2020.  I didn't believe that something would have a better performance than 3M.  However, 3M never said it is Nano tape, nor if it is washable.  What attracted me was the advertisement on Silverback: "The more you wash, the more adhesive it becomes".  How could I resist to this offer?  I need to wash off the fabric residue from the tape everyday.  So it turned out that the Silverback tape has lasted for almost a month now (today is Feb 17).

My goal:
- lightweight [Yes, physically]
- washable [Yes]
- instant dry, or very quick dry after washing [instant dry by wiping on the plastic, the nano tape needs to be air-dry.  However do not over air-dry, I usually repack the sweat-pad within 3 hours of washing.]
- durable [Yes]
- reduce waste [Yes.  One could also use thin fabric instead of tissue paper]
- easy to apply to clothings [Yes]
- absorbing material to be replaceable without taking off the whole sweat pad down (unsolved)
- able to wear in sports (unsolved)

Further development:
- Develop another version that does not require double-sided tape.  Advantages:
  - instant dry
  - replacement of tissue paper (to overcome functional bottleneck of the tape)


**************** VERSION FIVE ******************

Version Five: Sweat pad - Replaceable throughout the day (For Winter)
Completion date: February 29, 2020

In previous versions I wasn't able to replace the tissue paper throughout the day.  I would like a solution to be able to replace the tissue paper as many times as needed.  The two-layer approach: The detachable sweat pad, and the bottom layer which sticks to the underwear clothing.

Material
- PVC plastic: Purchased from Family House (HK$15/ft)
- 2 x 6cm long Silverback Nano double-sided tape (Taobao, RMB24.8 for 3cm x 300cm)
- 2 x Tempo tissue paper
- 2 pairs of 3M Command Velcro (HK$45 for 4 pairs)

Steps for creating the paper template
1. Cut paper 22cm x 7cm
2. Fold the pockets to be 4cm deep
3. Cut 4 tabs and tape them close to the end of the plastic
4. Trace the final shape to another piece of paper, and cut it out.



Steps for sweat pad
1. Trace the template to PVC plastic and cut the shape out.
2. Fold the pockets to be 4 cm deep
3. Turn the sweat pad over (backing facing towards you), Press a tab down onto the backing.
4. Use a marker to mark the top of the "mushroom" tab and the beneath of the "mushroom" cap (mark a dot).  Do that for all four "mushroom" tabs.
5. Take a cutter and cut a line between the top mark and the bottom mark.  There are 8 lines in total for each sweat pad.



6. Cut 2 pieces of 6cm x 13cm PVC plastics.  This is the bottom layer that will stick to clothing.


Fitted look.



7. Take 2 pairs of 3M velcro and cut them in half.  You now have 4 pairs of velcro.




8. Press a pair of velcros together.



9. Turn the sweat pad back side up (the side with no pockets),  Stick the velcro in the center.  A cutting board grid would be helpful to get the dead center.




10. Align the 6x13cm plastic on top correctly.  Flick half of 6x13cm plastic up.  Peel off the tape backing.  Lay the 6x13cm plastic down to have the velcro stick to it.




11. Repeat step 8-10 for the other side of the sweat pad.  Remember to bend (in half) the sweat pad and the 6x13cm plastic together, to get the correct position of the velcro.  (Reason: the 6x13cm plastic would get pushed forward when it is bent with the sweat pad.)



12. Separate the sweat pad from the 6x13cm plastic.

13. For 6x13cm plastic, on the side with NO VELCRO, stick the Silverback double-sided tape in the middle.



14.  Install the tissue paper on the sweat pad.




15. Press the sweat pad and bottom layer (6x13cm) velcros together. Peel off the Silverback double-sided tape backing.



16.  Stick the two-layer compound inside clothing near armpit area.

17.  On replacement of the tissue paper, just take the sweat pad part out and replace tissue paper.  Put back sweat pad and press the velcros until you hear clicks.


Install tissue paper
1.  Take the sweat pad.

2. With the "mushroom" tabs still loose, spread open tissue paper on top of the sweat pad and stick the "mushroom"tabs out from underneath.  Do that for all 4 tabs of a sweat pad.


3. Tuck the left and right flap (tissue paper) under, so that the tissue paper wraps around the pockets.

4. The tissue paper length is longer than the folded sweat pad.  Fold the excess tissue paper under one of the pockets.


5. Turn the sweat pad over and insert the tabs into the pre-cut lines.

6. Store the sweat pads away in a pouch for next day's use.


After thoughts:
Choice of materials.  I am glad I found the 3M command velcro.  I need a velcro that is
- easy to dry by wiping
- easy to apply (responsive "click" sound is very nice)
- easy to separate

My goal:
- lightweight [Not as lightweight]
- washable [Yes]
- instant dry [Yes, Because now the sweat pad is detachable and could be dried instantly with tissue paper]
- durable [Yes]
- reduce waste [Yes.  One could also use thin fabric instead of tissue paper]
- easy to apply to clothings [Yes]
- absorbing material to be replaceable without taking off the whole sweat pad down [Yes]
- able to wear in sports [Yes, depends on the Silverback double-sided tape]

Further development:
- Summer is coming. For women, this sweat pad would not be good with Cami Tanks.




**************** VERSION SIX ******************

Version Five: Sweat pad - Replaceable throughout the day (For summer)
Completion date: March 22, 2020

Summer is coming and Version Five sweatpad cannot handle the sweat with Cami tanks.  Problem is that sweat goes to both the Cami tank and shirt.  Version six sweat pad stops sweat at the source (armpit).

Material
- PVC plastic: Purchased from Family House (HK$15/ft)
- 2 x Tempo tissue paper
- 2 pairs of 3M Command Velcro (HK$45 for 4 pairs)
- 2 pieces of thin cotton fabric each 23.5cm x 12.5cm that doesn't stick to velcro (Free scrap)
- 4 x 0.7cm snap buttons
- A pair of narrow bra straps (HK$10/pair)
- 2 x 25cm Elastic bands (HK$5/meter)
- 2 x 2cm Elastic bands (HK$5/meter)
- Thin double-sided tape

Steps for template (Right armpit)
1. Cut out 23.5cm x 12.5cm paper.


2. Fold the template in half, the crease on 12.5cm side (below photo is had the crease on the wrong side).


3. The 3M velcro (already cut in half) and trace the velcro out on the template.  Leave around 1cm of margin from the velcro to the top edge.  Trace the bottom velcro on the template.  Leave around 1cm of margin from the velcro to the bottom edge.



4. Draw 2 diagonal lines inside the velcro box shape.


5. Cut the diagonal lines.


6. For each velcro box, fold the 4 "triangles" to the back.



7. Flip over the template over.  Mark button spots.  On the left, is masking tape for marking the spot for bra strap installation.



Steps for creating the sweat pad paper template
1. Cut paper 22cm x 7cm
2. Fold the pockets to be 4cm deep
3. Cut 4 tabs and tape them close to the end of the plastic
4. Trace the final shape to another piece of paper, and cut it out.



Steps for sweat pad
1. Trace the template to PVC plastic and cut the shape out.
2. Fold the pockets to be 4 cm deep
3. Turn the sweat pad over (backing facing towards you), Press a tab down onto the backing.
4. Use a marker to mark the top of the "mushroom" tab and the beneath of the "mushroom" cap (mark a dot).  Do that for all four "mushroom" tabs.
5. Take a cutter and cut a line between the top mark and the bottom mark.  There are 8 lines in total for each sweat pad.



6. Cut 2 pieces of 6cm x 13cm PVC plastics.  This is the bottom layer that will stick to clothing.



7. Take 2 pairs of 3M velcro and cut them in half.  You now have 4 pairs of velcro.



8. Turn the sweat pad back side up (the side with no pockets),  Stick the velcro in the center.  A cutting board grid would be helpful to get the dead center.





Steps for making the sweat pad carriage:
1. Cut the fabric out (23.5cm x 12.5cm + 0.5cm margin for hemming)




2. Trace the velcro cutout shapes onto the fabric.





3. Cut the diagonals on the velcro


4. Fold the 4 triangles to the back and secure a them with small masking tapes.


5. Sew along the border of the velcro cutouts.  Take out the masking tapes after done.


6. Fold the fabric in half.


7. Turn the edges (0.5cm) in and sew the 3 open sides.






8. On the no-velcro-cutout side, sew a 2cm elastic band on the left.  Sew snap button (male) to the right side.




9. Take a bra strap, cut a hook out.  Threat the end out and let out the other hook as well.





10. Thread the bra strap like so.



11. Sew snap button (female) to the end of the bra strap.


12. Cut a piece for 25cm elastic band,  Sew one end to the fabric (left), and a snap button (male) on the right.




13. Cut two 6cm x 3.5cm PVC plastics out.


14. Fit the PVC in side the fabric through the velcro cut out hole.  Mark the boundary with a masking tape.  Take out the PVC.



15. Sew a straight line along the masking tape.


16.  Put the PVC through the velcro hole again and tape the velcro in the cutout with a double-sided tape.



17. Repeat step 14-16 to the other velcro cutout.

Finished product (Version 6, summer version)



My goal:
- lightweight [Not as lightweight]
- washable [Yes]
- instant dry on the sweat pad [Yes, Because now the sweat pad is detachable and could be dried instantly with tissue paper]
- durable [Yes]
- reduce waste [Yes.  One could also use thin fabric instead of tissue paper]
- easy to apply to clothings [Yes]
- absorbing material to be replaceable without taking off the whole sweat pad down [Yes]
- able to wear in sports [Yes]

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