Patent Application
20180064179
The present invention relates generally to clothing garments. More specifically, it relates to fleece shorts designed for use in cold and cool temperatures.
Many people enjoy wearing short pants (shorts) in cool weather, such as in temperatures of about 35-70 F. Some people even wear shorts in freezing temperatures. However, there are few shorts products available for these people. Insulated shorts are essentially unknown.
Polyester fleece (e.g. POLARFLEECE™) is a warm, lightweight fabric that has been used extensively for warm outdoor clothing. Fleece is typically made of polyester or polyester terephthalate. One or both surfaces of fleece has soft pile, comprising freestanding cut or looped yarns or fibers.
Fleece is an excellent fabric for use in outdoor clothing, because it is warm, soft, lightweight and retains warmth in wet conditions.
There are several reasons why fleece is generally not suitable for use in outdoor shorts, however. First, fleece is typically easily stretched, torn and worn, and so is not durable enough for outdoor pants or shorts. Also, fleece is highly air permeable so wind flows through it easily. The result is that fleece shorts can be uncomfortably hot when the wind is still, and uncomfortably cold in windy conditions. Adding additional layers or windproofing can make the shorts too hot, especially in the crotch area. Also, additional layers will increase cost and detract from the desirable soft texture of fleece.
Also, fleece is stretchy and floppy, so it feels too insubstantial for people that prefer to wear shorts made of more rigid and durable fabric like denim, canvas, twill or the like.
For these reasons, fleece shorts are undesirable to many people.
Consequently, there is a need for fleece shorts that overcomes these problems.
The present invention provides a shorts garment comprising two tubes joined at one end, for receiving a human waist and legs. The tubes are made of fleece fabric and have front panels on one side. A waistband circumscribes the joined end. A patch pocket is attached to an exterior surface of each front panel. Each patch pocket comprises a non-stretch, non-fleece fabric. The fleece front panels and the patch pocket fabric have air permeabilities of at least 50 CFM/SF and at most 30 CFM/SF, respectively. Also, each patch pocket covers at least about 20% of each respective front panel.
The patch pockets can have an air permeability less than 35, 20, 15 or 10 CFM/SF, as measured by ASTM D737. The fleece fabric can have an air permeability of at least 40, 50, 60, 70 CFM/SF, or in the range of 50-350 CFM/SF, 60-350 CFM/SF or 70-350 CFM/SF, as measured by ASTM D737.
The air permeability of the patch pockets can be less than ½, ¼, or 1/10 of the air permeability of the fleece.
The patch pockets can cover at least 25%, 30%, 35% or 40% of each respective front panel.
The patch pockets can be attached to the waistband along a top edge. The patch pockets can have openings along a top edge or along a side edge.
A crotch area between the patch pockets can have an air permeability of at least 50 CFM/SF over at least 40% of the crotch area.
The patch pockets can cover up to 80% of the front panels.
The present shorts garment can also comprise rear patch pockets attached to rear panels made of fleece. The rear patch pockets can have an air permeability less than ½, ¼, or 1/10 the air permeability of the fleece fabric, and can cover at least about 10% of the rear panels.
The present invention provides a shorts garment for cool and cold temperatures (e.g. in the range of 35-70 F). The present shorts garment is made of fleece and has durable, wind-blocking patch pockets. The fleece has a relatively high air permeability, and the patch pockets have a relatively low air permeability. The patch pockets cover the thigh areas of the shorts, and preferably cover a large portion of the thigh areas. The patch pockets are spaced apart such that a fleece crotch area (located between the patch pockets) is not covered by the patch pockets. Consequently, the crotch area is ventilated by air flow through the fleece, thereby keeping the crotch area relatively cool. The thigh areas are better insulated due to the wind-blocking property of the patch pockets. This pocket placement provides a comfortable balance between warmth, and cooling air ventilation. Also, the present shorts garment is durable enough for outdoor use due to the durability and large size of the patch pockets.
Fleece: a fabric with pile of at least 1 mm on at least one side. Fleece is commonly made of polyethylene terephthalate, polyester, cotton, or cotton-poly blend. Fleece fabrics are typically knitted.
Pile: the raised surface or nap of a fabric, which is made of upright fiber loops or cut fibers. For the fleece fabrics contemplated herein, the pile height of the fleece will generally be about 1-6 mm on one or both sides.
Air Permeability: A measurement of resistance to air flow. A standard test method of air permeability of fabrics is ASTM D737, which indicates air permeability in units of cubic feet of air per minute, per square foot (CFM/SF), at a pressure differential of 0.5 inches water. All air permeability measurements given herein are based on ASTM D737 and are in units of CFM/SF at 0.5 inches water pressure.
Non-stretch: Non-stretch fabric has less than 15% elongation when subjected to tensile stress of about 10 pounds applied to a strip 1 inch wide. Alternatively can experience less than 10% or 5% elongation.
A total length 23 of the shorts can be about 10-30 inches or 15-25 inches for example. Shorts typically have lengths less than about 18, 20, 22, 24 or 28 inches for example.
The waistband 24 can comprise a non-stretch fabric, such as a woven polyester or nylon (e.g. twill or nylon taffeta). The waistband can be made of the same fabric as the patch pockets, for example. The waistband may further comprise belt loops and optionally a built-in belt (not shown), as known in the art. Also, the waistband can comprise elastic, as known in the art.
A crotch area 34 is defined as the space between the patch pockets 30A 30B. The crotch area can be about 2-14 inches wide or 4-8 inches wide, for example. However, the appended claims are not limited to any particular values for the width of the crotch area 34.
The patch pockets 30A 30B are optionally attached to the waistband 24 at a top edge 25. The pocket-waistband attachment avoids tensile stress on the front panel fleece fabric, which has a tendency to rip, stretch or wear poorly when under tensile load, especially if the tensile load is concentrated in a small area. Some fleece fabric cannot support the weight of the patch pocket when loaded or weight of a wearers hands. Fleece fabrics tend to be fragile and easily torn.
The patch pockets can be sewn directly on top of the fleece front panels, so the pocket (interior) has one side comprising the patch pocket fabric, and one side comprising fleece.
The patch pockets 30A 30B provide several functions besides mere pocket utility. The patch pockets 30A 30B block air flow through the fleece front panels 22A 22B. This is helpful for providing warmth for the wearer because fleece alone is highly air permeable and loses much of its insulating ability in windy conditions. The patch pockets are located over the thigh area of the wearer. This is an ideal location for blocking wind, because the thigh areas are generally the most exposed to wind.
Also, the patch pockets 30A 30B improve the durability of the shorts. The patch pockets 30A 30B are made of durable, non-stretch, abrasion-resistant fabric, and so protect the fleece in the thigh area, where intense wear occurs.
A critical aspect of the present invention is the air permeability of the fleece fabric comprising the front panels 22A 22B, and the air permeability of the fabric comprising the patch pockets 30A 30B.
The fleece fabric comprising the front panels will have an air permeability of at least 50, 60 or 70 CFM/SF, or in the range of 50-350 CFM/SF. Typical polyester fleece fabrics contemplated in the present invention have air permeabilities of 85, 135, 170 and 305 CFM/SF. The high air permeability of the fleece allows some fresh air to ventilate the crotch area 34, thereby preventing uncomfortable overheating in the crotch.
The fleece fabric can be about 2-12 mm or 3-10 mm thick, for example, with about 1-6 mm tall pile on one or both sides. In one specific embodiment, the fleece fabric has a total thickness of about 8-9 mm, with about 4 mm pile on each side, and an air permeability of about 80-90 CFM/SF. In another specific embodiment suitable for slightly warmer temperatures, the fleece fabric has a total thickness of about 5-6 mm, with about 3 mm pile on one side and 2 mm pile on the other, and an air permeability of about 130-140 CFM/SF. Also, the fleece fabric can have a weight of about 100-600 grams/square meter, or about 200-400 grams/square meter.
Fleece fabrics typically have some stretch capability in at least one direction (due to the fact that fleece fabrics typically are knitted). The fleece fabrics contemplated for use in the present shorts may have no stretch, or may have stretch in one or both directions. The present invention is not limited to having any particular amount of stretch in the fleece fabric. However, some stretch may be desirable because it allows the wearer greater freedom of movement.
In contrast, the patch pockets 30A 30B comprise a non-stretch fabric with lower air permeability than the fleece. Typical patch pocket fabrics contemplated in the present invention have air permeabilities of 24, 12, 7, and 2.5 CMF/SF. Fabrics with air permeabilities less than 20, 10 or 5 CFM/SF are generally preferred for the pockets. The low air permeability of the patch pockets, combined with the insulating nature of the front panel fleece fabric, provides exceptionally effective thermal insulation in the areas of the patch pockets (i.e. in the areas covering the thighs). Low air permeability, non-stretch fabrics suitable for the patch pockets include wovens such as denim, canvas, twill, taffeta, poplin and woven sueded fabrics. Sueded woven polyester fabrics such as PASSIONSUEDE™ are particularly desirable because they are extremely durable, have low stretch and have very low air permeability (often less than 5 CFM/SF).
Non-stretch fabrics contemplated for use in the patch pockets will typically have less than 15% or 10% elongation when subjected to ensile loading of 10 pounds per 1-inch width. Sueded woven polyester fabric for example will elongate less than about 3-5% when tensile loaded at about 10 pounds per 1 inch fabric width.
The patch pocket fabric may have a weight of about 4-10 ounces per square yard, for example.
It is noted that the patch pocket fabric can be coated (e.g. with urethane) to reduce air permeability. Also, the patch pocket may comprise multiple layers of fabric to achieve suitably low air permeability. Also, the patch pocket may be lined with a fleece (e.g. with single-sided pile) or other soft insulating fabric to improve comfort and warmth of the pocket.
Also, it is noted that the patch pocket fabric is more durable and wear-resistant than the fleece fabric comprising the front panels. Since the thigh areas are commonly exposed to abrasion and wear, the patch pockets greatly enhance the durability of the shorts.
The crotch area 34 will typically comprise a portion of the fleece front panels 22A 22B. At least a portion of the crotch area 34 optionally comprises a single layer of the fleece fabric, and therefore has a high air permeability. Preferably, at least a portion (e.g. 40%) of the crotch area has an air permeability greater than 50, 60 or 70 CFM/SF. Additional fabric layers may be present in the crotch area as part of the fly 26 (e.g. a zipper fly typically has a fabric backing), or fly cover flap 27. Such additional fabric layer(s) may reduce somewhat the air permeability in the fly portion of the crotch area 34. For example, about 20-80% of the crotch area can comprise a single fleece layer, but the present invention and appended claims are not limited to this range. However, the crotch area 34, on average, will necessarily have a higher air permeability than the patch pockets 30A 30B.
Due to the high permeability of the fleece, the crotch area 34 does not become uncomfortably hot. Also, due to the low permeability of the patch pockets, the thigh areas (the areas most exposed to wind) are protected against wind. Consequently, the crotch is insulated due to the fleece fabric, but is less insulated than the thigh areas covered by the patch pockets. The present shorts garment therefore provides the unique and surprising benefit of comfortable warmth over a wide temperature range. The present shorts garment is warm in cold or cool weather (e.g. in the range of 35-65 F), especially in the thigh areas, but does not cause crotch overheating in moderate or room temperatures (e.g. in the range of 65-75 F). An important consideration in the present invention is the size of the front patch pockets 30A 30B relative to the size of the front panels 22A 22B. Specifically, according to the present invention the front patch pockets 30A 30B should cover enough of the front panels 22A 22B to provide substantial wind, wear and abrasion protection for the thigh areas. Preferably, the front patch pockets 30A 30B cover at least about 20%, 25%, 30%, or 35% of the respective front panels 22A 22B.
The high surface coverage of the front patch pockets 30A 30B assures that the present shorts garment provides an adequate level of wind, wear and abrasion protection for the thigh areas. In shorts designed for use in relatively colder temperatures, the coverage can be relatively high, for example in the range of 50-70%. Shorts intended for use in warmer temperatures may have lower coverage of about 20-40%.
It is noted that the coverage is typically not more than 75%, 80% or 90%, however, as it is desirable to have some air ventilation in the crotch area 34.
The rear patch pocket 36B contributes to the wind protection, thermal insulation, and durability of the present shorts garment. The rear patch pockets, like the front patch pockets, increase the warmth in the thigh areas.
In the embodiment of
In the embodiment of
The present invention and claims are not limited to any particular shape of the patch pockets 30A 30B. In
A rear crotch area 39 exists between the rear patch pockets 36A 36B in the embodiments of
It is noted that the rear patch pockets 36A 36B are optional in the invention. The shorts according to the present invention can have zero, 1 or 2 rear patch pockets. The rear patch pockets 36A 36B will tend to increase the wind protection, thermal insulation, and durability of the present shorts garment.
The rear patch pockets 36A 36B can cover about 20%, 30%, 40% or more of the respective rear panels 34A 34B. In some embodiments, coverage by the rear patch pockets 36A 36B will be less than coverage by the front patch pockets 30A 30B. In some embodiments, this may be because the front patch pockets 30A 30B are larger, and the front panels and rear panels are roughly the same size.
It is noted that the coverage of the rear panels is typically not more than 75%, 80% or 90% of the rear fleece panels, however, as it is desirable to have some air ventilation in the rear crotch area 39.
Also illustrated in
It is noted that the waistband 24 can comprise elastic, as known in the art.
The above embodiments may be altered in many ways without departing from the scope of the invention. Accordingly, the scope of the invention should be determined by the following claims and their legal equivalents.
The present application claims the benefit of copending patent application Ser. No. 14/453,623, filed on Aug. 7, 2014.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14453623 | Aug 2014 | US |
| Child | 15805048 | US |
