Patent Application
20050079778
This invention relates generally to personal flotation devices and, more specifically, to foam stabilization for personal flotation devices.
Approved United States Coast Guard personal flotation devices are required for many water activities. Personal flotation devices come in many shapes, colors and materials, but typically incorporate buoyant foam material. A popular type of personal flotation device is designed as a vest that fits around the user's neck and upper torso, commonly secured to the user via a zipper, adjustable straps or belts.
Swimwear-style personal flotation devices have been developed, particularly for use with children. These devices incorporate buoyant foam material into a garment designed for continuous wear, similar to a swimming suit. As with most personal flotation devices, maintaining the location of the buoyant foam material with respect to the user's head and torso is critical to ensure proper flotation. Incorporating buoyant foam material into swimwear-style personal flotation devices has presented unique challenges. Should the buoyant foam material shift from its prescribed location in the chest and upper back areas, or curl or fan excessively, the attitude of the user in the water can be adversely influenced and the personal flotation device not perform the functions for which it is intended.
Solid foam blocks have been used in swimwear-style personal flotation devices in an effort to achieve proper flotation. The solid foam blocks, for example made from PVC foam, have been sewn into various portions of the swimsuit in an effort to maintain buoyancy and balance when worn by a user in the water. Using solid PVC blocks reduce the likelihood that the buoyant foam material will curl or fan. However, solid foam blocks are bulky, add significant weight and cost to the product and are cosmetically unappealing.
Flexible buoyant foam material, for example multiple layers of the polyethylene foam more commonly found in traditional life jackets and vests, is a more promising alternative. Use of multiple flexible layers of buoyant material avoids much of the bulk and weight associated with solid foam blocks. The stretchy nature of the fabrics used as a shell and lining for swimwear-style personal flotation devices presents new challenges when multiple layers of buoyant material are used. While such layers maintain an ideal position in flotation garments made from limited stretch material such as woven fabrics or marine netting, when used in the stretchy swimwear-style fabrics (for example neoprene or knit fabrics), the layers tend to shift from the prescribed location or curl or fan excessively. This results in an undesirable change in the attitude of the user in the water and threatens the proper performance of the personal flotation device.
Prior attempts to solve problems associated with using multiple layers of polyethylene foam with swimwear-style personal flotation devices have been largely unsuccessful. Bonding the polyethylene foam layers together to form a single layer reduces the curling and fanning issues while avoiding the weight issues present when using solid blocks of foam. But this solution requires the addition of an adhesive application step, which in turn introduces significant complexities in the manufacture of the personal flotation device. It also raises questions about the durability of the bond over time and use. Finally, use of an adhesive introduces safety concerns about the proper ventilation for the adhesive, both during manufacture and subsequent storage by the seller and end user, as well as long term potential health effects on the user.
Sewing pieces of the swimwear-style fabric directly to the flexible foam material to serve as attachment points to secure the foam into the garment is likewise not feasible. Such stitching is not an option when using preferred polyethylene foam material in the thickness required in swimwear-style personal flotation devices.
Thus, there is a need for improved stabilization of multiple layers of flexible foam material when used in personal flotation devices to reduce curling and fanning issues and avoid bulk and weight while providing a cosmetically appealing flotation device.
The preferred embodiment of the present invention is directed to a personal flotation device including a cover forming one or more compartments incorporating flotation material consisting of multiple layers of flexible buoyant material adjacent to each other within the covered compartment. One or more apertures are made in the layers of buoyant material. A fabric band or belt is passed through each aperture in the layers of buoyant material, the ends of the layers preferably connected. The fabric band limits the movement of each layer of buoyant material relative to the other layers of buoyant material.
In an alternative embodiment, the fabric band is connected to the cover of the personal flotation device to limit the movement of each layer of buoyant material within the compartment.
In yet an alternative embodiment, the flotation stabilization system and method of the present invention is incorporated into a swimwear-style personal flotation device incorporating buoyant material into a garment designed for continuous wear, similar to a swimming suit.
Accordingly, the present invention provides for improved stabilization of multiple layers of flexible foam material when used in personal flotation devices to reduce curling and fanning and avoid bulk and weight while providing a cosmetically appealing flotation device.
The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
The preferred embodiment of the present invention is directed to improved stabilization of multiple layers of flexible foam material in personal flotation devices. While the present invention has particular application when used in swimwear-style personal flotation devices, commonly referred to as personal flotation vests, it has general application to various types of personal flotation devices.
With reference to
The front right segment 20, the front left segment 22, the back right segment 24 and the back left segment 26 are preferably connected together to form a vest shape. The right front segment 20 is connected to the back right segment 24 over the user's right shoulder (not shown) along seam line 40 and below a right arm opening 90 on the right side of the vest along seam line 42. The left front segment 22 is connected to the back left segment 26 over the user's left shoulder (not shown) along seam line 44 and below a left arm opening 92 on the left side of the vest along seam line 46. The front right segment 20 and the front left segment 22 are preferably connected along seam line 50. The back right segment 24 is preferably connected to the back left segment 26 via zipper 100. The connections between the front right segment 20, the front left segment 22, the back right segment 24 and the back left segment 26 form a neck opening 94 in the vest 10.
The front right segment 20 and the front left segment 22, joined along seam line 50, are connected to front swimsuit segment 28 along seam line 52. The back right segment 24 and the back left segment 26, joined via zipper 100, are connected to the back swimsuit segment 30 along seam line 56. The front swimsuit segment 28 is connected to the back right segment 24 and the back swimsuit segment 30 across the user's right hip (not shown) along seam 60. The front swimsuit segment 28 is connected to the back left segment 26 and the back swimsuit segment 30 across the user's left hip (not shown) along seam 62. The front swimsuit segment 28 and the back swimsuit segment 30 are connected along seam line 64 to form a right leg opening 96 and a left leg opening 98.
In the preferred embodiment, the front right segment 20, the front left segment 22, the back right segment 24 and the back left segment 26 each have exterior fabric shells 20a, 22a, 24a and 26a and corresponding interior fabric liners 20b, 22b, 24b and 26b (not shown). The exterior fabric shell 20a is preferably connected to the interior fabric liner 20b along seam lines 40, 42, 50 and 52 and along the front sleeve 68 of the right arm opening 90 and the front collar 70 of the neck opening 94. The exterior fabric shell 22a is preferably connected to the interior fabric liner 22b along seam lines 44, 46, 50 and 52 and along the front sleeve 72 of the left arm opening 92 and the front collar 74 of the neck opening 94. The exterior fabric shell 24a is preferably connected to interior fabric liner 24b along seam lines 40, 42 and 56, via zipper 100, and along the back sleeve 76 of the right arm opening 90 and the back collar 80 of the neck opening 94. The exterior fabric shell 26a is preferably connected to interior fabric liner 26b along seam lines 44, 46 and 56, via zipper 100, and along the back sleeve 78 of the left arm opening 92 and the back collar 80 of the neck opening 94. Connecting the exterior and interior segments is preferably accomplished by stitching the fabric of the adjoining segments together along the seam lines. The buoyant material incorporated into the front right segment 20, the front left segment 22, the back right segment 24 and the back left segment 26 is retained between exterior fabric shells 20a, 22a, 24a and 26a and corresponding interior fabric liners 20b, 22b, 24b and 26b.
In a preferred embodiment, the front right segment 20, the front left segment 22 and the front swimsuit segment 28 are formed of a single piece of fabric and the back right segment 24, the back left segment 26 and the back swimsuit segment 30 are formed of a separate, single piece of fabric. In this embodiment, the front right segment 20 incorporating a buoyant material (not shown), the front left segment 22 incorporating a buoyant material (not shown) and the front swimsuit segment 28 are connected to the back right segment 24 incorporating a buoyant material (not shown), the back left segment 26 incorporating a buoyant material (not shown) and the back swimsuit segment 30 along seam lines 40-46, 50-52, 56, and 68-80 and via zipper 100. Connecting the segments is preferably accomplished by stitching the fabric of the adjoining segments together along the seam lines.
The foam stabilization system and method of the present invention is described more particularly with reference to
More specifically, the preferred foam stabilization system 110 of the present invention includes multiple layers 110a, 110b, 110c, 110d and 110e. These layers are preferably made from a flexible buoyant material such as polyethylene foam. Five layers of buoyant material are described. However, the number of layers used may vary according to the operational needs for the particular personal flotation device. For example, smaller children may require less buoyant material in the vest segments than larger children, and therefore fewer layers may be required. Likewise, the number of layers may vary for each segment of the personal flotation device.
The foam layers 110a, 110b, 110c, 110d and 110e are preferably secured to each other by way of a fabric band 112 inserted into one or more slits or other apertures 114 formed through the layers. Once passed through the slits in the foam layers, the ends of the fabric band 112 are preferably sewn together along seam line 116. The type of fabric band used to secure the foam layers may vary, but is preferably made from United States Coast Guard approved fabric designed to maintain its shape and strength under conditions associated with the use of personal flotation devices. Alternative ways to secure the foam layers to each other include other types of fabric bands, bands made out of different material, such as rope, wire, cable or a variety of synthetic materials. Likewise, while the thread used to secure the ends of the fabric band together may vary, it is preferably United States Coast Guard approved thread designed to maintain its integrity under conditions associated with the use of personal flotation devices. Alternatives ways to secure the ends of the fabric band together include tacking, gluing, heat bonding, radio frequency (RF) welding and Velcro.
In a similar fashion, the number of slits may vary according to the shape of layers of buoyant material. The preferred embodiment is directed to a personal flotation device for use in supporting the upper torso of a user. This dictates that the layers of buoyant material be in the shape of a torso. In this embodiment, using two slits to secure the layers of buoyant material improves foam stabilization by limiting the distance the foam layers can shift from their prescribed location and reducing curling or fanning of the material. Alternative embodiments may require a different number of slits. For example, a belt-shaped personal flotation device may require only a single slit to appreciably limit movement of multiple layers of buoyant material. Conversely, a more elaborately shaped vest or swimsuit-style personal flotation device may require more than two slits to appreciably limit movement of the multiple layers of buoyant material.
As shown with reference to
In an alternative embodiment, as shown with reference to
In this example, with reference to
With reference to
The present invention offers advantages over personal flotation devices incorporating solid foam materials. By using multiple layers of flexible foam material, such as polyethylene foam, the present invention provides improved stabilization while avoiding inflexible, bulky and heavy vests that are not only cosmetically unappealing but may be too cumbersome to successfully incorporate into swimwear-style personal flotation devices for children. By securing the multiple layers of flexible foam material using the slit locations, the present invention reduces curling and fanning issues that may alter the attitude of the user in the water and threaten the proper performance of the personal flotation device.
While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. While specific details of certain embodiments of the invention are set forth in the preceding description and in
In yet alternative embodiments, the zipper of the personal flotation device may be located along the front or sides of the vest. Alternatively, no zipper may be used, but rather the segments may be expanded to allow fitting to a user by stretchable fabric, buttons, clasps, Velcro or other similar connection methods.
In still alternative embodiments, one or more of the distinct segment may be merged with other segments such that several segments of the vest 10 are formed from unitary fabric material, thus reducing the need to connect separate fabric segments. Likewise, the buoyant material may be incorporated into a single piece of multiple layer fabric material rather than retained by connecting a separate shell and liner.
In addition, the precise location of seam lines may vary according to the desired shape and size of the vest 10. The fabric segments of the vest 10 may be connected together using a variety of methods including sewing, tacking, gluing, heat bonding, RF welding and Velcro. Likewise, in addition to sewing, the fabric band 112 or 122 may be connected to the front right segment 20, the front left segment 22, the back right segment 24 and the back left segment 26 by other methods such as tacking, gluing, heat bonding, RF welding and Velcro.
Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
