Patent Grant
11771156
Aspects herein relate to an insulated vented garment and methods for making an insulated vented garment.
Traditional ways of creating insulated garments comprise creating chambers through, for example, stitching panels of material together and blowing down or other synthetic fibers into the chambers. This often requires specialized machinery and can be messy. Moreover, traditional insulated garments may trap moisture vapor produced by the wearer which may result in wearer discomfort.
Examples of the present invention are described in detail below with reference to the attached drawing figures, wherein:
The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.
At a high level, aspects herein relate to methods of constructing insulated vented garments and garments resulting therefrom. Methods of constructing the insulated vented garment may utilize non-woven polymer sheets or sections of non-woven polymer material instead of materials such as down or loose poly-fill fibers. As used throughout this disclosure, terms such as “non-woven polymer sheet,” “poly-fill sheet,” “thermally insulating sheet material,” and “thermally insulating fill sheet” may be used interchangeably herein. Further, as used throughout this disclosure, terms such as “sections of non-woven polymer material,” “sections of poly-fill material,” “sections of thermally insulating sheet material,” and “sections of thermally insulating fill material” may be used interchangeably herein. Besides being easier to work with due to their cohesive structure, the use of non-woven polymer sheets or sections of non-woven polymer material imparts warmth to the finished garment. Moreover, the non-woven polymer materials described herein are generally hypoallergenic, do not require special laundering, have short dry times, and still provide warmth even when wet. They also do not require specialized handling or machinery when forming the garment which saves on manufacturing costs.
In a first method of construction that utilizes non-woven polymer sheets, one or more selected portions of the non-woven polymer sheet may be removed to create openings or voided portions in the non-woven polymer sheet. In an alternative aspect, the non-woven polymer may be formed to have one or more openings or voided portions. The non-woven polymer sheet is positioned between a first and second panel of material. The first panel of material is secured or bonded to the second panel of material in one or more areas corresponding to the voided portions in the non-woven polymer sheet. In an optional exemplary aspect, one or more perforations may be formed in the bonded areas where the perforations extend through the first panel of material and the second panel of material. As described further below, the perforations may be useful for allowing moisture vapor and/or excess heat produced by a wearer to escape from inside of the garment. The first and second panels of material may be used at least in part to form the garment.
Garments produced using the first method may comprise, for instance, at least one garment panel having an inner panel and an outer panel. A non-woven polymer sheet may be positioned between the inner and outer panels where the non-woven polymer sheet may comprise a voided portion (i.e., a portion from which the non-woven polymer sheet material has been removed or is absent). The garment may further comprise at least one seam that joins the inner panel to the outer panel at an area corresponding to the voided portion of the non-woven polymer sheet. In aspects, the garment may comprise multiple seams at areas corresponding to voided portions of the non-woven polymer sheet where the seams may help to define a plurality of chambers containing the non-woven polymer sheet. In an optional aspect, the garment may further comprise one or more perforations located on the seam, where the perforations extend through the inner panel and the outer panel.
In a second method of construction that utilizes sections or strips of non-woven polymer material, the section of non-woven polymer material may be positioned between a first and second panel of material. The first panel of material may be secured or bonded to the second panel of material in one or more areas adjacent to the section of non-woven polymer material. In an optional exemplary aspect, perforations may be formed in the bonded area where the perforations extend through the first panel of material and the second panel of material.
Garments produced using the second method of construction may comprise, for example, at least one garment panel having an inner panel and an outer panel. A section of non-woven polymer material may be positioned between the inner panel and the outer panel. The garment may further comprise one or more seams that join the inner panel to the outer panel at areas immediately adjacent or next to the section of non-woven polymer material; the seams may define a chamber that contains the section of non-woven polymer material. In an optional aspect, perforations may extend through the seam(s) such that they extend through the inner panel and the outer panel.
In general, garments produced using the first and second methods of construction are both insulating and breathable. This may be advantageous for a wearer undergoing physical exertion as these wearers often produce moisture in the form of perspiration. Perspiration still occurs in cold weather and may increase when the wearer is wearing a heat-insulating garment. By utilizing the perforations as described herein, the moisture vapor may escape to the exterior environment helping to keep the wearer comfortable. As well, the interior temperature of the garment may be regulated by facilitating a transfer of heat through the garment via the perforations.
Additional advantages may be obtained by using non-woven polymer sheets and/or sections of non-woven polymer material. Because of their non-woven structure formed, for example, by entangling fibers or filaments, they are able to maintain a cohesive or unitary structure as opposed to, for instance, loose poly-fill fibers and/or down. As such, they allow for the creation of chambers that are positioned vertically and/or diagonally on a garment. In other words, because there is little risk of drift of the materials (as opposed to, for example, down and/or loose poly-fill fibers that do not have a cohesive structure), the chambers may assume orientations other than generally discrete chambers having horizontal orientations. Further, the chambers can assume more organic or curvilinear shapes because there is no need to blow down or loose poly-fill fibers into the chambers. It is known that it is often difficult to evenly distribute down or loose poly-fill fibers into chambers that are curvilinear or that deviate from a more traditional horizontally oriented chamber. Additionally, since there is no need to contain loose fill materials, the chambers described herein may be in the form of “open-ended” chambers. That is, instead of a traditional chamber that is defined on all sides by seam lines to create an enclosed chamber, chambers described herein may comprise one or more sides or regions that are not bounded by seam lines.
Accordingly, aspects herein provide for a method of making an insulating garment, the method comprising providing a first panel of material; providing a second panel of material; and providing a thermally insulating fill sheet having one or more voided portions. The thermally insulating fill sheet is secured to at least the first panel of material, and the second panel of material is positioned such that the thermally insulating fill sheet is interposed between the first panel of material and the second panel of material. The first panel of material is affixed to the second panel of material in one or more areas corresponding to the one or more voided portions in the thermally insulating fill sheet and the garment is formed using at least the first panel of material and the second panel of material.
In another aspect, a garment is provided comprising at least a first garment panel. The first garment panel comprises an inner panel, an outer panel, and a thermally insulating fill sheet interposed between the inner panel and the outer panel, where the thermally insulating fill sheet comprising at least one voided portion. The garment further comprises at least one seam that joins the inner panel to the outer panel at an area corresponding to the voided portion of the thermally insulating fill sheet and a plurality of perforations located on the at least one seam, where the plurality of perforations extend through the at least one seam and through the inner panel and the outer panel.
In yet another aspect, a garment is provided comprising at least a first garment panel. The first garment panel comprises an inner panel, an outer panel, and a thermally insulating fill sheet interposed between the inner panel and the outer panel at a first area, where the thermally insulating fill sheet comprises at least a first voided portion and a second voided portion. The garment further comprises at least a first seam that joins the inner panel to the outer panel at a first location corresponding to the first voided portion of the thermally insulating fill sheet and at least a second seam that joins the inner panel to the outer panel at a second location corresponding to the second voided portion of the thermally insulating fill sheet, where the first seam is spaced apart from and unconnected to the second seam. Additionally the garment comprises an open-ended chamber formed between the inner panel and the outer panel and defined by the first seam and the second seam, where the chamber contains at least a portion of the thermally insulating fill sheet.
Aspects herein further provide for a method of making an insulated garment. The method comprises providing a first panel of material, providing a second panel of material, and providing a section of thermally insulating fill material. The section of thermally insulating fill material is positioned on the first panel of material and the second panel of material is positioned such that the section of thermally insulating fill material is interposed between the first panel of material and the second panel of material. The first panel of material is secured to the second panel of material at one or more areas adjacent to the section of thermally insulating fill material and the garment is formed using at least the first panel of material and the second panel of material.
In another aspect a garment is provided. The garment comprises at least a first garment panel comprising an inner panel, an outer panel, a first section of thermally insulating fill material interposed between the inner panel and the outer panel, and at least a first seam that joins the inner panel to the outer panel at a first area adjacent to the section of thermally insulating fill material.
In an additional aspect a garment is provided. The garment comprises at least a first panel of material comprising an inner panel, an outer panel, and a section of thermally insulating fill material interposed between the inner panel and the outer panel. The garment further comprises a first seam that joins the inner panel to the outer panel at a first area adjacent to the section of thermally insulating fill material and a second seam that joins the inner panel to the outer panel at a second area adjacent to the section of thermally insulating fill material. The first seam and the second seam define an open-ended chamber containing the section of thermally insulating fill material.
As used throughout this disclosure, positional terms used when describing, for instance, a garment, such as “anterior,” “posterior,” “inferior,” “superior,” “lateral,” “medial,” and the like are to be given their common meaning with respect to the garment being worn by a hypothetical wearer standing in anatomical position. Unless indicated otherwise, terms such as “affixed,” “coupled,” “secured,” and the like may mean releasably affixing two or more elements together using for instance, structural differences between the elements, releasable adhesives, snaps, buttons, hook-and-loop fasteners, and the like. These terms may also mean permanently affixing two or more elements together using, for example, stitching, bonding, adhesives, welding, and the like. Unless indicated otherwise, terms such as “proximate” or “adjacent” may mean within 0 cm to 5.0 cm of a designated reference point.
Aspects herein contemplate a method of forming an insulated vented garment using non-woven polymer sheets such as a thermally insulating poly-fill sheet. Aspects herein further contemplate an insulated vented garment formed using non-woven polymer sheets. As used throughout this disclosure the term “non-woven” may be defined as a mat or sheet-like structure formed by entangling fibers or filaments of a material. In exemplary aspects, the non-woven polymer sheet may comprise a single layer or multiple layers. Further, in exemplary aspects, the polymer material may comprise polyester fibers or filaments. The non-woven polymer sheet is generally lightweight but provides good insulation due to heated air being trapped between the entangled fibers.
Turning now to
In exemplary aspects, the first textile layer 110 and the second textile layer 114 may comprise a knitted, woven, or non-woven textile. Further, the first textile layer 110 may be formed of the same material (e.g., knit or woven material) as the second textile layer 114, or the layers 110 and 114 may be formed of different materials (i.e., the first textile layer 110 may be a knit material and the second textile layer 114 may be a woven material or vice versa). In exemplary aspects, one or more of the layers 110 and/or 114 may be treated with a durable water repellant (DWR) to make the resulting garment substantially impervious to water. For instance, the second textile layer 114, since it is an outer-facing layer, may be treated with a DWR finish. Further, it is contemplated herein that first textile layer 110 may be finished to provide a soft feel or hand to heighten wearer comfort since the first textile layer 100 is configured to potentially come into contact with the body surface of the wearer when the garment is worn. For instance, the first textile layer 110 may be brushed to impart a soft feel to the first textile layer 110. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
It is further contemplated herein that one or more of the first textile layer 110 and/or the second textile layer 114 may be formed from fabrics having different weights. For instance, the layers 110 and/or 114 may be formed of light fabrics (89 g/m2 to 30 g/m2) or even ultra-light fabrics (29 g/m2 or lighter). However, it is contemplated herein that heavier fabrics, such as fabrics with weights in the range of 90 g/m2 to 149 g/m2 or even 150 g/m2 to 250 g/m2 or higher may be used for the layers 110 and/or 114 in accordance with aspects herein.
The non-woven polymer sheet 112 is shown as being positioned between the first textile layer 110 and the second textile layer 114. It is contemplated herein that the non-woven polymer sheet 112 may comprise any number of different weights. Continuing, the non-woven polymer sheet 112 comprises a fifth surface 120 and an opposite-facing sixth surface 122. The fifth surface 120 is positioned adjacent to the fourth surface 126 of the second textile layer 114 in the construction 100, and the sixth surface 122 is positioned adjacent to the first surface 116 of the first textile layer 110 in the construction 100.
The non-woven polymer sheet 112 is shown with a portion removed to form an opening or a voided portion 132. In exemplary aspects, this may be done using a mechanical cutting process, ultrasonic cutting, laser cutting, water jet cutting, and the like to form the voided portion 132 in the non-woven polymer sheet 112. In an alternative exemplary aspect, the non-woven polymer sheet 112 may be pre-formed to have the voided portion 132. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein. Although shown with just one voided portion 132, it is contemplated herein that the non-woven polymer sheet 112 may comprise multiple voided portions. Further, it is contemplated herein, that the voided portion 132 may comprise any number of different lengths and may have different shapes such as curvilinear or organic shapes. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
The construction 100 depicted in
Once the first textile layer 110 and the second textile layer 114 are bonded together, a seam is formed at the bonded area. In other words, a seam is formed at the voided portion 132 of the non-woven polymer sheet 112 as will be discussed further below. It is contemplated herein, that only one of the adhesive materials 128 or 130 may be used herein to affix the first textile layer 110 to the second textile layer 114. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
The construction 100 further comprises one or more optional perforations 134. In exemplary aspects, the perforations 134 are made through the second textile layer 114 and the first textile layer 110 in the area corresponding to the voided portion 132. To put it another way, the perforations 134 are formed at the seam area created when the first textile layer 110 is affixed or bonded to the second textile layer 114 at the voided portion 132 of the non-woven polymer sheet 112. The perforations 134 may be formed using, for instance, a mechanical cutting process, a knitting or weaving process, laser cutting, water jet cutting, ultrasonic cutting, and the like. As stated above, the perforations 134 may be used to allow moisture vapor or excess heat produced by the wearer to exit the garment.
Turning now to
A cross-section of the construction 100 taken along cut line 4-4 of
Turning now to
Some or all of the garment 500 may comprise the construction 100 described with respect to
It is also contemplated herein that the construction 100 may be used on only portions of the garment 500. For instance, the garment 500 may be zoned into different areas such as areas needing a high amount of insulation, a moderate amount of insulation, and areas needing a low amount of insulation. In exemplary aspects, the zoning may be based on heat or sweat maps of the human body. Areas needing a high amount of insulation may comprise, for instance, the first and second sleeve portions 512 and 514. Areas needing a moderate to high amount of insulation may comprise, for instance, the front of the torso portion 510, and areas needing a moderate to low amount of insulation may comprise, for example, the back of the torso portion 510. These locations are exemplary only and it is contemplated herein that the garment 500 may be zoned differently.
Continuing, areas needing a high amount of insulation may be formed from the construction 100 but the non-woven polymer sheet 112 in these areas may not comprise voided portions. Instead, a continuous expanse of the non-woven polymer sheet 112 may be positioned between the first and second textiles layers 110 and 114 to provide a higher level of insulation. As such, it is contemplated herein that areas needing higher insulation may not comprise seams, such as the seam 310, and may not comprise perforations such as the perforations 134.
Areas needing a moderate amount of insulation may be formed from the construction 100 where the non-woven polymer sheet 112 comprises the voided portions and the first and second textile layers 110 and 114 are bonded together at locations corresponding to the voided portions to create one or more seams. By having voided portions in these areas, a lower amount of insulation may be achieved as compared to having a continuous expanse of non-woven polymer sheet. Perforations, such as the perforations 134 may be formed on some or all of the seams to impart increased permeability and breathability to the garment 500 in these areas.
Areas needing a low amount of insulation may also be formed from the construction 100. In exemplary aspects, an increased number of seams may be formed in these areas, and/or a greater number of seams may comprise perforations for a higher level of permeability and breathability. Alternatively, areas needing a low amount of insulation may be formed without using the construction 100. For instance, these areas may not comprise the non-woven polymer sheet 112 and instead may comprise just the first and second textile layers 110 and 114, just one of the layers 110 or 114, or the areas may comprise a different textile such as, for instance, a mesh material for greater permeability and breathability. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
Referring particularly to the garment 500 shown in
A close-up of perforations 531 located on the seams 536 is shown in
The seams 524 and 526 on the collar portion 520 of the garment 500 comprise both perforated and unperforated seams. For instance, the seams 524 are unperforated and the seam 526 is perforated. Having both perforated and unperforated seams at the collar portion 520 may help provide a moderate amount of insulation while still imparting a breathable and permeable characteristic to the collar portion 520.
The back of the garment 500 as shown in
In exemplary aspects, open-ended chambers may be formed between adjacent seams. For instance, with respect to
The pattern of the seams shown on the front and back of the garment 500 are exemplary only, and it is contemplated herein that different seam patterns may be utilized in accordance with aspects herein. Moreover, it is contemplated that seams may be present on the sleeve portions 512 and 514 when the sleeve portions 512 and 514 are formed using the construction 100. The perforation patterns shown in association with the seams on the garment 500 are also exemplary, and it is contemplated herein that different perforation patterns may be utilized in accordance with aspects herein. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
Similar to the garment 500, the garment 700 may be configured to provide varying levels of insulation over different portions of the garment 700. This may be based on heat or sweat maps of the human body. For instance, a greater amount of insulation may be needed in areas of the garment 700 adapted to cover the anterior thigh area of a wearer, and lower amounts of insulation may be needed over the back of the torso portion 710 of the garment 700. As such, the construction over different parts of the garment 700 may vary to include a non-woven polymer sheet without voided portions, a non-woven polymer sheet with voided portions, a non-woven polymer sheet with voided portions and perforations, and/or parts of the garment 700 that do not include a non-woven polymer sheet.
As stated, the garment 700 may be formed from the construction 100. As such, some or all of the garment 700 may comprise the first textile layer 110, the non-woven polymer sheet 112, and the second textile layer 114. One or more portions of the non-woven polymer sheet 112 may be removed to form voided portions, such as the voided portion 132 in
With respect to
The placement and pattern of the seams on the garment 700 is exemplary only and other patterns are contemplated herein. Moreover, the perforation pattern shown for the garment 700 is exemplary only and other perforation patterns are contemplated herein. Any and all aspects, and any variation thereof, are contemplated as being within the scope herein.
The seams shown for the garments 500 and 700 have generally been shown as being linear. However, it is contemplated that seams described herein may assume more organic or curvilinear shapes.
Turning now to
At a step 1014, a thermally insulating fill sheet such as the non-woven polymer sheet 112 is provided where the thermally insulating fill sheet comprises one or more voided portions or openings each defined by a perimeter edge. In one exemplary aspect, the voided portions may be formed by removing selected portions of the thermally insulating fill sheet using, for instance, a mechanical cutting process, laser jet cutting, water jet cutting, ultrasonic cutting, and the like. The portions removed from the thermally insulating fill sheet may be based on, for instance, a predetermined pattern. In an alternative exemplary aspect, the thermally insulating fill sheet may be pre-formed to have the voided portions.
At a step 1016, the thermally insulating fill sheet is secured to one or more of the first panel of material and/or the second panel of material. In exemplary aspects, this may occur by, for example, tacking or stitching the perimeter edge defining each of the openings or voided portions to the first and/or second panel of material. Other ways of securing the thermally insulating fill sheet to the first and/or second panels of material are contemplated herein such as using adhesives, bonding, spot welding, and the like.
At a step 1018, the first and second panels of material are positioned adjacent to each other such that the sheet of thermally insulating fill sheet is interposed between the first and second panels. At a step 1020, the first and second panels of material are secured to each other in areas corresponding to the openings or voided portions in the thermally insulating fill sheet to form seams. In exemplary aspects, this may occur by providing an adhesive material, such as an adhesive sheet, that is formed (e.g., cut) to have a shape corresponding to the shape of an opening in the thermally insulating fill sheet. The adhesive material is positioned between the first and second panels of material such that it is aligned with the respective opening or voided portion in the thermally insulating fill sheet. The adhesive material is activated by the application of, for example, heat, light, ultrasound, pressure, and the like in the area corresponding to the opening to bond the first panel of material to the second panel of material. A similar process is contemplated for each of the openings or voided portions formed in the thermally insulating fill sheet. At a step 1022, the garment is formed using at least the bonded assembly described above.
Additional method steps are contemplated herein. For instance, perforations may be formed through some or all of the seams to impart breathability characteristics to the garment in addition to the insulation characteristics provided by the use of the thermally insulating fill sheet. It is further contemplated herein that the seams formed in the areas corresponding to the openings or voided portions in the thermally insulating fill sheet may be reinforced with stitching. The listing of the method steps 1000 is exemplary only, and it is contemplated herein that the steps may take place in other orders unless specified otherwise.
Another exemplary method of construction contemplated herein comprises using non-woven polymer sheets that do not have voided portions. In other words, the non-woven polymer sheets comprise continuous expanses without openings or voided portions formed therein. The non-woven polymer sheet is positioned between a first and second textile layer such as the first and second textile layers 110 and 114 of
As described, aspects herein are directed to a method of forming an insulated vented garment using non-woven polymer sheets such as a thermally insulating poly-fill sheet. Aspects herein are further directed to an insulated vented garment formed using non-woven polymer sheets. The use of non-woven polymer sheets provides an economical and efficient production method, and garments produced using this type of construction may comprise organically shaped or curvilinear chambers that can be positioned on the garment to provide targeted insulation and venting features.
Aspects herein further contemplate a method of forming an insulated vented garment using sections or strips of a non-woven polymer material. Aspects herein also contemplate an insulated vented garment formed using sections or strips of non-woven polymer material. As used throughout this disclosure, the term “strips” or “sections” of non-woven polymer material may be defined as disparate or non-continuous portions of a non-woven polymer material that are used in the construction of a garment where adjacent disparate sections of non-woven polymer material may be separated by a seam as described below. In some aspects, the section may take the form of a narrow piece of non-woven polymer material (e.g., a piece whose width is less than its length) which is hereinafter known as a “strip” of non-woven polymer material. However, it is contemplated herein that the term “section” may also encompass other geometries such as square pieces of non-woven polymer material, rectangular pieces of non-woven polymer material, circular or triangular pieces of non-woven polymer material, curvilinear or organically shaped pieces of non-woven polymer material, and the like. Similar to above, the sections of non-woven polymer material, when incorporated into a garment, may provide good insulation due to heated air being trapped between the entangled fibers while still being lightweight.
Turning now to
In exemplary aspects, the first textile layer 1110 and the second textile layer 1114 may have a similar pattern shape. However, it is also contemplated herein that the first textile layer 1110 and the second textile layer 1114 may comprise different pattern shapes. For example, the first textile layer 1110 may have a pattern shape comprising a smaller surface area than the second textile layer 1114. To describe it a different way, the first textile layer 1110 may be applied to the second textile layer 1114 as sections or “patches” at one or more areas of the second textile layer 1114. Thus, the insulation features described herein using the first and second textile layers 1110 and 1114, and the section of non-woven polymer material 1112 may be incorporated at one or more discrete portions of a garment or apparel item. This will be described further with respect to
Similar to the construction 100, the first textile layer 1110 and the second textile layer 1114 may comprise a knitted, woven, or non-woven textile. Further, the first textile layer 1110 may be formed of the same material (e.g., knit or woven material) as the second textile layer 1114, or the layers 1110 and 1114 may be formed of different materials (i.e., the first textile layer 1110 may be a knit material and the second textile layer 1114 may be a woven material or vice versa). In exemplary aspects, one or more of the layer 1110 and/or 1114 may be treated with a durable water repellant (DWR) to make the resulting garment substantially impervious to water. For instance, the second textile layer 1114, since it is an outer-facing layer, may be treated with a DWR finish. Moreover, the first textile layer 1110 may be finished such that is has a soft feel or hand. Finishing may include, for example, brushing the second surface 1118 of the first textile layer 1100. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
It is further contemplated herein that one or more of the first textile layer 1110 and/or the second textile layer 1114 may be formed from fabrics having different weights. For instance, the layers 1110 and/or 1114 may be formed of light fabrics (89 g/m2 to 30 g/m2) or even ultra-light fabrics (29 g/m2 or lighter). However, it is contemplated herein that heavier fabrics, such as fabrics with weights in the range of 90 g/m2 to 149 g/m2 or even 150 g/m2 to 250 g/m2 or higher may be used for the layers 110 and/or 114 in accordance with aspects herein.
The section of non-woven polymer material 1112 is shown as having a curved strip-like shape. However, it is contemplated herein that the section of non-woven polymer material 1112 may comprise different shapes as described above. The section of non-woven polymer material 1112 is further shown as being positioned between the first and second textile layers 1110 and 1114. More specifically, the section of non-woven polymer material 1112 is shown as being positioned between the first surface 1116 of the first textile layer 1110 and the fourth surface 1122 of the second textile layer 1114.
Similar to the non-woven polymer sheet 112 in
The construction 1100 further comprises a first adhesive material 1124 and a second adhesive material 1126. In exemplary aspects, the first adhesive material 1124 and the second adhesive material 1126 may comprise an adhesive tape formed to have a shape generally corresponding to the shape of the section of non-woven polymer material 1112. The first adhesive material 1124 and the second adhesive material 1126 may be used to bond the first textile layer 1110 to the second textile layer 1114.
To assemble the construction 1100, the section of non-woven polymer material 1112 may be secured to the first surface 1116 of the first textile layer 1110, and the first and second adhesive materials 1124 and 1126 may be positioned adjacent to the section of non-woven polymer material 1112 on the first surface 1116 of the first textile layer 1110. More particularly, the first adhesive material 1124 and the second adhesive material 1126 may be positioned on the first surface 1116 of the first textile layer 1110 adjacent to the section of non-woven polymer material 1112 on opposing sides of the section of non-woven polymer material 1112. As used with respect to this aspect, the term “adjacent” may mean within 0.0 mm to 20.0 mm of an edge of the section of non-woven polymer material 1112. The fourth surface 1122 of the second textile layer 1114 may then be positioned adjacent to the first surface 1116 of the first textile layer 1110. The two layers 1110 and 1114 may be pressed together with sufficient force and/or energy applied in the areas generally corresponding to the adhesive materials 1124 and 1126 to activate the adhesive materials 1124 and 1126 and cause a bond between the two layers 1110 and 1114. The adhesive materials 1124 and 1126 may be activated by, for instance, heat, or ultrasonic energy, or any other type of applied energy. In the construction 1100, the first and second textile layers 1110 and 1114 are un-affixed or un-bonded in areas corresponding to the section of non-woven polymer material 1112.
Once the first textile layer 1110 and the second textile layer 1114 are bonded together, seams are formed at the bonded areas. In other words, a seam is formed at an area corresponding to the first adhesive material 1124 and a seam is formed at an area corresponding to the second adhesive material 1126. It is contemplated herein, that instead of positioning the first and second adhesive materials 1124 and 1126 adjacent to the first textile layer 1110, the adhesive materials 1124 and 1126 may be positioned adjacent to the second textile layer 1114. It is further contemplated herein that additional adhesive materials may be used to bond the first and second textile layers 1110 and 1114 together in areas adjacent to the section of non-woven polymer material 1112. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
The construction 1100 further comprises one or more optional perforations 1134 and 1136. In exemplary aspects, the perforations 1134 may be made through the second textile layer 1114 and the first textile layer 1110 in the area corresponding to the second adhesive material 1126, and the perforations 1136 may be made through the second textile layer 1114 and the first textile layer 1110 in the area corresponding to the first adhesive material 1124. To put it another way, the perforations 1134 are formed at the seam area created when the first textile layer 1110 is affixed or bonded to the second textile layer 1114 using the second adhesive material 1126. And the perforations 1136 are formed at the seam area created when the first textile layer 1110 is affixed or bonded to the second textile layer 1114 using the first adhesive material 1124. The perforations 1134 and 1136 may be formed using, for instance, a mechanical cutting process, a knitting or weaving process, laser cutting, water jet cutting, ultrasonic cutting, and the like. As stated above, the perforations 1134 and 1136 may be used to allow moisture vapor or excess heat produced by the wearer to exit the garment.
Turning to
As described above, it is contemplated herein that the first textile layer 1110 may have a different pattern shape than the second textile layer 1114 such that the first textile layer 1110 has a smaller surface area than the second textile layer 1114. This is shown in
The configuration shown in
Continuing, a cross-section of the construction 1100 taken along cut line 14-14 of
Although the construction 1100 is shown comprising one section of non-woven polymer material 1112, it is contemplated herein that the construction 1100 may comprise multiple sections of non-woven polymer material, where each section is separated from an adjacent section of non-woven polymer material by a seam, where the seam may comprise optional perforations. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
Turning to
Some are all of the garment 1500 may comprise the construction 1100 shown in
Similar to the garment 500, it is also contemplated herein that the construction 1100 may be used on only portions of the garment 1500. For instance, the garment 1500 may be zoned into different areas such as areas needing a high amount of insulation, a moderate amount of insulation, and areas needing a low amount of insulation.
Continuing, areas needing a high to moderate amount of insulation may be formed from the construction 1100. However, seams formed in these areas may not be perforated. Areas needing a low amount of insulation may also be formed from the construction 1100. Seams in these areas may be perforated to increase permeability and breathability in these areas. Alternatively, areas needing a low amount of insulation may be formed without using the construction 1100. For instance, these areas may not comprise sections of non-woven polymer material 1112 and instead may comprise just the first and second textile layers 1110 and 1114, just one of the layers 1110 or 1114, or the areas may comprise a different textile such as, for instance, a mesh material for greater permeability and breathability. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
Referring particularly to the garment 1500, the garment 1500 comprises a number of seams such as seam 1520 and seam 1522 located on an upper aspect of the torso portion 1510 on a first lateral side, and seam 1526 and 1528 located on an upper aspect of the torso portion 1510 on a second opposite lateral side. In an optional aspect, the seams 1520, 1522, 1526, and 1528 may be reinforced with stitching. The stitching may be along one edge of the seams 1520, 1522, 1526, and 1528 or along both edges of the seams 1520, 1522, 1526, and 1528. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
In exemplary aspects, the seam 1520 and the seam 1522 define a first chamber 1524 comprising a section of non-woven polymer material, and the seam 1526 and the seam 1528 defined a second chamber 1530 comprising an additional section of non-woven polymer material. The chambers 1524 and 1530 are shown as being defined on two sides by seams but as being open at each end. Some or all of the seams 1520, 1522, 1526, and 1528 may be perforated. For instance, the seams 1520 and 1526 are shown as comprising perforations 1532. Similar to the discussion of the perforations with respect to the garment 500, the perforations 1532 may comprise different sizes, shapes, and may be formed continuously or intermittently along the seams 1520 and 1526. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.
Although the seams 1520, 1522, 1526, and 1528 and the chambers 1524 and 1530 are shown in a generally horizontal orientation, it is contemplated herein that the garment 1500 may comprise seams and chambers that have a generally vertical orientation or that assume a more curvilinear or organic shape such as the exemplary shapes shown in
Similar to the garment 700 of
As shown in
Although the seams 1622, 1624, 1628, and 1630 and the chambers 1626 and 1632 are shown in a generally horizontal orientation, it is contemplated herein that the seams 1622, 1624, 1628, and 1630 and the chambers 1626 and 1632 may assume a more vertical orientation or they may assume a more curvilinear or organic aspects. Moreover, the placement of the seams 1622, 1624, 1628, and 1630 and the chambers 1626 and 1632 shown in
Turning to
At a step 1714, a section of thermally insulating fill material, such as the section of non-woven polymer material 1112, is provided. The section of thermally insulating fill material may be cut from a sheet of thermally insulating fill material, or the section of thermally insulating fill material may be formed to have a specific shape as needed for construction.
At a step 1716, the section of thermally insulating fill material is positioned between the first and second panels of material. In exemplary aspects, the section of thermally insulating fill material may be secured to the first panel of material and/or the second panel of material by stitching or tacking the section of thermally insulating fill material along its perimeter edge to the panel(s). Other ways of securing the section of thermally insulating fill material to the first and/or second panels of material are contemplated herein such as using adhesives, bonding, spot welding, and the like.
At a step 1718, the first and second panels of material are positioned adjacent to each other such that the section of thermally insulating fill material is interposed or positioned between the first and second panels. At a step 1720, the first and second panels of material are secured to each other in areas adjacent to the section of thermally insulating fill material to form seams. In exemplary aspects, this may occur by providing an adhesive material, such as an adhesive sheet, that is formed (e.g., cut) to have a shape corresponding to the general shape of the section of thermally insulating fill material. The adhesive material is positioned between the first and second panels of material such that it is positioned adjacent to one or more edges of the section of thermally insulating fill material. The adhesive material is activated by the application of, for example, heat, light, ultrasound, pressure, and the like in the areas adjacent to the section of thermally insulating fill material to bond the first panel of material to the second panel of material. A similar process is contemplated for additional sections of thermally insulating fill material. At a step 1722, the garment is formed using at least the bonded assembly described above.
Additional method steps are contemplated herein. For instance, perforations may be formed through some or all of the seams to impart breathability characteristics to the garment in addition to the insulation characteristics provided by the use of the sections of thermally insulating fill material. It is further contemplated herein that the seams formed in the areas adjacent to the sections of thermally insulating fill material may be reinforced with stitching. The listing of the method steps 1700 is exemplary only, and it is contemplated herein that the steps may take place in other orders unless specified otherwise.
As described, aspects herein are directed to a method of forming an insulated vented garment using sections of non-woven polymer material such as a poly-fill material. Aspects herein are further directed to an insulated vented garment formed using sections of non-woven polymer material. The use of sections of non-woven polymer material provides an economical and efficient production method, and garments produced using this type of construction may comprise organically shaped or curvilinear chambers that can be positioned on the garment to provide targeted insulation and venting features.
Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.
This application assigned U.S. application Ser. No. 16/924,781, filed Jul. 9, 2020, and entitled “Insulated Vented Garment Formed Using Non-Woven Polymer Sheets” is a Continuation Application of U.S. application Ser. No. 15/286,913, filed Oct. 6, 2016, and entitled “Insulated Vented Garment Formed Using Non-Woven Polymer Sheets” which issued as U.S. Pat. No. 10,743,596 on Aug. 18, 2020. The entirety of the aforementioned application is incorporated by reference herein.
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| Office Action received for Canadian Patent Application No. 3,125,031, dated Oct. 28, 2022, 4 pages. |
| Notice of Allowance received for Canadian Patent Application No. 3,056,451, dated Nov. 8, 2022, 1 page. |
| Non-Final Office Action received for U.S. Appl. No. 17/208,548, dated Dec. 14, 2022, 10 pages. |
| Office Action received for European Patent Application No. 17765040.5, dated Jan. 24, 2023, 5 pages. |
| Office Action received for European Patent Application No. 17765042.1, dated Jan. 26, 2023, 5 pages. |
| Office Action received for European Patent Application No. 21163471.2, dated Jan. 24, 2023, 4 pages. |
| “Barbour Mens Chukka Quilted Jacket Military Brown Navy”, Barbour, Available on Internet at: <http://www.coveredbridgecyclery.com/barbour-mens-chukka-quilted-jacket-military-brown-navy-1423.html>, Accessed on Jan. 23, 2015, 1 page. |
| Bendzovski, Daniel, “Trend-sandwich: Exploring New Ways of Joining Inspiration, Such as Different Kinds of Trends, Through Processes of Morphing and Melding Different Trendy Garments and Materials, for New Methods, Garment Types, Materials and Expressions”, MA Fashion Design Thesis, University of Boras, 2015, 224 pages. |
| “C9 Loft Jacket”, Houdini, Available on Internet at: <http://www.houdinisportswear.com/en/women/womens-c9-loft-jacket>, Accessed on Jan. 23, 2015, 1 page. |
| “Greenland Baffled Jacket”, Marmot For Life, Available on Internet at: <http://marmot.com/products/details/greenland-baffled-jacket>, Accessed on Jan. 23, 2015, 1 page. |
| “Laser Perforated Jacket”, Akris Punto, Nordstrom, Available on Internet at: <http://shop.nordstrom.com/s/akris-punto-laser-perforated-jacket/3667112>, Accessed on Jan. 23, 2015, 1 page. |
| “Mavic Helium Jacket (Men's)”, MEC, Available on Internet at: <http://www.mec.ca/product/5038-526/mavic-helium-jacket-mens/>, Accessed on Jan. 23, 2015, 1 page. |
| “Nike Aeroloft”, Nike, Available on Internet at: <http://www.nike.com/us/en_us/c/running/aeroloft>, Accessed on Jan. 23, 2015, 1 page. |
| “Pizzoli' Knit & Quilted Jacket”, Boss Hugo Boss, Nordstrom, Item #73989, Available on Internet at: <http://shop.nordstrom.com/s/boss-hugo-boss-pizzoli-knit-quilted-jacket/3782194>, Accessed on Jan. 23, 2015, 1 page. |
| “Quilted Front Down Sweater Jacket”, Moncler, Nordstrom, Item #803724, Available on Internet at: <http://shop.nordstrom.com/s/moncler-quilted-front-down-sweater-jacket/3900159>, Accessed on Jan. 23, 2015, 1 page. |
| “Salomon Men's S-Lab Hybrid Jacket”, Running Warehouse, Model No. L36344900, Available on Internet at: <http://www.runningwarehouse.com/Salomon_Mens_S-Lab_Hybrid_Jacket/descpage-SMSLHJ.html>, Accessed on Jan. 23, 2015, 1 page. |
| “Woman's Aconcagua Jacket”, The North Face, Available on Internet at: <http://www.thenorthface.com/catalog/sc-gear/womens-jackets-vests/women-8217-s-aconcaguajacket.html?from=subCat&variationId=R8F &cm_mmc=Google-_-ProductListingAds-_-ProductTerms-_-The+North+Face+Women+s+Aconcagua+Jacket&gclid=Cj0KEQiAiuOIBRCU-8D6idaPz_UBEiQAzTagNG1Cj7lahwV8b1m5Eh-Q2W_EcYDilCjgsF8EXvFMbEaApbd8P8HAQ>, Accessed on Jan. 23, 2015, 1 page. |
| “Women's Better than Naked™ Cool Jacket”, The North Face, Available on Internet at: <http://www.thenorthface.com/catalog/sc-gear/women-39-s-better-than-naked-cool-jacket.html>, Accessed on Jan. 23, 2015, 1 page. |
| Final Office Action received for U.S. Appl. No. 15/597,540, dated Apr. 12, 2023, 15 pages. |
| Notice of Allowance Received for U.S. Appl. No. 17/208,548, dated Mar. 29, 2023, 10 pages. |
| Number | Date | Country | |
|---|---|---|---|
| 20200337399 A1 | Oct 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15286913 | Oct 2016 | US |
| Child | 16924781 | US |
