Patent Application
20240381954
The present invention relates to monosuits for cold weather activities.
Monosuits, or so called “freedom suits,” are useful for cold weather activities and winter sports. Monosuits are typically preferred over a jacket and trouser combination because they offer a popular “microclimate” for the body and tend to reduce snow or water penetration.
Prior art monosuits have problems. One problem associated monosuits of the past is that they must be removed to address personal needs.
Another problem is flexibility. Waterproof fabrics which are used in prior art suits are typically difficult to stretch because of the tight weave and various coatings used. Movements with non-stretch material tend to place undue stress on zippers and other closures leading to premature failure.
Yet another problem is created by closure mechanisms used in monosuits of the past is that they are difficult to use in very cold weather. Prior art snaps, zipper pulls, and closure flaps are difficult to find and manipulate in extremely cold conditions. Ice and snow deposits also complicate use of these closures. In some situations, the inability to find and use closure devices quickly can create health risks due to exposure to the elements.
The prior art has attempted to address these problems but has not been entirely successful.
One example can be found in U.S. Pat. No. 9,247,774 to Davis. Davis discloses coveralls having a drop seat extending from one leg to the other which is connected by a single zipper. The coveralls may be made from waterproof material with a flap covering the zipper. But, Davis fails to disclose a material with sufficient elasticity or a flap monosuit to protect the zipper.
Another example is U.S. Pat. No. 7,966,672 to Hagerman. Hagerman discloses coveralls having an inseam zipper that extends from one leg to the other. But, Hagerman fails to disclose zipper extending that extends from the outer seam of one leg around the small of the lower back and to the outer seam of the opposite leg. Hagerman also fails to disclose use of an elastic material to protect the zipper.
U.S. Pat. No. 10,093,401 to Myerscough discloses waterproof compression flaps that provide abrasion protection for a zipper. But, Myerscough fails to disclose a drop seat connected by a zipper, or connecting the zipper to the monosuit by an elastic material.
U.S. Pat. No. 3,711,865 to Schifman discloses a body suit having a continuous zipper closure extending between the outer seams of legs. An envelope is secured to a back panel which covers the zipper. But, Schifman fails to disclose a stretch material connected to the zipper, or a flap integrally formed with the monosuit.
U.S. Pat. No. 10,765,156 to Myerscough discloses a body suit having a zippered opening spanning the back waist along the outer sides of the legs, to each knee. But Myerscough fails to disclose a zipper that extends continuously from one ankle to the other or a stretch material connected to the zipper.
Therefore, a need still exists for a durable monosuit and drop seat combination which can withstand stress induced from outdoor activities without premature failure, and yet still provide ease of access for the user.
A monosuit is provided which has a durable zippered drop seat which is easily opened or removed in various configurations. In one embodiment, the zipper extends from the outer seam of one leg to the small of the lower back and to the outer seam of the opposite leg. The zipper incorporates the use of four cars which cooperate to allow the drop seat to be partially or fully removed. The cars are positioned on the zipper so that the drop seat may be attached to the main body in only a single orientation.
The zipper is connected to the body of the monosuit by a novel pair of semi elliptical elastic portions adjacent each side of the zipper. Each semi-elliptical portion is formed of an elastic material adjacent the generally semicircular path of the top arc of the zipper, to resist stress resulting from various movements. The semi elliptical portions provide durability for the suit as they isolate the zipper from stress induced by the surrounding material.
Another preferred embodiment provides an integrally formed flap which protects the zipper and the elastic material to increase longevity and reliability of the monosuit. The integrally formed flap forms a protective pocket or “garage” which may be easily accessed by the user from either side of the suit and which provides a novel tactile indicator to aid in locating the zipper cars in inclement weather.
In the detailed description of the preferred embodiments presented below, reference is made to the accompanying drawings.
In the description that follows, like parts are marked throughout the specification and figures with the same numerals, respectively. The figures are not necessarily drawn to scale and may be shown in exaggerated or generalized form in the interest of clarity and conciseness. Unless otherwise specified, use of the term “about” indicates a tolerance of ±20%.
Referring to
Monosuit 100 includes main body 102 and removable drop seat 101. Main body 102 further comprises of cooperating exterior components of hood 109, arm components 150 and 151, back panel 114, integrally formed flap 110, and front leg sections 122 and 126. Removable drop seat 101 further comprises integrally formed back leg section 124, seat section 175, and back leg section 128. Main body 102 and drop seat 101, are preferably manufactured from a nylon or polyester material such as Gore-tex® or eVent®, or a weave of waxed cotton. A sealant of polyurethane may be applied to the material for increased water impermeability.
Monosuit 100 further comprises a non-removable interior liner 107, adjacent and bonded to all exterior components, including main body 102 and removable drop seat 101. The interior lining is preferably manufactured from a fleece backing, nylon, silk, cotton or taffeta material and is bonded in place by various seams and stitching or a suitable industrial adhesive.
Back panel 114 further comprises of flap 110. Flap 110 is integrally formed with the back panel and creates downward facing zipper pocket 111. In a preferred embodiment, flap 110 is configured with straight central edge 118 bounded by angled edges 116 and 120. Central edge 118 further comprises central notch 118a, along a midline of the monosuit, as will be further described. In another embodiment, central edge 118 may take the form of a downwardly oriented semicircle. The angled edges are important because they allow the zipper pocket to be easily located at the hip by either hand, thereby aiding in rapid location of the zipper. Likewise, central notch 118a is important to aid the user in locating the zipper cars by providing tactile feedback to the midline which is highly useful in the dark and in extreme temperatures where the hands may be gloved.
Main body 102 is removably connected to drop seat 101 by zipper 108, as will be further described.
Right leg 106 is comprised of front leg section 122 and back leg section 124. Left leg 104 is comprised of front leg section 126 and back leg section 128. Front leg sections 122 and 126, and back leg sections 124 and 128, are connected to zipper 108 by stitching interfaces 123 and 125, respectively.
Zipper 108 generally forms an inverted elliptical shape extending continuously from left leg 104 to right leg 106. The semi-elliptical shape is important because it disperses stresses from the surrounding material when the monosuit is in use.
Right leg 106 further comprises cover 130 connected at front leg section 122 and by durable stitching. Similarly, cover 132 is connected to the left leg at front leg section 126 by durable stitching. Cover 130 is releasably connected to back leg section 124 by snap fastener 134. Likewise, cover 132 is releasably connected to back leg section 128 by snap fastener 138.
Referring to
Zipper 108 is connected to seat section 175 by elastic portion 211. Likewise, zipper 108 is connected to back panel 114 by elastic portion 210. Elastic portion 211 is connected to seat section 175 along bottom arc 220 with durable stitching or an inductive heat weldment. The zipper is connected to both elastic portion 210 and elastic portion 211 by durable stitching or an inductive heat weldment. Likewise, elastic portion 210 is connected to back panel 114 along top arc 218 with a durable stitching. In a preferred embodiment, the elastic material is a blend of spandex and nylon, preferably about 8% spandex and about 92% nylon, at a medium to heavy weight thickness of about 150 grams/m2 to about 450 grams/m2 which provides sufficient elasticity to greatly reduce the stress implied to the zipper by the back panel and the seat section. Of course, other elastic blends may be used. In a preferred embodiment, the elastic portion 210 and elastic portion 211 are semi-elliptical in shape and track the path of zipper 108 around the top of seat section 175 and terminate at connection points 212 and 213, respectively. The shape of the flexible material is very important because it uniformly disperses stress from multiple angles across the flexible material, induced by bending, thereby reducing the stress on the zipper and increasing the durability of the zipper connection. Integrally formed flap 110 and zipper pocket extend from connection point 212 to connection point 213. Each connection point includes a reinforcing gusset. Gusset 213a is positioned at connection point 213. Gusset 212a is positioned at connection point 212. The reinforcing gussets are important to strengthen the connection points to prevent failure of the elastic portions and the angled edges where they are connected to the main body.
Zipper 108 further comprises of upwardly oriented cars 202 and 208, and downwardly oriented cars 204 and 206. Each of the cars is operatively connected to the zipper and functions to engage and disengage the zipper teeth, as will be further described. Upwardly oriented car 202 and downwardly oriented car 204 are non-removably fixed to the zipper along the front leg sections, as will be further described. Upwardly oriented car 208 and downwardly oriented car 206 are non-removably fixed to the zipper along the back leg sections, as will be further described. The opposing non-removable connections of the pairs of cars is important because they allow the drop seat to be attached to the main body in only one orientation, thereby saving time when the drop seat is reattached to the main body. This time savings is important in cold weather situations where cold exposure is a concern.
Cover 132 is fixed to front leg section 126 adjacent car 202. Cover 132 is preferably manufactured from a rayon strapping material which is durably stitched to the front leg section. Cover 132 further comprises snap section 133a. In use, cover 132 is used to secure car 202 in place on the zipper by engaging snap section 133b fixed to back leg section 128.
Cover 130 is fixed to front leg section 122, adjacent car 208. Cover 130 is preferably manufactured from a rayon strapping material which is durably stitched to the front leg section. Cover 132 further comprises snap section 134a. In use, cover 132 is used to secure car 202 in place on the zipper by engaging snap section 134b fixed to back leg section 124.
Referring then to
Fabric elasticity is described in terms of elastic recovery. If a fabric possesses more elasticity, then it may resist more stress and recover before undergoing strain than a fabric which possesses less elasticity. Elasticity is measured in percent elongation as a function of width. Assuming that the fabric is of the same type, a wider fabric section is capable of undergoing more stress before strain than a narrower fabric section.
In a preferred embodiment, the elastic portions are formed of a spandex, Lycra® or elastin blend which typically demonstrates an elongation of between about 500% to about 800% before undergoing strain. The main body and the drop seat are preferably formed of a Gore-tex® or similar material which typically demonstrates elongation of between about 15% to about 32% before undergoing strain.
The inventor has realized that the tensile stress placed on the zipper by the mono suit and the drop seat when in use, varies depending on the movement of the user. The stress may be measured along a set of bending axes originating at origin 300. Preferably, origin 300 is located at the intersection of midline axis 380 and the apex of zipper 108. As the monosuit undergoes flexion, or forward bending, perpendicular to the 0° midline axis, 380, stress is placed on the zipper from elastic portions 210 and 211 in directions A and A′. The stress is greatest in this direction. Movement about the transverse axis occurs in one of two transverse planes when the monosuit is twisted at the waist, perpendicular to either of 45° axes 382 or 383. Stress induced by movement about the transverse axis results in forces in directions B and B′, or B″ and B′″. Movement about the coronal axis, perpendicular to either 160° axes 385 or 387 results in stress on the zipper in directions C and C′, or C″ and C′″.
It is estimated that the average maximum tensile force exerted by the monosuit on the drop seat when in use in direction A to A′ is between about 15 lbs. to about 40 lbs. The average maximum tensile force exerted by the monosuit on the drop seat in the B to B and B″ to B′″ directions is between about 5 lbs. to about 20 lbs. The average maximum tensile force exerted by the monosuit in the C to C′ and C′″ to C′″ directions is about 2 lbs. to about 10 lbs.
The semi-elliptical shapes of elastic portions 210 and 211 are designed to place wider portions of material where stress from the monosuit is the greatest, and more narrow portions of material where the stress from the monosuit is less severe. The width of the elastic portions varies according to the bending axes according to the following table. All dimensions have a tolerance of ±20%.
As can be seen, the elastic portions exhibit a width ratio which corresponds to the associated bending axis. In a preferred embodiment, the width ratio is about 4:2.25:2.7 corresponding to bending axes perpendicular to 0°, 45° and 160°, respectively.
Referring then to
Zipper 108 is further comprised of tape sections 222 and 224. Tape section 222 is fused to interlocking teeth 402. Tape section 224 is fused to interlocking teeth 403. When the zipper is engaged, interlocking teeth 402 flexibly engage interlocking teeth 403 to connect the front leg sections to the back leg section and the seat section to the back panel, as previously described.
Tape section 222 is connected to elastic portion 210 and the front leg sections by stitching interface 123. Likewise, tape section 224 is connected to elastic portion 211 and the back leg sections by stitching interface 125.
Tape section 222 is terminated at starter box 450, adjacent teeth 402 and insertion pin 452, adjacent teeth 402. Likewise, tape section 224 is terminated by insertion pin 460, adjacent teeth 403, and starter box 462, adjacent teeth 403. Starter box 450 and insertion pin 460 cooperate in attaching and detaching cars 202 and 204 from zipper 108 when attaching and detaching drop seat 101 from main body 102, as will be further described. Likewise, insertion pin 452 and starter box 462 cooperate in attaching and detaching cars 206 and 208 from zipper 108 when attaching and detaching removable drop seat from main body 102, as will be further described.
Car 202 is operatively connected to pull 202a through a hinged connection which allows pull 202a to be grasped by the user at various different angles. Likewise, cars 204, 206 and 208 are operatively connected to pulls 204a, 206a and 208a, respectively, which serve similar functions.
In a preferred embodiment, zipper 108 is a closed end reverse coil zipper available from The YKK Group of Tokyo, Japan. Preferably, the zipper is sized as a “#20”, having teeth which measure approximately 20 millimeters across. Preferably zipper teeth 403 and 402 are made of a Delrin plastic and are molded onto the zipper tape which makes them both durable and weatherproof.
Referring to
Car 202 is positioned on zipper 108 such that teeth 402 are disengaged from teeth 403 as car 202 is moved in direction “A” from left leg end point 480 to midline 422. As car 202 is moved in the reverse direction, teeth 402 are engaged with teeth 403 and insertion pin 460 is fixed in slot 450a of starter box 450. Insertion pin 460 is designed to engage starter box 450 through internal slot 450a. Similarly, car 208 is positioned on zipper 108 such that teeth 402 are disengaged from teeth 403 as car 208 is moved in direction “B” from right leg end point 482 to midline 422. As car 208 is moved in the opposite direction, teeth 402 are engaged with teeth 403 and insertion pin 452 is positioned in slot 462a of starter box 462. Insertion pin 452 is designed to engage starter box 462 through internal slot 462a.
Referring then to
As car 204 is moved in direction “C” from midline 422 to left leg end point 480, teeth 402 are disengaged from teeth 403. In the opposite direction, car 204 is moved from the left leg end point to midline 422 thereby engaging teeth 402 with teeth 403. Likewise, as car 206 is moved in direction “D” from midline 422 to right leg end point 482, teeth 402 are disengaged from teeth 403. As car 206 is moved in the opposite direction from right leg end point 482 to midline 422, teeth 402 are engaged with teeth 403.
Referring to
As both cars 202 and 204 are moved in direction “C” to a position directly adjacent starter box 450. Insertion pin 460 may be disengaged by removing it from slot 450a, car 202 and car 204, thereby releasing teeth 402 from teeth 403. In the same way as both cars 206 and 208 are moved in direction “D” from midline 422 to right leg end point 482, adjacent starter box 462. Insertion pin 452 may be removed from slot 462a, car 206 and car 208, thereby completely disengaging teeth 402 from teeth 403. At this point, drop seat 101 may be moved in direction “F”, and back panel 114 may be moved in direction “E”, thereby be completely removing the drop seat from the main body.
Importantly, the length, Y, of insertion pin 452 should be sized to traverse the entire length, Y′ of car 206, car 208, and slot 462a, of starter box 462, thereby allowing engagement of car 206, car 208 and starter box 462 with pin 452 to reattach the drop seat to the main body. Likewise, length, X, of insertion pin 460 should be sized to transverse the length X′, of car 202, and car 204, and slot 450a of starter box 450, through thereby allowing engagement of car 202, car 204, and starter box 450 with insertion pin 460 to reattach the drop seat to the main body.
Referring to
At step 506, the user engages one or both of angled edge 116 and angled edge 120.
At step 504, the user locates central notch 118a in flap 110.
At step 505, the user opens zipper pocket 111 to expose zipper cars 204 and 206.
At step 506, the user moves zipper car 206 to right center point 503.
At step 508, the user moves car 204 to left center point 509.
At step 510, the user moves drop seat 101 away from back panel 114, thereby placing the monosuit in the “seat open” position.
In other preferred embodiments, the order of execution of steps 506 and 508 may be reversed.
Referring to
At step 602, right cover 130 is disengaged from back leg section 124.
At step 604, car 208 is moved from the right leg end point 482 to right center point 502.
At step 606, cover 132 is disengaged from back leg section 128.
At step 608, car 202 is moved from left leg end point 480 to left center point 509 thereby placing the monosuit in leg open position.
Another preferred embodiment, at steps 602 and 604, and steps 606 and 608, respectively, may be executed in reverse order.
Likewise, another embodiment, steps 602 and 604 may be omitted in favor of steps 606 and 608. Likewise, steps 606 and 608 may be omitted in favor of steps 602 and 604.
Referring to
At step 702, cover 130 is disengaged from back leg section 124.
At step 704, cover 132 is disengaged from back leg section 128.
At step 706, either angled edge 120 or angled edge 116 (or both) is engaged by the user.
At step 708, the user locates central notch 118a.
At step 709, zipper pocket 111 is opened to expose cars 204 and 206.
At step 710, car 206 is moved from midline 422 to right leg end point 482.
At step 712, car 206 and car 208 are disengaged from the main body but retained on zipper 108 by starter box 462.
At step 714, car 204 is moved from midline 422 to left leg end point 480.
At step 716, cars 204 and 202 are disengaged from the drop seat, but retained on zipper 108 by starter box 450.
At step 718, drop seat 101 is removed from main body 102, thereby completing the method.
