GARMENT INCLUDING SELECTIVELY LOCATED VENTILATION PANELS OF THREE-DIMENSIONAL MESH

A garment, including: a garment shell; and a ventilation region, wherein the ventilation region comprises a three-dimensional mesh member attached to the garment shell. Other features, and a method of manufacturing a garment, are also described.

TECHNICAL FIELD

This patent application relates generally to garments, such as jackets and pants, and more specifically, recreational clothing having panels of three-dimensional mesh for improved ventilation.

BACKGROUND

Clothing for people with an active lifestyle has existed for a number of years. For example, such clothing is typically used during recreational activities such as hiking, climbing, skiing, and other outdoor activities. Additionally, recreational clothing is often worn for everyday life activities. Examples of recreational clothing include at least, for example, jackets, shirts, pants, shorts, and other types of outerwear. Due to body heat that may be generated during recreational activities, there is often a need for recreational clothing to provide adequate ventilation. Additionally, in order to protect against inclement weather, there is often a need for the clothing to be waterproof while providing sufficient breathability and ventilation to the wearer.

SUMMARY

According to an embodiment, a garment is disclosed comprising: a garment shell; and a ventilation region, wherein the ventilation region comprises a three-dimensional mesh member attached to the garment shell.

According to another embodiment, a garment is disclosed comprising a three-dimensional mesh panel; and an outer layer; wherein the three-dimensional mesh panel comprises a face and an edge; wherein the outer layer overlays the three-dimensional mesh panel; wherein the three-dimensional mesh panel is connected to the outer layer at the edge of the three-dimensional mesh panel and the face of the three-dimensional mesh panel is at least partially disconnected from the outer layer.

According to another embodiment, a method for manufacturing a garment is disclosed comprising providing a plurality of outer garment layer panels; providing a three-dimensional mesh panel; attaching the three-dimensional mesh panel to at least one of the outer layer panels to form at least one ventilation garment panel; and attaching the plurality of outer garment layer panels to form the garment.

DETAILED DESCRIPTION

Various embodiments of the invention are discussed in detail below. While specific embodiments are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the invention.

As used herein, terms such as “horizontal” and “x-y” when referring to, for example, a material, is used to describe the direction of the surface or face of the material, while terms such as “vertical” and “z-” are used to describe the direction perpendicular to the surface or face of the material and is also referred to as the “depth” or “thickness” of the material. Terms such as “horizontal,” “x-y,” “vertical,” “z-,” “first,” “second,” “inner,” “outer,” “front,” and “back” are used to describe positions relative to one another only and not to denote an absolute position. For example, a “vertical” or “z-” portion may become a “horizontal” or “x-y” portion by rotating the item, although it may still be referred to as a “vertical” portion of the item. In the same manner, a “first portion” may become a “second portion” by rotating the item.

Embodiments may provide garments that selectively combine waterproof materials and ventilation. For example, a jacket may include a shell of waterproof and breathable materials, as well as ventilation panels of mesh fabrics, for air flow and ventilation. Although the term “jacket” may be used to describe embodiments of the invention, a person skilled in the relevant art will recognize that other garments or clothing, such as shirts, vests, pants, and other garments may be used without departing from the spirit and scope of the injection.

A material is “two-dimensional” if the material is comprised of x-y (horizontal) components but does not have a significant z-(vertical) component. A two-dimensional material may include a single layer of material, such as a single knit or woven layer. A two-dimensional material may also include a thin, multi-layer laminate, such as a waterproof breathable laminated fabric such as, for example, GORE-TEX® made by W.L. Gore & Associates, Inc. of Newark, Del., or DVstorm made by eVent of Overland Park, Kans. A material that has a noticeable vertical component may be considered “three-dimensional.” A three-dimensional material may include multiple layers of material that are interconnected, such as a double knit material. In an embodiment, a three-dimensional fabric may include a first knit layer created by a stitch yarn and a second knit layer created by a stitch yarn, the first knit layer and second knit layer interconnected with a pile yarn. The interconnecting yarns may be spaced such that the three-dimensional fabric may provide for a “space” or “void” between the layers of material.

Embodiments may provide a shell of waterproof breathable material including panels of mesh that aid in ventilation. The mesh may comprise a two or three-dimensional knitted, woven, or non-woven material or combination thereof. In some embodiments, the mesh may be comprised of a continuously knitted or woven material with a significant z-direction component. According to an embodiment, the mesh is comprised of two knit or woven layers of x-y components, with z-oriented pile fibers or yarns interconnecting the two substantially two-dimensional layers. In the above described mesh, the two knit or woven layers contain pores, and the z- or vertically oriented fibers create an air space to distance the shell of the garment away from the skin or clothing of the wearer to provide a space for air flow. According to an embodiment, the mesh may comprise a 100% polyester, double knit, 2 mm mesh made by Burltex in Hong Kong, China; however, other materials are possible.

Embodiments may provide garments that selectively combine waterproof materials and ventilation. For example, a jacket may include a shell of waterproof and breathable material, as well as ventilation panels of mesh fabrics for air flow and ventilation. According to embodiments, the shell material may have an outer face fabric, a waterproof breathable membrane, and an inner liner laminated together. According to embodiments, the mesh fabric may be attached on the inside of the garment to the inner liner.

Referring toFIGS. 1-5, an embodiment of a jacket10is shown. The jacket10may generally include a plurality of panels12,14,23,24,25,26,32,34,36,40, and44. For example, at least one of the plurality of panels may be a vent panel, such as front selective vent panel16. For example, at least another one of the plurality of panels may be a ventilation panel30,42(seeFIG. 4). As described in more detail below, the jacket10may include a shell and a three-dimensional mesh. For example, the shell may be a waterproof-breathable material that is a substantially solid fabric. According to an embodiment, the three-dimensional mesh may extend over selective areas of the shell (e.g., on the interior) to selectively allow for direct air flow between the inside of the jacket and the outside of the jacket. For example, the jacket10may include a front selective vent panel16on the first front panel12that extends down the front of the wearer's torso. According to an embodiment, the front selective vent panel16is located on a first front panel12adjacent to first fastening member18. According to embodiments, the fastening members18,22may comprise a zip fastener, hook and loop, snap fastener, button, or other fastener known in the art, or a combination thereof.

Referring now toFIGS. 1-3, the jacket10may include a first front panel12having a close-side first fastening member18located adjacent to the front selective vent panel16closest to the second front panel14, and a far-side first fastening member20located adjacent to the front selective panel16farthest from the second front panel14. According to an embodiment, the jacket may also include a second fastening member22on the second front panel14that may be selectively fastened to either the close-side first fastening member18or the far-side first fastening member20. The wearer may selectively connect the far-side first fastening member20to the second fastening member22so that the front vent panel16is connected inside the jacket10underneath the waterproof-breathable shell material. Alternatively, the wearer may selectively connect the close-side first fastening member18to the second fastening member22(as shown inFIG. 1), so that the front vent panel16spans between adjacent panels12,17of waterproof-breathable shell material, thereby venting the wearer's body heat and cooling the wearer by evaporative cooling.

According to embodiments, the second fastening member22may comprise a zipper track, and the first fastening members18,20may comprise complementary zipper tracks such that the second fastening member22may engage with either first fastening members18,20with a zipper slide. According to embodiments, one or more zipper slides may reside on any of second fastening member22, and first fastening members18,20. According to embodiments, multiple zipper tracks may reside on a fastening member to allow for selectively engaging the complementary zipper track.

As mentioned above, and as further shown inFIG. 3, the second fastening member22may be configured to engage with either the close-side first fastening member18or the far-side first fastening member20. For example, as shown inFIGS. 1 and 2, when the second fastening member22is engaged with the close-side first fastening member18, the front selective vent panel16is uncovered or unobstructed to allow for air movement between the inside of the jacket10and the outside of jacket10. According to an embodiment, when the second fastening member22is engaged with the far-side first fastening member20, the front selective vent panel16is substantially covered in order to, for example, protect the wearer and the inside of the jacket10from precipitation and the elements. The front selective vent panel16may be attached to the shell fabric of the first front panel12by, for example, stitching, bonding, laminating, ultrasonic welding, taping, or other technique known in the art, to form a seam on the inside face of the jacket10.

In an embodiment, a ventilation panel may comprise a three-dimensional mesh located inside the jacket10such that the mesh face contacts either the wearer's skin or clothing. According to an embodiment, the three-dimensional mesh is substantially covered on the exterior face of the jacket10by a shell material that is substantially the same shape as the three-dimensional mesh. According to an embodiment, the three-dimensional mesh material may have a thickness or z-direction that is greater than the thickness of the shell material.

Due to the thickness of the three-dimensional mesh used in the ventilation panels, the mesh can lift the water-proof breathable shell material away from the wearer's body or mid/under layers. The mesh may define an open lattice through which air flow is possible, allowing body heat and air to flow freely through the mesh from the wearer to the shell material. By elevating the shell material away from the wearer's body via the mesh, a wearer's body may cool by evaporative cooling. Additionally, the likelihood of the shell material becoming saturated with perspiration is reduced, preserving the waterproof nature of the waterproof-breathable shell material.

Referring toFIGS. 4 and 5, embodiments of the plurality of ventilation panels are described in more detail. The jacket may include a yoke ventilation panel30comprising a three-dimensional mesh located inside the jacket10at a yoke region near a front shoulder and extending across the upper back of the wearer to the opposite front shoulder, such that the mesh face of the yoke ventilation panel30contacts either the wearer's skin or clothing. According to an embodiment, the yoke ventilation panel30is substantially covered on the exterior face of the jacket10by the yoke panel32comprised of shell material. For example, the three-dimensional mesh of the yoke ventilation panel30, as shown inFIG. 6B, is substantially the same shape and size as the yoke panel32, as shown inFIGS. 1 and 2; however, according to alternative embodiments, the yoke ventilation panel30and the yoke panel32can have different shapes and sizes from one another. As shown inFIGS. 5 and 6B, the edge of the three-dimensional mesh of the yoke ventilation panel may interface the shell material, and according to embodiments, the edges of the three dimensional mesh are connected to the shell material by stitching to form seam30aon the inside face of the jacket10. As an alternative to sewing the mesh to the outer shell material, the mesh may be attached to the shell by seam sealing all or a portion of the mesh (e.g., the outer perimeter) to the outer shell material using seam sealing techniques known in the art.

According to an embodiment, the jacket10may include a hood40comprising a hood ventilation panel42located inside the hood40. The hood ventilation panel42may be substantially covered on the external face of the hood by the exterior hood panel44comprising shell material. Thus, the exterior hood panel44may protect the head of a wearer from precipitation and the elements, while the hood ventilation panel42located within the interior of the exterior hood panel44allows air to flow freely through the mesh between the wearer and the shell material. For example, the three-dimensional mesh of the hood ventilation panel42, as shown inFIGS. 4 and 5, may be substantially the same shape and size as the exterior hood panel44, as shown inFIGS. 1 and 2; however, according to alternative embodiments, the hood ventilation panel42and the hood panel44may be different shapes and sizes from one another. According to embodiments, the edges of the three-dimensional mesh of the hood ventilation panel42are connected to the shell material of the exterior hood panel44by stitching to form seams on the inside face of the hood40. As an alternative to sewing the mesh to the outer shell material, the mesh may be attached to the shell by seam sealing all or a portion of the mesh (e.g., the outer perimeter) to the outer shell material using seam sealing techniques known in the art.

In embodiments, a garment is constructed by piecing together a plurality of separate panels to form a garment of the desired shape. For example, a garment may be constructed by determining the shape of the desired finished garment; determining the shape and configuration of the plurality of panels; determining the placement of panels that will include a ventilation panel; providing the plurality of shell panels of a shell material; providing at least one or more of three-dimensional mesh panels corresponding to the shape of the determined at least one or more of the plurality of shell panels to be the ventilation panel; affixing the three-dimensional mesh panel to the shell panel to form the ventilation panel; and affixing the shell panels and the ventilation panels together to form the garment. In embodiments, any of the plurality of panels may be selected to be the ventilation panel based on, for example, the type of garment, desired ventilation in a particular body region of a wearer, and the activity the garment is intended for. In other embodiments, the mesh doesn't necessarily correspond to a shell panel and may be formed as an “island” on a larger shell panel, or the mesh may be placed over multiple panels of shell material that are joined together.

Referring again toFIGS. 1 and 2, embodiments of jacket10are constructed by piecing together and connecting separate panels by stitching or sealing to form a seam. For example, as shown inFIGS. 1 and 2, the yoke panel32may be joined to the first and second front panels14and16by stitching along the edges of the respective panels to form seams32aand32bacross the front chest region. According to embodiments, the seam joining two panels may be extended continuously to join an adjacent panel. For example, as can be seen inFIGS. 1 and 2, seams32aand32bmay be extended continuously to join the yoke panel32to the first and second side panels34and36, respectively. However, other configuration of panels are possible.

Referring toFIGS. 7 and 8, the plurality of ventilation panels30,42may include an inner layer of three-dimensional mesh48and an outer layer of shell material, outer shell56, that overlays or covers the three-dimensional mesh48. As shown inFIG. 7, the three-dimensional mesh48may comprise an inner mesh face50that contacts the wearer's skin or clothing, an outer mesh face52that contacts the inside surface of the outer shell56, and mesh pile fibers54that interconnect the inner mesh face50and the outer mesh face52. According to embodiments, the three-dimensional mesh48is connected along its periphery to an inner layer of shell material, inner shell58. The inner shell58may then be connected to the outer shell56such that the outer mesh face52is adjacent to and at least partially disconnected from the inner face of the outer shell56.

According to an embodiment, the three-dimensional mesh48may be connected to the inner shell58by stitching to form seams extending around all or a part of the mesh panel's perimeter. See, for example, seams58aand58b. As an alternative (or addition) to stitching, all or a portion of the mesh panel's perimeter may be seam sealed to the inner shell58. According to an embodiment, the inner shell58may be connected to the outer shell56at seams56aand56bby stitching and/or seam sealing or taping. As is apparent fromFIG. 8, outer mesh face52may be completely disconnected from the inside face of the outer shell56. In other embodiments, outer mesh face52may not be completely disconnected from outer shell56. For example, according to embodiments, all or a portion of the outer mesh face52may be adhered to the inside face of outer shell56.

Although the shell material is referred to as “substantially solid,” embodiments are envisioned where the shell material has some degree of porosity, e.g., containing pores sized large enough to facilitate escape of sweat vapors, but small enough to substantially prevent penetration by wind, rain, or snow. Although embodiments of the shell material may have some degree of porosity, generally, the pores may not be visible to the human eye. Outer shell56and inner shell58may be the same fabric or different fabrics. According to embodiments, inner and outer shells56and58may include layers of tightly woven or knitted cotton/nylon blends, nylon and nylon blends, polyester and polyester blends. According to embodiments, inner and/or outer shells56and58comprise a waterproof breathable laminated material (such as GORE-TEX®) including, for example, an outer face fabric, a membrane, and an inner liner laminated together. According to embodiments, inner and/or outer shells56and58may be constructed from a laminated or coated waterproof material, such as those made by W.L. Gore & Associates, Inc. of Newark, Del., eVent Fabrics of Overland Park, Kans.; Toyota Tsusho of Nagoya, Japan; Amaterrace Inc. of Osaka, Japan; TORAY® of Tokyo, Japan, and PERTEX® of Tokyo, Japan; however, other fabrics known in the art may alternatively be used.

As shown inFIG. 6A, according to embodiments, the three-dimensional mesh48may have pores visible to the human eye. The outer mesh face52and the inner mesh face50may contain a matrix of pores. The pore sizes of the outer mesh face52and the inner mesh face50may be the same or different sizes. According to an embodiment, the mesh pile fibers54may be spaced from each other. According to an embodiment, the three-dimensional mesh48may include layers of cotton/nylon blends, nylon and nylon blends, polyester and polyester blends, polyamide, polypropylene, or other synthetic textile. According to an embodiment, the three-dimensional mesh is a polyester double knit with an approximate thickness of about 2 mm. According to an embodiment, other mesh thicknesses may be used to provide adequate air space between the body of the wearer and the waterproof layer. According to an embodiment, the plurality of ventilation panels may contain three-dimensional mesh with varying pore sizes, thicknesses, and materials. According to an embodiment, the three-dimensional mesh may have a thickness of about 1 mm to about 5 mm. In another embodiment, the three-dimensional mesh may have a thickness of about 2 mm to about 4 mm. According to embodiments, the plurality of ventilation panels may be made from three-dimensional mesh such as Fukui Warp Knitting made by Fukui Tateami Co. of Fukui, Japan, and double knit mesh made by Burltex of Hong Kong, China; however, other mesh known in the art may alternatively be used.

According to an embodiment, jacket10may be constructed using various materials and construction techniques. For example, all or parts of jacket10may be constructed from synthetic and/or natural fiber materials or fabrics, such as cotton, cotton blends, nylon, nylon blends, polyester, polyester blends, polyamide, and polypropylene. Other materials and/or combinations of materials will be identifiable by one of ordinary skill in the art based on this disclosure depending on the type and style of garment and/or intended use of the garment.

According to an embodiment, all or a portion of the fabric for jacket10may be coated, for example, with a durable water repellent (DWR) or other coating. According to an embodiment, jacket10may be constructed by joining multiple panels of material using techniques such as, for example, sewing, gluing, bonding, adhering, taping, seam sealing, or ultrasonic bonding. According to an embodiment, the jacket10may include additional features, such as pockets, loops, toggles, draw cords, gussets, vents, and flaps.

In the foregoing description, reference is made to “stitching” various parts of jacket10together. However, one of ordinary skill in the art will understand, based on this disclosure, that other construction techniques may alternatively be used, for example, without limitation, mechanical bonding, adhesives, lamination, ultrasonic welding, seam taping, or other technique known in the art or a combination of these applications.