# Patent

## Title
Protective garment with curved and protected extremities

## Abstract

A protective garment including a body portion and a curved extremity permanently coupled to the body portion and being shaped and configured to receive a leg or an arm of a wearer therein. The extremity has a seam coupling portions of the extremity together such that the seam thereby directly provides curvature to the extremity.

## Background
This application claims priority to provisional application Ser. No. 60/671,425 filed on Apr. 14, 2005, the entire contents of which are hereby incorporated by reference.
This application relates to garments, and more particularly, to protective garments having curved and/or protected extremities, such as sleeves or legs.


BACKGROUND
Protective or hazardous duty garments are used in a variety of industries and settings to protect the wearer from hazardous conditions such as heat, smoke, cold, sharp objects, chemicals, liquids, fumes and the like. Such protective or hazardous duty garments are often used in adverse conditions, such as high heat, exposure to smoke or chemicals and the like. In addition, the wearers of such garments are typically placed under physical strain by carrying heavy gear and equipment. Wearers seek to avoid fatigue to remain mentally sharp and physically ready to carry out tasks.
Protective garments are often constructed from sturdy and stiff materials to provide sufficient protection. However, the stiffness of these materials may prevent the garment from freely moving and flexing. In particular, many existing protective garments require a wearer to somewhat strain against the garment when the user desires to bend the garment (e.g., when the wearer bends an arm or leg). Accordingly, there is a need for a protective garment that can reduce stress upon the wearer.
In addition, protective garments are typically subjected to wear and tear that may reduce the useful life of the garments. Particularly, joint area of a garment, such as the knee, elbow and shoulder regions of the garment may experience relatively high abrasions and loads. In addition, certain areas (such as the joints) of the garment can be compressed, such as when a wearer crawls on his or her knees, rests on his or her elbows, or carries a load on his or her shoulders. When the garment is compressed in the manner the heat protection of the garment may be reduced. Thus locating protective pads on the knee, elbow and shoulder areas may provide additional heat protection to the wearer and the garment.
However, existing protective pads may be made of relatively stiff material and thus may restrict movement of the wearer. Thus, the protective pads may restrict the wearer's ability to bend his or her joints, such as the knees, elbows or shoulders, where the pads are located.
Accordingly, there is a need for a protective garment that provides reinforcement to the joint regions of the garment while allowing relatively free movement.
SUMMARY
In one embodiment, the invention is directed to a garment having extremities, such as arms and legs, with a natural curvature. In particular, in one embodiment the invention is a protective garment including a body portion and a curved extremity permanently coupled to the body portion and being shaped and configured to receive a leg or an arm of a wearer therein. The extremity has a seam coupling portions of the extremity together such that the seam thereby directly provides curvature to the extremity.
In another embodiment the invention is a method for assembling a protective garment. The method includes providing a generally tubular extremity comprising providing a piece of material and forming a seam in the piece of material such that the seams imparts a curvature to the piece of material. The piece of material constitutes or forms a part of the extremity. The method further includes the step of coupling the extremity to a body portion of a protective garment such that the extremity is shaped and configured to receive a leg or an arm of a wearer therein, whereby the seam provides a curvature to the extremity.
In another embodiment, the invention is directed to a garment having protective pads that can be easily bent. In particular in one embodiment the invention is protective garment including an outer shell configured to be worn by a wearer, and a protective pad permanently coupled to the outer shell. The protective pad is predisposed to bend about an axis, and the axis of the protective pad is configured to be generally aligned with an axis of rotation of a joint of the wearer when the garment is worn to increase the ease of bending at the joint.
In yet another embodiment the invention is a garment including a body portion configured to be worn by a wearer, the body portion being made of abrasion, flame and heat resistant material such that the body portion resists igniting, burning, melting, dripping or separation when exposed to a temperature of 500° F. for at least five minutes. The garment further includes a protective pad permanently coupled to the body portion and including an outer perimeter having a pair of notches formed therein, wherein each notch is configured to be aligned with an axis of rotation of a joint of the wearer when the garment is worn to increase the ease of bending at the joint.
Other embodiments of the present invention will be apparent from the following description, the accompanying drawings and the claims.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a protective garment in the form of a coat according to one embodiment of the present invention;
FIG. 2 is a front perspective view of a protective garment in the form of a pair of trousers;
FIG. 3 is a side view of the garment of FIG. 1 in a vertical position;
FIG. 4 is a front view of the garment of FIG. 1, with one of the sleeves of the outer shell exploded away from the body of the garment;
FIGS. 5A-5H are a series of front views showing steps for making a sleeve of the garment of FIG. 1;
FIG. 6 is a rear perspective view of the garment of FIG. 1, with one of the elbow pads exploded away from the associated sleeve;
FIG. 7 is a front view of a protective pad of the garment of FIG. 6;
FIG. 8 is a front perspective view of a bent sleeve of the protective garment of FIG. 1; and
FIG. 9 is a front view of another protective pad located on a garment.



DETAILED DESCRIPTION
FIG. 1 illustrates a protective or hazardous duty garment in the form of a firefighter's coat, generally designated 10. The coat 10 may include a body portion 12 having a left front panel 14, right front panel 16 and a back panel 18. The left front panel 14 and right front panel 16 may be releasably attachable by a fastener 20, such as a zipper, snaps, clasps, clips, hook-and-loop fastening material (i.e., VELCRO®) or the like. The body portion 12 may define a torso cavity 22 that is shaped to receive a wearer's torso therein. The coat 10 may include a pair of sleeves 24 coupled to and extending generally outwardly from the body portion 12 and may be shaped to receive a wearer's arms therein and cover at least about 90% of the arms of an average sized adult wearer.
The coat 10 may include various layers through its thickness to provide various heat, moisture and abrasion resistant qualities to the coat 10 so that the coat 10 can be used as a protective, hazardous duty, or firefighter garment. For example, the coat 10 may include an outer shell 26, a moisture barrier 28 located inside of and adjacent to the outer shell 26, a thermal liner or barrier 30 located inside of and adjacent to the moisture barrier 28, and an inner liner or face cloth 32 located inside of and adjacent to the thermal liner 30.
The outer shell 26 may be made of or include a variety of materials, including a flame, heat and abrasion resistant material such as a compact weave of aramid fibers and/or polybenzamidazole fibers. Commercially available aramid materials include NOMEX and KEVLAR fibers (both trademarks of E.I. DuPont de Nemours & Co., Inc. of Wilmington, Del.), and commercially available polybenzamidazole fibers include PBI fibers (a trademark of PBI Performance Fabrics of Charlotte, N.C.). Thus, the outer shell 26 may be an aramid material, a blend of aramid materials, a polybenzamidazole material, a blend of aramid and polybenzamidazole materials, or other appropriate materials. If desired, the outer shell 26 may be coated with a polymer, such as a durable, water repellent finish (i.e. a perfluorohydrocarbon finish, such as TEFLON® finish sold by E. I. Du Pont de Nemours and Company of Wilimington, Del.). The materials of the outer shell 26 may have a weight of, for example, between about 6-10 oz/yd2.
The moisture barrier 28 and thermal liner 30 may be generally coextensive with the outer shell 26, or spaced slightly inwardly from the outer edges of the outer shell 26 (i.e., spaced slightly inwardly from the outer ends of the sleeves 24, the collar 34 and from the lower edge of the coat 10) to provide moisture and thermal protection throughout the coat 10. The moisture barrier 28 may include a semi-permeable membrane layer 28a and a substrate 28b. The membrane layer 28a may be generally moisture vapor permeable but generally impermeable to liquid moisture.
The membrane layer 28a may be made of or include expanded polytetrafluoroethylene (“PTFE”) such as GORE-TEX or CROSSTECH materials (both of which are trademarks of W.L. Gore & Associates, Inc. of Newark, Del.), polyurethane-based materials, neoprene-based materials, cross-linked polymers, polyamid, or other materials. The membrane layer 28a may have microscopic openings that permit moisture vapor (such as water vapor) to pass therethrough, but block liquids (such as water) from passing therethrough. The membrane layer 28a may be made of a microporous material that is either hydrophilic, hydrophobic, or somewhere in between. The membrane layer 28a may also be monolithic and may allow moisture vapor transmission therethrough by molecular diffusion. The membrane layer 28a may also be a combination of microporous and monolithic materials (known as a bicomponent moisture barrier), in which the microporous or monolithic materials are layered or intertwined.
The membrane layer 28a may be bonded or adhered to a substrate 28b of a flame and heat resistant material to provide structure and protection to the membrane layer 28a. The substrate 28b may be or include aramid fibers similar to the aramid fibers of the outer shell 26, but may be thinner and lighter in weight. The substrate 28b may be woven, non-woven, spunlace or other materials. In the illustrated embodiment, the membrane layer 28a is located between the outer shell 26 and the substrate 28b. However, the orientation of the moisture barrier 28 may be reversed such that the substrate 28b is located between the outer shell 26 and the membrane layer 28a. 
The thermal liner 30 may be made of any suitable material that provides sufficient thermal insulation. In one embodiment, the thermal liner 30 may include a relatively thick (i.e. between about 1/16′′- 3/16′′) batting, felt or needled non-woven material 30a which can include aramid fiber batting (such as NOMEX batting), aramid needlepunch material, an aramid non-woven material, an aramid blend needlepunch material, an aramid blend batting material, an aramid blend non-woven material, or foam (either open cell or closed cell) materials. The batting 30a may trap air and possess sufficient loft to provide thermal resistance to the coat 10.
The batting 30a is typically quilted to a thermal liner face cloth 30b which can be a weave of a lightweight aramid material. Thus, either the batting 30a alone, or the batting 30a in combination with the thermal liner face cloth 30b, may be considered to constitute the thermal liner 30. In one embodiment, the thermal liner 30 may have a thermal protection performance (“TPP”) of at least about twenty, or of at least about thirty-five. If desired, the thermal liner 30 may be treated with a water-resistant or water-repellent finish. In the illustrated embodiment, the batting 30a is located between the outer shell 26 and the thermal liner face cloth 30b. However, the orientation of the thermal liner 30 may be reversed such that the thermal liner face cloth 30b is located between the outer shell 26 and the batting 30a. 
Although the moisture barrier 28 is shown as being located between the outer shell 26 and the thermal liner 30, the positions of the moisture barrier 28 and thermal liner 30 may be reversed such that the thermal liner 30 is located between the outer shell 26 and the moisture barrier 28.
The face cloth 32 may be the innermost layer of the coat 10, located inside the thermal liner 30. The face cloth 32 can provide a comfortable surface for the wearer and protect the thermal liner 30 and/or moisture barrier 28 from abrasion and wear.
Each layer of the coat 10, and the coat 10 as a whole, may meet the National Fire Protection Association (“N.F.P.A.”) 1971 standards for protective firefighting garments (“Protective Clothing for Structural Firefighting”), which are entirely incorporated by reference herein. The NFPA standards specify various minimum requirements for heat and flame resistance and tear strength. For example, in order to meet the NFPA standards, the outer shell 26, moisture barrier 28 and thermal liner 30 must be able to resist igniting, burning, melting, dripping and/or separation at a temperature of 500° F. for at least five minutes. Furthermore, in order to meet the NFPA standards, all combined layers of the coat 10 must provide a thermal protective performance rating of at least thirty-five.
As shown in FIG. 2, the protective or hazardous duty garment may take the form of a pair of trousers 40. The trousers 40 may have the same construction including the outer shell 26, moisture barrier 28, thermal liner 30 and face cloth 32 as described above and illustrated for the coat 10. The trousers 40 may include a body portion or torso portion 42 that is shaped and configured to receive the pelvis or lower portion of a wearer's torso therein. The trousers 40 may include a pair of legs 44 coupled to and extending generally outwardly or downwardly from the body portion 42 and may be shaped and configured to receive a wearer's legs therein and cover at least about 90% of the legs of an average sized adult wearer. In addition, the garment of the present invention may include or take the form of vests, jumpsuits, full-body jumpsuits including a coat and trousers combined into a single garment, and the like.
As best shown in FIGS. 2-4, each sleeve 24 and/or leg 44 may have a natural curvature or bend. As shown in FIGS. 5A-5H, a seam may be utilized to provide the desired curvature to the sleeves 24 and/or legs 44. The seam can be formed by providing a generally rectangular piece of material 50, as shown in FIG. 5A. For example, when forming sleeves 24 for the outer shell, the piece of material 50 is made of the same material as the outer shell 26. Next, a pair of generally triangular-shaped folds 52 are formed in the piece of material 50, as shown in FIG. 5B. Each triangular-shaped fold 52 extends up from a fold line 53 and generally inwardly, and in the configuration shown in FIG. 5B extend generally perpendicular to the plane of the piece of material 50. The folds 52 are formed by bringing two portions 54 of the piece of material 50 together until the portions 54 face each other or are overlapping. In the illustrated embodiment, the triangular-shaped folds 52 are aligned, and each is formed at about the midpoint of the short side of the piece of material 50.
Next, as shown in FIG. 5C, stitching 56 is applied along the bottom length of each triangular-shaped fold 52 (i.e., along the fold lines 53) to secure the two portions 54 of each fold 52 together. Next, as shown in FIG. 5D, each triangular-shaped fold 52 is laid flat against the piece of material 50. Stitching 58 is then applied along the outer edge of each triangular-shaped fold 52 to secure each triangular-shaped fold 52 (which can also be termed remainder material 52) flat against the piece of material 50 to form a dart seam 60. In the illustrated embodiment the two triangular-shaped folds 52 are folded in different directions, although if desired the folds 52 can be folded in the same direction.
The dart seam 60 is located generally internally to the piece of material 50, and generally does not extend along an outer perimeter thereof. In addition, in the illustrated embodiment the dart seam 60 only joins portions of the piece of material 50 to itself, and does not join the piece of material 50 to any other sleeve sections/pieces of material.
Due to the presence of the dart seams 60, the height of the piece of material 50 is less than its width, which induces a curvature in the piece of material 50. For example, as shown in FIGS. 5D and 5E the natural curvature of the piece of material 50 (which can also be termed an outer sleeve section 50) can be seen. A vertical cross section of the outer sleeve section 50 of FIG. 5E would show a profile that is generally “C” shaped.
Next, as shown in FIG. 5F, the outer sleeve section/piece of material 50 is positioned (with the folds 52 facing inwardly and thus not visible) between an upper sleeve section 62 and a lower sleeve section 64. The outer sleeve section 50 is also positioned adjacent to an inner sleeve section 66, which is also positioned between the upper sleeve section 62 and lower sleeve section 64. The upper sleeve section 62, lower sleeve section 64 and inner sleeve sections 66 may be generally flat, and may be made of the same material as the outer sleeve section 50 (i.e., the materials of the outer shell 26 when forming a sleeve for the outer shell 26). It may advantageous to make the upper 62, lower 64 and inner sleeve 66 sections from generally flat standard pieces of material and to make a relatively small, short outer sleeve section 50 which contributes curvature to the sleeve 24. In this case the upper 62, lower 64 and outer 66 sections can be easily made by standard manufacturing processes, and do not have any curvature.
Next, as shown in FIG. 5G, the upper sleeve section 62, inner sleeve section 66, outer sleeve section 50, and lower sleeve section 64 are coupled together, such as by stitching. In addition, in the illustrated embodiment, an elbow pad 68 (which will be described in greater detail below) is located on the outer sleeve section 50.
As shown in FIG. 5H, the sleeve section of FIG. 5G is then rolled or formed into a generally cylindrical or generally tubular shape. The adjacent longitudinal edges of the rolled sleeve section are then joined together, such as by stitching, to form a sleeve 24. The sleeve 24 can then be coupled to the body portion 12 of the coat 10. Thus, in one embodiment each sleeve 24 may be constructed from three generally tubular or generally cylindrical sleeve sections, namely an upper section 62, a middle section 50/66 and a lower section 64.
As noted above the dart seams 60 provide a natural curvature to the outer sleeve section 50, and thus to the sleeve 24 as a whole. In addition, the inner sleeve section 66 includes a relatively narrow throat portion 66a to also encourage/allow bending of the sleeve 24 without bunching. In addition, rather than using a dart seam 60, curvature may be provided by using a pleat, such as a standard pleat wherein portions of the material are pulled into an overlapping configuration and joined together. In this case the pleat(s) can be replace the dart seam(s) and be located at the same location as the dart seams 60 shown herein. For the purposes of this application the term “seam” as used herein is construed to cover the dart seam 60 described herein, as well as a pleat.
The use of a seam to impart the desired curvature to the sleeves 24 provides a relatively easy and efficient method to form the curved sleeve 24. In particular, because no cutting of fabric or material may be required, the use of a seam may provide for ease of manufacture. In addition, the cutting and removal of fabric or material removes material that can provide heat insulation, flame protection etc., and is thus avoided.
The outer sleeve section 50 may be joined to the inner sleeve section 66 to form an elbow section 50/66. The outer portion of each elbow section 50/66 (i.e. extending along the outside of the elbow) may have a length that is at least about ten percent, or at least about twenty percent, or at least about forty percent longer than the inner portion of that elbow section 50/66 (i.e. extending along the inner crux 66a of the elbow section). Thus, when the sleeve 24 is assembled as described above, the sleeve 24 has an inner length less than an outer length to provide an outside-in curvature, as more clearly shown in FIG. 3, that conforms to the natural curvature of the wearer's arm. The sleeve 24, at its end or at the cuff 59, may form an angle A of at least about five degrees, or at least about ten degrees, or at least about fifteen degrees with a vertical axis when the sleeve 24 hangs free.
The natural curvature of the sleeves 24 reduces stress upon the user. In particular, when a person is resting, his or her arms typically rest with a slight break at the elbows. Thus the curvature in the sleeves 24 allows the wearer's arms to assume a natural resting position without having to bend the sleeves 24 of the garment 10. In addition, when a user bends his or her arms at the elbow, less work is required to bend the sleeve 24 given that the sleeve 24 is already “pre-bent.” In other words, if the sleeves 24 were to be straight and were to be desired to be bent to an angle of forty-five degrees, a force required to bend the sleeves 24 the full forty-five degrees must be exerted. In contrast, if the sleeves 24 are pre-bent to an angle of fifteen degrees, the user only needs to bend the sleeves 24 thirty degrees which imparts less stress upon the wearer. The reduced stress can be significant in repetitive motion activity, particularly given the weight of the garment 10 and other equipment required to be carried by the wearer, as well as the stiffness of the garment 10.
In addition the dart seam 60 and throat portion 66a reduce bunching of materials. For example, the remainder portions of the sleeve 52 (i.e., the triangular folds 52) are positioned internally. Thus the crux of the elbow thus includes less material than a standard sleeve to eliminate material that can be bunched during elbow movement (i.e., when moving a hand towards the shoulder). Because bunching of material is reduced freer movement and a greater range of motion are provided.
If desired, only one layer of the garment (i.e. the outer shell 26) may have sleeves 24 with a natural curvature (i.e. an outer sleeve portion 26 with dart seams 60). In this case the moisture barrier 28, thermal liner 30, and face cloth 32 may be formed in the standard manner and may lack any curvature and may be flexible enough to be easily bent. However, if desired one, some, or all of the inner layers 28, 30, 32 may also be made to have a natural curvature (i.e. by forming a dart seam therein). In this case all or the selected ones of the inner layers 28, 30, 32 can be formed using the method described above and shown in FIGS. 5A-5H which provides a sleeve 26 with a more defined curvature. Of course, the seams of the various layers 28, 30, 32 may be aligned (i.e. with the elbow of the garment 10 or of the wearer) to provide ease of bending. For example, as shown in FIG. 4, the moisture barrier 28 has a pair of dart seams 60 formed in the same manner outlined above.
The arrangement described above shown for use with a sleeve 26 may also be utilized in the pant leg 44 of a pair of trousers 40, as shown in FIG. 2. Each leg 44 may have leg sections 44a, 44b, 44c, 44d in the same manner as the sleeve sections 62, 50, 64, 66 described and shown above. In this manner each leg 44 may have a curvature that conforms to the natural curvature of the wearer's leg, thereby providing the same or similar advantages to those outlined above in the context of the sleeves 26.
The coat 10 may be provided with pliable protective pads 68 secured to the outer shell 26 on the sleeves 24/legs 44 to reinforce the elbow/knee regions of the coat 10/trousers 40. Additional pads may be provided at other locations on the garments, such as along or adjacent to joints of the wearer such as shoulders, wrists, hips, etc.
Each pad 68 may be made from a relatively durable and generally stiff material. In one embodiment each pad 68 is made of the same material as the outer shell 26. Thus each pad 68 can be made of the same materials as those listed above for the outer shell 26 material such as an aramid material (i.e. in one case a polymer-coated KEVLAR® aramid material), a blend of aramid materials, a polybenzamidazole material, a blend of aramid and polybenzamidazole materials, or other appropriate materials. The pads 68 could also be made of leather or synthetic leather. The pads 68 can be attached to the garment by a variety of methods, such as stitches, adhesives, bonding, sonic welding, heat welding or the like.
Thus, each pad 68 may be made from a durable and fire-resistant material and may have a stiffness sufficient to absorb impacts and abrasions and provide resistance to wear and tear. Each pad 68 may have a thickness of less than about 1 mm, or greater than about 0.1 mm, or between about 0.3 mm and about 0.6 mm. Each pad 68 may have a TPP factor of at least about 3, or at least about 5, or at least about 10. The material of each pad 68 may be able to resist igniting, burning, melting, dripping and/or separation at a temperature of 500° F. for at least five minutes. If desired, each pad 68 may trap a protective layer, such as foam or the like, between the pad 68 and the outer shell 26 to provide further protection and padding.
As best shown in FIG. 7, each pad 68 may be generally rectangular in shape (in top view) in which case the pad 68 includes two longitudinal edges 72 and two lateral edges 74 forming an outer perimeter. Each pad 68 may have a length of at least about four inches, or at least about six inches, and a width of at least about four inches, or at least about six inches. Each pad 68 may have a length that is at least about 1⁄8, or at least about 1⁄4, of the length of an associated extremity (i.e. the length of an associated sleeve 24 or leg 44 of the garment). Besides being rectangular, the pads 68 can have a variety of shapes, including but not limited to square, circular, oval, triangular, hexagonal, trapezoidal, irregular and the like.
Each pad 68 may include a notch or cut-out 76 positioned generally centrally in each longitudinal edge 72. Each notch 76 may be positioned to align with the axis of rotation B or center of pivot (see FIG. 8) of the wearer's joint (such as a knee or elbow) when the garment is worn. Each notch 76 may, for example, be positioned along the length of a sleeve 24 or leg 44 that generally corresponds to the elbow or knee of the garment 10/40, or of a wearer. Each notch 76 may also be aligned with the dart seam 60 if the dart seam 60 is present, which also allows for ease of pivoting at the joint. Thus the dart seam 60 and notches 76 can cooperate to provide improved flexibility and ease of bending.
With reference to FIG. 8, the notches 76 facilitate bending of the garment and pad 68 about the axis formed by the aligned notches 76. In particular, because the notches 76 define an area of the pad 68 having a reduced width, the pad 68 is inherently easier to bend about the axis formed by the aligned notches 76. In addition, the removed areas of the pad 68 provided by the notches 76 help to reduce bunching of the pad 68 when the wearer flexes or bends his or her joint to thereby provide easier flexing, as shown in FIG. 8. By providing the notches 76 in the pad 68, the portion of the pad 68 that would bunch up when the wearer flexes or bends his or her knee or elbow is removed.
In the illustrated embodiment the notches 76 are generally semi-oval or generally “V” shaped in front view. These or other similar shapes may provide certain advantages in that the point or tip 78 of the cut-out 76 provides a distinct point or line of bending for the pad 70. However, the notches 76 can be any of a variety of shapes, including but not limited to triangular, rectangular, square, semicircular, etc. The notches 76 may merely provide an area of removed material and provide an area about which the pad 68 is predisposed to bend, or about which bending of the pad 68 is easier.
In addition, the notches 76 need not necessarily be located on the same position along the longitudinal edges 72 of the pad 68. For example, one notch 76 could be located on an upper portion of the longitudinal edge 72, and the other notch 76 could be located on a lower portion of the other longitudinal edge 72 to define an angled fold guide line. Further, if desired the pad 68 may include only a single notch 76.
Each pad 68 may be located only on the outer sleeve section 50, 44b of the associated sleeve 24 or leg 44. This may allow for ease of manufacturing as each pad 68 can be located on the associated outer sleeve section 50, 44b before the outer sleeve section 50, 44b is coupled to the other sections (as shown in FIG. 5G), which allows increased access and ability to manipulate the outer sleeve section 50, 44b while attaching the pad 68. If desired, the outer sleeve section 50, 44b may be sized to generally match the height/length of the associated pad 68, or vice versa, to ensure each outer sleeve section 50, 44b can fully support a pad 68 thereon.
In addition, the pad may have a variety of other shapes or configurations-which allow the pad to bend about the desired axis B. For example, as shown in FIG. 9, in one embodiment the pad 68′ includes a central “notch” 76′ or area wherein portions of the pad material are removed to expose the outer shell 26 therebelow. The central cut-out 76′ also provides an area of weakness upon which the pad 68′ is predisposed to bend. In addition, rather than being removed material, the area 76′ may instead be an area of weakness (i.e., a thinned portion of the pad material) or the like that extends along the desired axis. Of course, any of a wide variety of other embodiments or methods to provide a pad 68, 68′ which is predisposed to bend about a desired axis can be utilized without departing from the scope of the invention.
The ability of the pads 68 to bend reduces stress upon the wearer, in particular during repetitive movement activity. In addition, the ability of the pads 68 to bend easily allows the sleeves 24 and legs 44 to easily assume their nature curvature shape as outlined above.
Although the invention is shown and described with respect to certain embodiments, it is obvious that modifications will occur to those skilled in the art upon reading and understanding the specification, and the present invention includes all such modifications.

## Claims

1. A protective garment comprising:
a body portion; and
a curved or bent extremity permanently coupled to said body portion and being shaped and configured to receive a leg or an arm of a wearer therein, said extremity having seam coupling portions of said extremity together such that said seam thereby directly provides curvature or bending to said extremity;
wherein said garment includes a plurality of pieces of material joined together, and wherein said seam does not directly couple one of said plurality of pieces of material to another one of said plurality of pieces of material.

2. The protective garment of claim 1 wherein said seam includes stitching which couples said portions of said extremity together.

3. The protective garment of claim 2 wherein said portions of said extremity are at least partially overlapping, and wherein said stitching couples said overlapping portions together.

4. A protective garment comprising:
a body portion; and
a curved or bent extremity permanently coupled to said body portion and being shaped and configured to receive a leg or an arm of a wearer therein, said extremity having seam coupling portions of said extremity together such that said seam thereby directly provides curvature or bending to said extremity;
wherein said seam joins together two fold lines formed in said extremity and forms a remainder portion of fabric extending generally away from said seam.

5. The protective garment of claim 1 wherein said seam is a dart seam.

6. The protective garment of claim 1 wherein said garment includes a plurality of pieces of material joined together, each piece of material having an outer perimeter, and wherein said seam generally does not extend along an outer perimeter of any of said plurality of pieces of material.

7. The garment of claim 1 wherein said extremity is generally tubular shaped.

8. The garment of claim 1 wherein said extremity includes an inside section and an outside section that join together to form an elbow or knee section of the extremity and wherein each of the inside section and the outside section have a length available for joinder to other sections of the extremity; wherein the length of the inside section is less than the length of the outside section.

9. The garment of claim 1 wherein said seam is configured to be located immediately adjacent to the elbow or knee of a wearer of said garment when said garment is worn.

10. The garment of claim 9 wherein said seam is configured to be located immediately adjacent to an outer bend of the elbow or knee of a wearer of said garment when said garment is worn.

11. The garment of claim 1 wherein said extremity includes a first piece of material having said seam formed therein, and a second piece of material directly and permanently coupled to said first piece of material, said second piece of material forming a crux of a knee or elbow portion of said extremity, said first piece of material forming an outer portion of a knee or elbow portion of said extremity.

12. A protective garment comprising:
a body portion; and
a curved or bent extremity permanently coupled to said body portion and being shaped and configured to receive a leg or an arm of a wearer therein, said extremity having seam coupling portions of said extremity together such that said seam thereby directly provides curvature or bending to said extremity;
wherein said extremity includes a first piece of material having said seam formed therein, and a second piece of material directly and permanently coupled to said first piece of material, said second piece of material forming a crux of a knee or elbow portion of said extremity, said first piece of material forming an outer portion of a knee or elbow portion of said extremity;
wherein said first and second pieces of material together form a first generally tubular piece of material, wherein the extremity further includes a second generally tubular piece of material directly and permanently coupled to said first generally tubular piece of material, said second generally tubular piece of material being generally aligned with said first generally tubular piece of material.

13. The garment of claim 12 wherein said second generally tubular piece of material forms an upper arm or upper leg section of said extremity and is directly and permanently coupled to said body portion.

14. The garment of claim 12 wherein said second generally tubular piece of material forms a lower arm or leg section of said extremity and includes a cuff at a distal end thereof.

15. The garment of claim 12 wherein said second generally tubular piece of material is generally straight and generally does not include any curvature or bending.

16. The garment of claim 1 further comprising a protective pad located on an elbow or knee portion of said extremity, and wherein said protective pad is predisposed to bend about an axis that is generally aligned with the elbow or knee of said garment.

17. The garment of claim 16 wherein said protective pad includes an outer perimeter and a pair of generally aligned notches formed therein, wherein said aligned notches define said axis.

18. The garment of claim 1 wherein said garment meets National Fire Protection Association 1971 standards for protective firefighting garments.

19. The garment of claim 1 wherein body portion and said extremity include an outer shell that is abrasion, flame and heat resistant.

20. The garment of claim 19 wherein said outer shell resists igniting, burning, melting, dripping or separation when exposed to a temperature of 500° F. for five minutes.

21. The garment of claim 19 wherein said outer shell includes a material selected from a group of consisting of an aramid material, a blend of aramid materials, a polybenzamidazole material, and a blend of aramid and polybenzamidazole materials.

22. The garment of claim 19 further comprising a moisture barrier located generally inside of said outer shell such that when said garment is worn said moisture barrier is located generally between said outer shell and a wearer of said garment, said moisture barrier being made of a material that is generally liquid impermeable and generally moisture vapor permeable.

23. A protective garment comprising:
a body portion; and
a curved or bent extremity permanently coupled to said body portion and being shaped and configured to receive a leg or an arm of a wearer therein, said extremity having seam coupling portions of said extremity together such that said seam thereby directly provides curvature or bending to said extremity;
wherein body portion and said extremity include an outer shell that is abrasion, flame and heat resistant;
further comprising a thermal liner located generally inside said outer shell such that when said garment is worn said thermal liner is located generally between said outer shell and a wearer of said garment, said thermal liner having a thermal protection performance of at least about 20.

24. The garment of claim 1 wherein said extremity includes at least one outer material and at least one inner material such that said extremity has at least two plies, wherein said outer material has said seam formed therein, and wherein said inner material has an inner material seam coupling portions of said inner material together such that said inner material seam thereby directly provides curvature or bending to said inner material, and wherein said seam of said outer material and said inner material seam are generally aligned.

25. A method for assembling a protective garment comprising:
providing a generally tubular extremity comprising:
providing a piece of material; and
forming a seam in said piece of material such that said seam imparts a curvature or bending to said piece of material, said piece of material constituting or forming a part of said extremity and imparting said curvature or bending to said generally tubular extremity;
wherein forming said seam includes joining together two fold lines formed in said extremity which forms a remainder portion of fabric extending generally away from said seam; and

coupling said extremity to a body portion of a protective garment such that said extremity is shaped and configured to receive a leg or an arm of a wearer therein, whereby said seam provides a curvature or bending to said extremity.

26. A protective garment comprising:
an outer shell configured to be worn by a wearer; and
a protective pad permanently coupled to said outer shell, wherein said protective pad is predisposed to bend about an axis, and wherein said axis of said protective pad is configured to be generally aligned with an axis of rotation of a joint of said wearer when said garment is worn to increase the ease of bending at said joint; and
wherein said protective pad is generally rectangular in front view having a pair of opposed edges, and wherein a notch is formed at or adjacent to a center of each of said edges to define said axis.

27. The garment of claim 26 wherein said protective pad includes an outer perimeter having a notch formed therein, wherein said notch at least partially defines said axis.

28. The garment of claim 27 wherein said protective pad includes a supplemental notch formed in said perimeter, and wherein said notch and said supplemental notch define said axis.

29. The garment of claim 28 wherein each notch is generally V-shaped.

30. The garment of claim 26 wherein said protective pad includes an internal cut-out which defines said axis.

31. The garment of claim 26 wherein said protective pad includes an area of weakness which defines said axis.

32. The garment of claim 26 wherein said protective pad is made of the same material as the material of said outer shell.

33. The garment of claim 26 wherein said protective pad is made of leather, or an aramid material, or a blend of aramid materials, or a polybenzamidazole material, or blend of aramid and polybenzamidazole materials.

34. The garment of claim 26 wherein said outer shell is in the form of a coat and said pad is located on an elbow of said coat, or wherein said outer shell is in the form of a pair of trousers and said pad is located on a knee of said trousers.

35. The garment of claim 26 wherein said garment meets National Fire Protection Association 1971 standards for protective firefighting garments.

36. The garment of claim 26 wherein said outer shell is abrasion, flame and heat resistant.

37. The garment of claim 26 wherein said outer shell resists igniting, burning, melting, dripping or separation when exposed to a temperature of 500° F. for five minutes.

38. The garment of claim 26 further comprising a moisture barrier located generally inside of said outer shell such that when said garment is worn said moisture barrier is located generally between said outer shell and a wearer of said garment, said moisture barrier being made of a material that is generally liquid impermeable and generally moisture vapor permeable.

39. The garment of claim 26 further comprising a thermal liner located generally inside said outer shell such that when said garment is worn said thermal liner is located generally between said outer shell and a wearer of said garment, wherein said thermal liner has a thermal protection performance of at least about 20.

40. The garment of claim 26 wherein said garment further includes an extremity shaped and configured to receive the arm or leg of a wearer therein, wherein said extremity has a seam coupling portions of said extremity together such that said seam thereby directly provides a curvature or bending to said extremity, and wherein said seam is generally aligned with said axis.

41. A garment including:
a body portion configured to be worn by a wearer, said body portion being made of abrasion, flame and heat resistant material such that said body portion resists igniting, burning, melting, dripping or separation when exposed to a temperature of 500° F. for at least five minutes; and
a protective pad permanently coupled to said body portion and including an outer perimeter having a pair of notches formed therein, wherein each notch is configured to be aligned with an axis of rotation of a joint of said wearer when said garment is worn to increase the ease of bending at said joint;
wherein said protective pad is generally rectangular in front view having a pair of opposed edges, and wherein the notches are formed at or adjacent to a center of each of said edges.

42. A protective garment comprising:
a body portion; and
a curved or bent extremity permanently coupled to said body portion and being shaped and configured to receive a leg or an arm of a wearer therein, said extremity having seam coupling portions of said extremity together such that said seam thereby directly provides curvature or bending to said extremity;
wherein said extremity includes an joint about which said extremity is designed to bend, an upper portion above said joint, and a lower portion below said joint, and wherein said seam provides a curvature or bending at said joint such that said upper portion forms an angle with said lower portion.

43. The garment of claim 42 wherein said angle is an acute angle corresponding to the acute angle formed when a wearer bends an associated arm or leg to be received in said extremity.

44. The garment of claim 42 wherein said upper portion and said lower portion are both generally tubular portions, and wherein said extremity further includes a generally tubular joint portion which includes said seam, and wherein said joint portion is positioned between and coupled to said upper portion and said lower portion about generally circumferential seams thereof.

45. The garment of claim 1 wherein said seam is formed in an outermost layer of said protective garment such that said seam thereby directly provides curvature or bending to said outermost layer of said extremity.

46. The garment of claim 5 wherein said extremity is generally tubular and wherein said dart seam includes a generally triangular portion of gathered material which is attached by a line of attachment extending generally circumferentially about said extremity.

47. A method for assembling a protective garment comprising:
providing a generally tubular extremity comprising:
providing a piece of material; and
forming a seam in said piece of material such that said seam imparts a curvature or bending to said piece of material, said piece of material constituting or forming a part of said extremity; and

coupling said extremity to a body portion of a protective garment such that said extremity is shaped and configured to receive a leg or an arm of a wearer therein, whereby said seam provides a curvature or bending to said extremity;
wherein said extremity includes an joint about which said extremity is designed to bend, an upper portion above said joint, and a lower portion below said joint, and wherein said seam provides a curvature or bending at said joint such that said upper portion forms an angle with said lower portion.

48. The method of claim 47 wherein said angle is an acute angle corresponding to the acute angle formed when a wearer bends an associated arm or leg to be received in said extremity.

49. The method of claim 47 wherein said upper portion and said lower portion are both generally tubular portions, and wherein said extremity further includes a generally tubular joint portion which includes said seam, and wherein said joint portion is positioned between and coupled to said upper portion and said lower portion about generally circumferential seams thereof.

50. The method of claim 25 wherein said piece of material is an outermost layer of said protective garment such that said seam thereby directly provides curvature or bending to said outermost layer of said extremity.

51. The garment of claim 26 wherein said protective pad is positioned on an outer surface of said outer shell and generally conforms to said outer shell.

52. The garment of claim 41 wherein said protective pad is positioned on an outer surface of said outer shell and generally conforms to said outer shell.

53. The garment of claim 1 wherein said extremity includes a supplemental seam coupling portions of said extremity together such that said seam and said supplemental seam together thereby directly provide curvature or bending to said extremity.

54. The garment of claim 53 wherein said seam and said supplemental seam are positioned on opposite positions of said extremity with respect to an axis about which said extremity is configured to bend.

55. The garment of claim 54 wherein said seam and said supplemental seam are generally aligned with said axis.

56. The garment of claim 1 wherein said extremity includes an upper sleeve section, a middle sleeve section, and a lower sleeve section, each sleeve section being a separate generally tubular component, said middle sleeve section being positioned between said upper and lower sleeve sections and coupled thereto, wherein said seam is positioned on said middle sleeve section.

57. The garment of claim 56 wherein said middle sleeve section provides curvature or bending to said extremity, and wherein said upper and lower sleeve sections are both generally straight and wherein said upper sleeve section forms an angle with said lower sleeve section.

58. The garment of claim 56 wherein said middle sleeve section has an inside portion having a length that is less than a length of an outside portion of said middle sleeve section, and wherein said upper and lower sleeve sections each have an inside portion that does not have a length that is less than a length of an outside portion thereof.

59. The garment of claim 1 wherein a distal end of said extremity forms an angle of at least about 10 degrees with a vertical axis when said extremity hangs free and said garment is positioned generally vertically.