Abstract:
An improved fishing wader uses light weight nylon faced laminate material and taped unsewn sonic welds to achieve a durable, light weight, comfortable wader.

Description:
BACKGROUND OF THE INVENTION 
     The present invention is broadly concerned with waders for use in fishing. More particularly, the disclosure pertains to waterproof breathable waders for use in fishing. 
     Waders are used by men and women while fishing. Fishermen, particularly fly fishermen, often walk to and in rivers and streams in pursuit of fish. Waders allow the fishermen to walk into the stream without getting their feet, legs and the garments under the wader wet. Waders are used in a variety of weather conditions. Thus, a fisherman may walk to a stream or along a stream when the air temperature is well above freezing and then enter the stream when the water temperature is close to freezing. The fisherman will often prefer to dress with sufficient layers to keep warm while in the stream. This may cause the fisherman to perspire when walking outside the stream. Waterproof breathable waders allow this perspiration to escape, helping to keep the fishermen comfortable. 
     Fishermen often travel to locations where they fish. Such travel may include a long car ride or airline travel on a vacation fishing trip. Therefore, the ability to pack gear and waders into a reasonable size for traveling can be important. 
     Waders are different from other clothing items, even “waterproof” clothing items. Wades are intended for fully immersed use for relatively extended periods. A fisherman may stand or wade in a stream in a depth of several feet for several hours. The waders are expected to withstand the pressure of the flowing water and keep the wearer&#39;s legs and feet dry. Conventional waterproof jackets are not expected to be immersed. Rather, they are expected to keep a wearer&#39;s trunk dry in rain. The pressure of immersion is not an expected condition. 
     Waterproof breathable waders have been commercially available for several years. Some of those waders comprise a trunk portion, two leg portions and two foot portions joined together at various seams to create a waterproof breathable wader. The foot portions can be stocking-like foot portions in a wader used with separate wading boots. The foot portions can be integral boots for use in what is called a boot foot wader without separate wading boots. 
     Such breathable waders are often constructed of laminate materials. Three-layer laminates comprising an outer layer of abrasion resistant woven material, a middle layer which is waterproof but breathable and an inner layer of knit material such as nylon tricot are popular. The outer layer is sometimes a dense (high thread count) polyester layer to provide durability. The middle layer is often expanded PTFE (polytetrafluoroethylene). The middle layer is sometimes a polyurethane waterproof breathable membrane. The inner layer is often woven nylon tricot. Other materials are sometimes used. 
     Waders are sometimes made of heavier material to increase durability. Waders are seamed in various ways including stitched seaming. The use of seam seals and seam tapes to avoid leaking is also common. There remains a need for a waterproof breathable wader which is durable, does not leak, is light weight, and packable. 
     SUMMARY OF THE INVENTION 
     A waterproof breathable fishing wader is provided which does not leak, which is sufficiently durable to be packed and unpacked multiple times and which is lightweight and comfortable. In accordance with the disclosure, the principle seams of the wader are not stitched seams but rather welded seams. 
     Still further in accordance with the invention, the wader is constructed of a three layer fabric comprising a light weight nylon outer layer, a waterproof breathable middle layer and a light weight nylon tricot inner layer. 
     Still further in accordance with the invention, the principle seams of the wader are welded seams in which edges are adjacently in contact but not overlapping one another. 
     Yet further in accordance with the invention, the middle layer is a polyurethane waterproof breathable membrane. 
     Still further in accordance with the invention, the seams of the wader are comprised of adjacent sections of the three layer wader material abutting one another sonically welded together. Seam tape is applied to one side of the seam. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic front elevational view of waders in accordance with the invention; 
         FIG. 2  is a cross-sectional view of the laminate used to form the panels of the waders seen in  FIG. 1  taken along line  2 - 2 ; 
         FIG. 3  is a cross-sectional view of a type of seam conventionally used to join panels of waders in the prior art; 
         FIG. 4  is a cross-sectional view of a seam used to join the edges of panels in the wader of  FIG. 1 ; and, 
         FIG. 5  schematically shows the process creating a sonic welded seam. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Fishing waders  10  as seen in  FIG. 1  comprise a trunk portion  12 , a left leg portion  14 , a right leg portion  16 , a left foot portion  18 , and a right foot portion  20 . The left foot portion  18  and the right foot portion  20  are sometimes stocking-like portions and are sometimes integrated boot portions. 
     One type of fishing wader is constructed from waterproof breathable material. In such waders, the trunk portion  12 , the left leg portion  14  and the right leg portion  16  are often made of waterproof breathable laminate panels. The two foot portions  18  and  20  can sometimes be made of such waterproof breathable laminates but other times are made of either a different, non-breathable material or are boots. Various panels of waterproof breathable materials are joined together at seams to form the trunk portion  12 , the left leg portion  14 , and the right leg portion  16 . A left leg seam  22  and a right leg seam  24  are shown in the leg portions of the wader  10 . Additionally, a left foot seam  26  joins the bottom of the left leg portion  14  to the top of the left foot portion  18 . Similarly, a right foot seam  28  joins the bottom of the right leg portion  16  to the top of the right foot portion  20 . 
     Waders are often constructed with additional seams providing reinforcement at knees. Seams are sometimes added to join additional panels to alter fit. Seams are often added to join panels of different materials to accomplish different results in the waders. Pockets are sometimes added. Thus, seams are necessary to join panels to form waders. 
     The construction of the laminate material  30  used in the present invention to form the trunk portion  12 , the left leg portion  14  and the right leg portion  16  is shown in  FIG. 2 . The laminate  30  is a three layer laminate. The outer layer  34  is a light weight nylon woven fabric. The middle layer  36  is a waterproof, breathable membrane. Such membranes are widely available commercially and are often fabricated from expanded polytetrafluoroethylene or polyurethane. The preferred middle layer is a waterproof breathable polyurethane membrane. The inner layer  38  is a light weight knitted nylon tricot. The preferred tricot is not coated. 
     This laminate material  30  is lighter and thinner than the laminate materials used in many waders. Many conventional waders use a thicker polyester outer layer. 
     Nylon generally has more stretch than polyester in a given application. 
     In a conventional wader, many important seams are sewn and taped as seen in  FIG. 3 . Thus, two edges of a panel or edges of two separate panels  42 ,  44 , are brought together and laid face to face. To create the seam seen in  FIG. 3 , two identical panels each having three layers,  46 ,  48 ,  50  are laid one on top of the other. The outer layer  46  of each panel is a polyester layer. The middle layer  48  of each panel is a breathable waterproof membrane and the inner layer  50  of each panel is a knitted nylon tricot. The two panels  42 ,  44  are sewn together at stitch line  52 . The two panels are pulled away from one another. Adhesive seam tape  54  is then applied covering the edges of the panes where they are seamed together. A ridge of material in which the stitch line  52  resides is covered by the seam tape  54 . The side of the panels  42 ,  44  opposite the seam tape  54  provides a conventional neat, clean seam appearance. The edges of the fabric are not abutted against one another in this seam. Rather, a portion of a face of panel  42  lies against a portion of a face of panel  44 . 
       FIG. 5  shows the process of making the seam of the present invention. Two panels  66 ,  68  are laid, one on top of the other with the inner layers  38 ,  38  against one another on an ultrasonic joining machine  80 . Such machines are commercially available from sources such as ARDMEL of Glenrothes, Fife, KY6 2SD in the United Kingdom (www.ardmel-group.co.uk). The stacked panels  66 ,  68  are supported on the machine table  82  and the proposed seam line moved through the ultrasonic welding gap  84 . The two panels  66 ,  68  are continuously bonded together as they pass through the gap  84  and the portions  86 ,  88  of the panels  66 ,  68  on the “waste” side of the seam line are cut away. The panels are pulled away from one another. Adhesive seam tape  70  is then applied covering the ultrasonically joined seam. 
       FIG. 4  illustrates applicants&#39; seam. A first panel edge  62  is adjacent and butted against a second panel edge  64 . The two panel edges  62 ,  64  are either edges of the same panel (for example, to form the leg) or edges of different adjacent panels. The panels  66 ,  68  are each three layer panels having an outer layer  34 , a middle layer  36 , and an inner layer  38  as described above. Seam tape  70  overlays the inner face edges of the adjacent panel edges  62 ,  64 . The adjacent edges of all three layers are joined together in a weld  72 . The weld inner edge  74  extends lightly above the adjacent inner layers creating a slight ridge  76  in the seam tape  70 . The weld  72  and seam tape  70  are sufficient to form a reliable waterproof seam without the overlap and stitching seen in prior art waders. Moreover, sufficient tensile strength is provided by the sonic weld  72  and seam tape  70  so that a durable, functional wader is provided. 
     Applicants have found that that use of nylon material rather than polyester aids in achieving a reliable welded seam. Applicants have found that using thinner layers aids in achieving a reliable welded seam. 
     This seaming technique allows the use of lighter weight, more flexible panels in forming waders. The panels do not need to have sufficient body to support a stitched seam. Rather, welding of adjacent nylon and polyurethane edges along with seam tape provides sufficient strength. Weight is saved through use of lighter weight panels and also through use of less material as overlapped seams are not required. A smoother more comfortable seam is also provided. It must be remembered that fishing waders are often worn in a fast flowing stream several feet deep. Wader may be pressed against the leg with considerable force. A thick bumpy seam may cause significant irritation. A smoother seam is less likely to irritate. 
     As described above, fishing waders are available in many different configurations including boot foot, stocking foot, waist high, chest high and with various configurations of reinforcing panels and pockets. The present invention provides improved functionality, increased comfort and lighter weight in a wader. Such advantages are particularly noticeable in a light weight packable stocking foot wader for use in traveling. However, the advantages and advances of the present invention are also useful in other fishing waders. 
     While the invention has been disclosed herein in connection with certain embodiments and detailed descriptions, it will be clear to one skilled in the art that modifications or variations of such details can be made without deviating from the gist of the invention and such modifications or variations or equivalents are considered to be within the scope of the claims hereinbelow.