Abstract:
The present disclosure describes a protective stretchable material and a garment made therewith. The protective stretchable material comprises a first protective fabric, and a second protective fabric partially superposing the first protective fabric. The protective stretchable material further comprises a stretchable structure. The first and second protective fabric are affixed to the stretchable structure in such a manner as to allow movement of the first protective fabric with respect to the second protective fabric while remaining partially superposed upon stretching of the stretchable structure.

Description:
FIELD 
       [0001]    The present disclosure relates to a protective stretchable material and to a garment made using such protective stretchable material. 
       BACKGROUND 
       [0002]    Protective garments are worn for various activities such as sports, work, construction, security, and law enforcement. Protective garments are usually designed by incorporating a cushioning fabric and/or one or several layers of protective fabric within a sealed pocket. One particular type of protective garment is the ballistic or puncture protection garment, which is worn by various types of law enforcement agents and armed services. The best known ballistic garment is the bulletproof vest. This type of garment is made of front and rear panels, each composed of several layers of ballistic grade material, between which a cushioning may be added to distribute the impact caused by bullets. The distance between the front and rear panels is adjusted by means of Velcro™ strips, which also secure the bulletproof vest on the torso of a wearer. 
         [0003]    Protective garments, such as for example ballistic or puncture protection, are also desirable for other parts of the body, such as the lower body, legs, arms and neck. More recent protective fabrics such as ballistic grade materials have become thinner and more flexible, allowing manufacturing of thinner garments. For example, the British Army and United States Army have started providing to soldiers ballistic boxer shorts made of flexible thin ballistic grade material. The ballistic boxer shorts comprise a protective crotch made of flexible ballistic grade material, inserted within a front pocket sewn into regular boxer short fabric. A ballistic undershirt is also provided. The ballistic undershirt also consists of a pocket, in which the flexible ballistic grade material, or multiple layers thereof, is inserted. 
         [0004]    Although the new protective fabrics provide an improvement to currently available protective fabrics and garments designed therewith, current protective fabrics could be displaced during movement, thus exposing the wearer to harm. Furthermore, the current protective fabrics cannot be used safely for legs, arms and the neck, which require materials which must follow body movements. It is thus not possible to design adjusted protective garments which include protective fabrics which stretch to follow movements of a wearer with the current protective fabrics and manufacturing methods. 
         [0005]    There is thus a need for a providing a material which is protective and stretchable, and to provide garments made of such protective stretchable material. 
       SUMMARY 
       [0006]    The present disclosure relates to a protective stretchable material and a garment made therewith. The protective stretchable material comprises a first protective fabric and a second protective fabric partially superposing the first protective fabric. The stretchable material further comprises a stretchable structure. The first and second protective fabric are affixed to the stretchable structure in such a manner as to allow movement of the first protective fabric with respect to the second protective fabric, while remaining partially superposed upon stretching of the stretchable structure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    In the appended drawings, similar references denote like parts. 
           [0008]      FIG. 1  is cross-sectional view of the present protective stretchable material according to a first embodiment; 
           [0009]      FIG. 2  is a cross-sectional view of a variant of the present protective stretchable material; 
           [0010]      FIG. 3  is a cross-sectional view of another variant of the present protective stretchable material; 
           [0011]      FIG. 4  is a cross-sectional view of another variant of the present protective stretchable material; 
           [0012]      FIG. 5  is a front view of an undergarment made of the present protective stretchable material of any of  FIGS. 1-4 ; 
           [0013]      FIG. 6  is a rear view of the undergarment of  FIG. 5 ; 
           [0014]      FIG. 7  is a perspective view of the undergarment of  FIGS. 5-6 , with arrows indicating a stretching direction of the present protective stretchable material; 
           [0015]      FIGS. 8   a ,  8   b ,  8   c  and  8   d  are, respectively, a front perspective view of an undergarment showing outer protective material, a front perspective view of the undergarment showing inner protective material, a rear perspective view of the undergarment showing outer protective material, and a rear perspective view of the undergarment showing inner protective material; 
           [0016]      FIG. 8   e  is a front perspective view of showing a partial overlap of the view of  FIG. 8   a  over the view of  FIG. 8   b;    
           [0017]      FIG. 9  is cross-sectional view of the present protective stretchable material according to a second embodiment; 
           [0018]      FIG. 10  is a perspective view of a protective fabric configured to protect male genitalia; 
           [0019]      FIG. 11  is a cross sectional view of the protective fabric of  FIG. 10  taken along line A-A; and 
           [0020]      FIG. 12  is a perspective view of a protective fabric configured to protect female genitalia; 
           [0021]      FIG. 13  is a cross sectional view of the protective fabric of  FIG. 11  taken along line B-B; and 
           [0022]      FIG. 14  is a perspective view of the undergarment of  FIGS. 5-6  further showing a protective fabric configured to protect male or female perineum region. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    The present disclosure relates to a protective stretchable material and a garment made therewith. Throughout the present specification the expression ‘protective fabric’ is used to refer to any fabric which has one or several protective properties and does not extend or stretch, or does not extend or stretch sufficiently to follow movements of a wearer. Examples of protective fabrics include ballistic grade fabrics, puncture grade fabrics, high resistance yarns and weaves, waterproof materials, impact absorption fabrics, impact dispersion fabrics, etc. 
         [0024]    Reference is now made to  FIGS. 1-4 , which are cross-sectional views of the present protective stretchable material. The present protective stretchable material  10  is composed of at least two protective fabrics  12  and  14 . The two protective fabrics  12  and  14  may be identical protective fabrics, different protective fabrics or complementary protective fabrics. For example, if the protective stretchable material  10  is to protect against ballistics, the protective fabric  12  may be made of a fabric, yarn or material having greater ballistic properties than the protective fabric  14 , or vice-versa. The protective fabrics  12  and  14  could alternatively or concurrently include impact absorption fabrics and/or impact dispersion fabrics. 
         [0025]    The protective fabrics  12  and  14  are affixed to a stretchable structure  16 . The stretchable structure  16  may be made of a single stretching material as shown on  FIG. 1 , or of multiple complementary layers of stretching materials  16 A- 16 D as shown on  FIGS. 2-4 . The stretchable structure  16  is composed of one or multiple layers of any known stretchable textile, suitable for the application to which the present protective stretchable material will be used. Examples of stretchable textiles which may be used include fabrics including spandex and/or elastane, fabrics which weaving provides stretching properties such as for example cotton, etc. The stretchable structure  16  may provide a two-way stretch, or a four-way stretch. 
         [0026]    Affixing  20  of the protective fabrics  12  and  14  to the stretchable structure  16  may be performed by any means known in the art, such as for example stitching, laminating, heat welding, high-frequency welding, gluing, tacking, and stapling. The protective fabrics  12  and  14  may be affixed on each extremity to the same layer of the stretchable structure  16 , as shown on  FIG. 1 , or to different layers  16 A- 16 D of the stretchable structure  16 , as shown on  FIGS. 2-4 . 
         [0027]    The protective fabrics  12  and  14  are affixed to the stretchable structure  16  so as to partially superpose one another, and remain partially superposed upon stretching of the stretchable structure  16 . Furthermore, stretching of the stretchable structure  16  allows relative movement of the protective fabrics  12  and  14 , while maintaining the protective fabrics  12  and  14  partially superposed. 
         [0028]    Either or both of the protective fabrics  12  and  14  may be flexible and/or stretchable. The overall construction of the present protective stretchable material  10  is made such that at least partial superposition of the protective fabrics  12  and  14  is maintained, upon stretching of the stretchable structure, including upon stretching or flexing of the protective fabrics  12  and  14 , within an intended range of uses of the protective stretchable material  10 . 
         [0029]    Reference is now specifically made to  FIG. 2 , which depicts a variant of the present protective stretchable material  10 . In this variant, the protective fabric  14  is composed of two protective fabrics  14 A and  14 B having one side affixed to a stretchable fabric  18 . The stretchable fabric  18  is not part of the stretchable structure  16 . The two protective fabrics  14 A and  14 B may be affixed to the stretchable fabric  18  by any means previously discussed. The stretchable fabric  18  and each of the two protective fabrics  14 A and  14 B are superposed by the protective fabric  12 . 
         [0030]    Reference is now made to  FIGS. 3 and 4 , which depict other variants of the present protective stretchable material  10 . In these variants, three partially superposed protective fabrics  14 A and  14 B are depicted. The stretchable structure is multi-layered, so as to provide multiple movement relative movement between the protective fabrics  12 ,  14 A and  14 B. As seen on  FIG. 3 , the protective fabric  12  is affixed near its extremities to layer  16 A of the stretchable structure  16 . The protective fabric  14 A fits mostly underneath the protective fabric  12 , and is affixed near one of its extremities to layers  16 A and  16  and near its other extremities to layer  16 . The protective fabric  14 B is also affixed near one of its extremities to layer  16  and near its other extremity to layers  16 A and  16 . By affixing different extremities of protective fabric to different layers or combined layers of the stretchable structure  16 , it is possible to create multilayers of partially superposed protective fabrics, capable of movement therebetween upon stretching of the stretching structure  16 , so as to maintain the protective fabrics  12 ,  14 A and  14 B in relative position during movement. 
         [0031]    As can be seen from  FIGS. 3 and 4 , it is possible to affix the protective fabrics  12 ,  14 A and  14 B along the extremities of the layers of the stretchable structure  16 . However, it is also possible to affix the protective fabrics  12 ,  14 A and  14 B anywhere along a layer or multiple layers of the stretchable structure  16 , so as to provide various configurations of protective stretchable material  10 . 
         [0032]    It is possible to further provide a cushioning (not shown) between the protective fabrics  12  and  14 , or between any combination of protective fabrics, to absorb an impact or distribute the energy received by an impacting object. 
         [0033]    Although only four variants have been depicted, it is possible to design and develop protective stretching materials  10  with many more layers than the three protective layers depicted. In fact, the present protective stretchable material  10  could include many more layers of substantially superposed protective materials, affixed to a stretchable structure have multiple layers. The stretchable structure  16  is a convenient way of securing and affixing the protective fabrics  12 ,  14 A and  14 B. 
         [0034]    Each of the protective fabrics  12 ,  14 A and  14 B may be affixed to the stretchable structure  16  on its opposite extremities, or on all its extremities. Thus in the case of a 4-way stretch stretchable structure  16 , by affixing the protective fabrics  12 ,  14 A and  14 B on different layers of the stretchable structure  16  on all extremities, it is possible to provide a 4-way stretch protective stretching material. 
         [0035]    Reference is now made concurrently to  FIGS. 1-7 , where  FIGS. 5-7  are view of an undergarment having multiple sections made of the present protective stretchable material. The present protective stretchable material is particularly interesting to use in garments which require adjusted fitting, such as for example the undergarment shown in  FIGS. 5-7 . The present protective stretchable material may be used to cover particularly vulnerable areas of the body, such as certain organs, blood vessels, organs. Because of the stretching capacity of the present protective stretchable material, adjusted garments may be designed, which will follow a wearer&#39;s movements. The present protective stretchable material may be used to create complete garments, or used only for certain sections of the garment. To allow greater comfort to the wearer, the stretching direction of the protective stretching material should be taken into consideration when designing and creating a garment, so as to ensure that the stretch of the protective stretching material corresponds to the movements.  FIG. 7  represents a garment with 3 different areas using the present protective stretching material. Each section is cut and assembled so as to provide the required stretch, while maintaining protection for the wearer. 
         [0036]      FIGS. 8   a ,  8   b ,  8   c  and  8   d  are, respectively, a front perspective view of an undergarment showing outer protective material, a front perspective view of the undergarment showing inner protective material, a rear perspective view of the undergarment showing outer protective material, and a rear perspective view of the undergarment showing inner protective material. FIG.  8   e  is a front perspective view of showing a partial overlap of the view of  FIG. 8   a  over the view of  FIG. 8   b . Areas  30  represent outer protection zones while areas  32  represent inner protection zones and areas  34  represent stretch zones (not all stretch zones are indicated by reference number  34  in order to simplify the illustration). The undergarment having areas  30 ,  32  and  34  is flexible and easy to wear close to the body while maintaining at least partial overlap of areas  30  and  32  at all times under normal intended use conditions of the undergarment. 
         [0037]    There is no a priori limit to the size of each section of protective fabrics  12  and  14  (i.e. areas  30  and  32 ). In some variants, a garment may comprise a small number of overlapping fabric sections, as shown for example on  FIGS. 8   a - 8   d . In other variants, a given section of protective fabric may be have a rectangular or hexagon shape being, for example, sized to about one (1) square inch. 
         [0038]      FIG. 9  is cross-sectional view of the present protective stretchable material according to a second embodiment. Only elements of  FIG. 9  not previously introduced in the foregoing description of  FIG. 1  will now be discussed. Pockets  40  are formed between a layer of protection material such as  42  and a layer of stretch material such as  44 . In the embodiment shown on  FIG. 9 , the protection material  42  may be non-stretchable and rigid, or may alternatively be stretchable and/or flexible. Inserts  46  made of protection material are placed within the pockets  40 . Pockets  40  may also be formed by two layers of non protective, stretch material  44 . The pockets  40  are either configured (e.g. by the manner in which they are sown or otherwise assembled) so that the inserts  46  are permanently affixed therein or so that the inserts  46  are removable. 
         [0039]      FIG. 10  is a perspective view of a protective fabric configured to protect male genitalia. A cup  50  is provided with two (2) side extensions  52 , also called wings, covering the junction between the wearer&#39;s pelvic region and thighs and covering at least in part the wearer&#39;s thighs. The cup  50  and the side extensions  52  are configured for use with the undergarment introduced in the description of  FIG. 5 . The cup  50  and the side extensions  52  may be permanently affixed to the undergarment, or may be inserted in a suitably formed pocket. The side extensions  52  are configured to overlap, at least partially, with protective fabric of the undergarment covering the thighs so that at least partial overlap of the protective fabrics is maintained during use of the undergarment. 
         [0040]      FIG. 11  is a cross sectional view of the protective fabric of  FIG. 10  taken along line A-A. A thickness of the material forming the cup  50  and the side extensions  52  is greatly exaggerated in order to better illustrate its construction. A number of layers shown on  FIG. 11  is for illustration purposes only. Seems  54  shown between the cup  50  and the side extensions  52  or between halves of the cup  50  may be sown, glued, or assembled in other manners known in the art. As shown on  FIG. 11 , materials of the cup  50  and of the side extensions  52  may overlap at least in part at the seems  54  in order to provide continuous protection. In a variant, each layer of the cup  50  and of the side extensions  50  may be molded of a single material. A number of layers forming the protective fabric configured to protect male genitalia and the type of materials used may vary according to the needs of a particular intended use. In some variants, layers of polyethylene, Kevlar, carbon film made of carbon nanotubes, or combinations of layers made of these materials may be used. 
         [0041]      FIG. 12  is a perspective view of a protective fabric configured to protect female genitalia.  FIG. 13  is a cross sectional view of the protective fabric of  FIG. 11  taken along line B-B. A protector  50 F having side extensions  52 F is similar to the cup  50  and to the side extensions  52  in terms of construction. 
         [0042]      FIG. 14  is a perspective view of the undergarment of  FIGS. 5-6  further showing a protective fabric configured to protect male or female perineum region. A protective fabric  60 , including side extensions  62  are configured for use with the undergarment introduced in the description of  FIG. 5 . The protective fabric  60 , including side extensions  62  may be permanently affixed to the undergarment, or may be inserted in a suitably formed pocket. Fabrication of the protective fabric  60  and of the side extensions  62  may be similar to that of the cup  50  and of its side extensions  52 . 
         [0043]    Although the present protective stretchable material and garment have been described in the foregoing description by way of illustrative embodiments thereof, these embodiments can be modified at will, within the scope of the appended claims without departing from the spirit and nature of the appended claims.