Patent Publication Number: US-2012023631-A1

Title: Water-sport garment with breathable fabric panels

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/369,643 filed on Jul. 30, 2010, entitled “WATER-SPORT GARMENT WITH BREATHABLE FABRIC PANELS,” which is hereby incorporated in its entirety by reference as if fully set forth herein. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     Embodiments of the present disclosure are generally related to garments suitable for water-sports activity, and more particularly to an improved water-sport garment having one or more panels of waterproof, breathable fabric allowing the wearer to maintain a comfortable body temperature and enjoy increased freedom of movement. 
     2. Description of the Related Art 
     Maintaining a comfortable body temperature while participating in water-sport activities is a challenge. Wetsuits and other similar form-fitted garments have been developed that allow the wearer to spend more time in cold water due to their heat retention capability. However, many water-sports only require the participant to be submerged in the water infrequently, spending a significant amount of time with their body at least partially out of the water. In these situations the body temperature of the person wearing the form-fitted garment may rise to uncomfortable levels because of physical exertion, high ambient temperatures, direct exposure to sunlight, or some combination of the three. It is desirable then to have a garment that insulates the body from the effects of cold water while allowing the wearer to dissipate heat, thereby maintaining a comfortable body temperature. Additionally, it is desirable to have a garment that allows for the effective maintenance of a comfortable body temperature without overly restricting the wearer&#39;s freedom of movement. 
     Wetsuits are a typical example of a form-fitted garment suitable for water sports. Wetsuits are tight-fitting water-permeable suits worn by divers, surfers, board sailors, kayakers, and swimmers to retain body heat. Modern wetsuits typically comprise flexible, heat-insulative material such as elastomer foam, one example being Neoprene foam. Full body wetsuits exhibit full-length arm and leg portions as well as the trunk portion. A spring suit is one which has short sleeves and shortened leg portions, and is typically used by surfers who desire greater freedom of movement. A bib top, similar to a tank top garment, may also be worn to increase the freedom of movement. Other examples of similar types of garments include vests which cover the torso and arms, shorts which cover from the waist to the knee, hoods which cover the head, booties which cover the feet, and gloves which cover the hands. 
     Wetsuits and other such form-fitted garments typically retain heat by allowing a small portion of water to enter the garment that is then heated by the wearer&#39;s body until it reaches a comfortable level. One attempt at increasing the effectiveness of these types of garments is seen in U.S. Pat. No. 4,741,050, issued to O&#39;Kane et al. In this patent, a certain type of stitching is claimed for use in wetsuits that is durable, strong, flexible, and substantially waterproof. The overlock stitching technique in the patent reduces the influx of cold water into the suit. 
     Another wetsuit designed to more effectively retain heat is seen in U.S. Pat. No. 7,395,553 issued to O&#39;Hara. In this wetsuit, wool is affixed to the inside of the inner layer of a wetsuit in sections which also creates channels without wool. The wool is more effective in retaining heat than synthetic fibers and the channels allow for water to leave the suit. In this way the wearer may more effectively retain heat. 
     In an attempt to create a wetsuit suitable for a variety of temperatures, a wetsuit with limb extensions is seen in U.S. Pat. No. 6,473,904 issued to Long. This wetsuit comprises removable arm and leg portions so that the wetsuit is easily modifiable for a variety of conditions. However, the wearer&#39;s torso, chest, shoulders, and legs from the knee up are still covered in material that is designed to retain heat. 
     A uniform-stretch wetsuit material is seen in U.S. Pat. No. 7,051,375 issued to Polak et al. The material in this patent comprises layers of synthetic rubber treated with a hydrophobic coating. This material is rapid-drying and substantially impermeable to water, but does not allow for heat to be effectively dissipated through the material. 
     Therefore, there is a need for a form-fitted garment for water-sport activity that allows the wearer to maintain a comfortable body temperature by retaining heat where the wearer&#39;s body is submerged and by allowing the user to dissipate heat when necessary without overly restricting the freedom of movement. 
     SUMMARY OF THE INVENTION 
     The present disclosure provides a garment for water-sports that combines a waterproof, breathable fabric treated with a durable water repellant coating with conventional heat retention waterproof material. 
     In accordance with some embodiments, the water-sport garment provides a waterproof, breathable layered fabric comprising at least one layer of synthetic knit fabric and a layer of a waterproof breathable membrane, which, when affixed to a conventional heat retention waterproof material such as Neoprene, provides a fabric construction suitable for applications where both heat retention and heat dissipation are desired. 
     In some embodiments, two layers of synthetic knit fabric surround a layer of waterproof breathable membrane material. These two layers of synthetic knit fabric may be of the same or different thicknesses and may be treated with a durable water repellant chemical to prevent water absorption while still retaining breathability. 
     Construction of a garment suitable for water sports using the disclosed waterproof, breathable layered fabric in combination with another waterproof non-breathable material also results in a garment with improved stretchiness, allowing a wearer greater flexibility and freedom of movement as well as decreased muscle fatigue. Additionally, the desirable heat retention properties are maintained in order to keep the wearer warm during water sports activities. 
     In another embodiment, a method of manufacturing a garment suitable for water sports is presented comprising affixing one or more panels of foam rubber material having an inner and outer laminate of synthetic fabric and one or more layers of a waterproof breathable layered fabric to form a form-fitting garment. Preferably, the method further comprises treating at least an outer layer with a durable water-repellant chemical. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects and advantages of the embodiments of the water-sport garment are described in detail below with reference to the drawings of certain embodiments. The figures and descriptions are intended to illustrate certain aspects, advantages, and novel features of the garment without limiting it. 
         FIG. 1  is a perspective and schematic split section of the waterproof, breathable fabric used in some embodiments of the garment. 
         FIG. 2  is a schematic cross-section of the waterproof, breathable fabric used in some embodiments of the garment. 
         FIG. 3  is a schematic cross-section of the neoprene fabric used in some embodiments of the garment. 
       FIG. °  4  is a schematic cross-section to illustrate the joined combination of the neoprene fabric and the waterproof, breathable fabric used in some embodiments of the garment. 
         FIG. 5  is a front perspective view of a wetsuit constructed in accordance with one embodiment of the garment. 
         FIG. 6  is a rear perspective view of the wetsuit in  FIG. 5 . 
         FIGS. 7A and 7B  are front and rear perspective views of a fitted vest constructed in accordance with one embodiment of the garment. 
         FIGS. 8A and 8B  are front and rear perspective views of a fitted vest with shortened arm portions constructed in accordance with one embodiment of the garment. 
         FIG. 9  is a side perspective view of a bootie constructed in accordance with one embodiment of the garment. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIGS. 1-4  illustrate a novel waterproof, breathable fabric for use in the construction of water-sport garments. Although this waterproof, breathable fabric is principally shown and described in conjunction with a full-body wetsuit, many of the inventive aspects can readily be adapted to other styles, such as spring suits, hoods, gloves, sleeves, booties, vests, shorts and bibs. 
     Certain prior art garments for water sports are constructed from a plurality of panels of foam rubber, preferably Neoprene, having at least an inner layer of laminate of nylon for strength, some of the panels being more pliable than others. The nylon laminate is formed by a weave of long nylon strands and is characterized by a particular density, or denier number, according to industry standards. The denier number is a unit of fineness denoting the weight (or mass) of a specified length of nylon strand. One industry standard used is the gram weight of the nylon per 9000 meters of strand. A conventional type of nylon used in wetsuits has a denier number of 70. The nylon strands are twisted together in a crosswise fashion, and the higher the density of the weave, the closer together the adjacent parallel strands, resulting in more and bigger loops in each cross strands, and visa versa. Because there are more and bigger loops per strand, each strand travels a longer path through a given length of material and, consequently, has more slack therein, allowing greater expansion when the ends are pulled. Over an area of such high density nylon weave, the fabric can be stretched in two dimensions to a much greater extent than straighter weave nylon fabric. This conventional wetsuit material is very durable and has high heat insulation capacity but is not breathable and can also be heavy and limit the wearer&#39;s freedom of movement. 
     For certain applications such as sports conducted in cold water on warm days or for participants in highly aerobic water-sports where substantial amounts of heat are generated, heat dissipation from areas of high heat generation is desired to make the garment more comfortable for the wearer. However, the garment must also retain enough heat that the wearer is comfortable in the cold water. Conventional materials used in the construction of garments for water sports have high heat retention capability but can inhibit freedom of movement and retain more heat than is comfortable for the wearer. Accordingly, the water-sport garment with breathable fabric panels discussed herein incorporates both the highly durable, high heat retention materials of conventional water-sport garments and a layered fabric composed of synthetic knit layers sandwiching a waterproof, breathable membrane into a form-fitting garment having improved stretchiness and heat dissipation qualities. 
     As illustrated in  FIGS. 1 and 2 , the waterproof, breathable material  10  has an inner layer of synthetic knit fabric  103  and an outer layer of synthetic knit fabric  101 . This synthetic knit comprises nylon, polyester, or any combination thereof. Between these two layers is a layer of a waterproof breathable membrane  102 . The inner knit layer  103  and outer knit layer  101  are treated with a durable water repellant chemical such that the resultant construction is both waterproof and breathable. The construction of these layers results in a fabric with improved two-dimensional stretchiness and heat dissipation capability that has a lighter weight than conventional materials used in the construction of water sports garments. In a preferred embodiment, the waterproof, breathable membrane comprises thermoplastic polyurethane (TPU) film, or microporous polytetrafluoroethylene (PTFE) film. These films have an elongation of about 450-550% when tested using the ASTM D882 method. 
     Preferably, each layer of synthetic knit fabric  101 ,  103  is comprised of 100% polyester high gauge four-way stretch fabric having a gram weight about 57 g/m 2 ±5% Additionally, the inner  103  and outer  101  layers of synthetic knit need not be the same gram weight. To increase the thickness of the waterproof, breathable layered fabric  10 , it is necessary to increase the thickness of the synthetic knit fabric  101 ,  103 . 
     Prior art waterproof, breathable fabric is rigid and lacks stretchiness. The combination of a waterproof, breathable layer  102  with synthetic knit inner and outer layers  101 ,  103  improves the two-dimensional stretchability of the fabric and any garment constructed of the fabric. This additional stretchiness is especially desired in the construction of wetsuits, for example, where a uniform stretchiness prevents the garment from binding and limiting the wearer&#39;s freedom of movement. 
     In a preferred embodiment, treatment of the waterproof, breathable layered fabric  10  with a durable water-repellant chemical on both the inside  103  and the outside  101  synthetic knit layers allows the fabric to resist water absorption and allows the fabric to dry more quickly. Application of the durable water repellant chemical occurs by spraying both sides of the waterproof, breathable layered fabric, by chemically washing the fabric in the durable water repellant chemical, or by sponging the durable water repellant chemical onto the synthetic knit inner and outer layers  101 ,  103 . Preferably, the durable water repellant chemical is applied by spraying the inner and outer synthetic knit layers  101 ,  103  or by chemically washing the fabric with the durable water repellant chemical and other chemicals (such as dye). 
     A conventional fabric used in the construction of water-sports garments is depicted in  FIG. 3 . This conventional fabric is typically composed of an air encapsulated rubberized core layer  302  enclosed within two layers of a synthetic knit fabric  301 ,  303 . These three layers together form a construction of a typical waterproof, non-breathable fabric  30 , such as Neoprene. 
     As seen in  FIG. 4 , an area of affixation, or “seam,”  401  connects the waterproof breathable laminate fabric  10  and the waterproof non-breathable conventional material  30 . The industry standard for joining panels of material in the construction of water sport garments is a flat lock stitch or a flat lock stitch with tape. It is also possible to heat weld or glue the panels together edge to edge. Additionally, the panels could be glued by overlapping the sides of the fabric or using heat glue tape to hold the seams together. Other methods of affixation not specifically discussed may also be used. 
       FIGS. 5 and 6 , respectively, illustrate front and rear views of a wetsuit  50  according to some embodiments of a water-sport garment. The wetsuit  50  comprises a plurality of panels of foam rubber, preferably Neoprene, and a plurality of panels of waterproof breathable laminate. The panels of waterproof breathable laminate fabric are shown as shaded areas and the unshaded areas are panels of foam rubber. The lines connecting the panels represent seams. 
     Referring to  FIGS. 5 and 6 , the wetsuit  50  comprises a foam rubber chest portion  500  affixed to foam rubber arm portions  509  at an arm hole sleeve seam  503 . The chest portion  500  is also affixed to foam rubber side panels  611  at a body seam  507 . The foam rubber chest portion  500  is also affixed to a waterproof breathable laminate neck portion  501  and waterproof breathable laminate under-arm portions  504  and  605 . 
     The foam rubber side panels  611  in  FIG. 6  are affixed to a foam rubber upper leg portion  610  and foam rubber arm portions  509  and  510 . The side panels  611  are also affixed to a waterproof breathable laminate back portion  606 . Additionally, the side panels  611  are affixed to waterproof breathable laminate under-arm portions  504  and  605 . 
     The zipper  603  in  FIG. 6  extends from the waterproof breathable laminate back portion  606  starting at  604  to the foam rubber neck portion  602 . Where the zipper  603  terminates, a section of fabric  601  is included to protect the wearer&#39;s neck. The foam rubber neck portion  602  is affixed to a foam rubber front neck portion  502  and to foam rubber arm portions  509 . The front neck portion  502  additionally is affixed to a waterproof breathable laminate neck portion  501 . 
     The foam rubber upper leg portion  610  in  FIG. 6  is affixed to foam rubber lower leg portions  609  at knee seams  508 . The upper leg portion  610  is also affixed to a waterproof breathable laminate inside leg portion  506  and  607 . Additionally, the upper leg portion  610  is affixed to waterproof breathable laminate panels behind the wearer&#39;s knees  608 . 
     In some embodiments, the number, size, thickness, and location of the foam rubber panels and panels of waterproof breathable laminate may be varied to alter the heat retention, heat dissipation, and flexibility characteristics of the water-sport garment. The waterproof breathable laminate panels may be located additionally or alternatively on the shoulders, chest, legs, sides, or behind the elbows. The foam rubber panels may also be located additionally or alternatively under the arms, behind the knees, on the inside of the legs, or between the neck and chest portions. The locations of the foam rubber panels in conjunction with the waterproof breathable laminate panels may be configured in such a way as to maximize the wearer&#39;s efficiency in regulating body temperature. Additionally, the size of the panels may be altered to affect the amount of heat that is dissipated or retained. 
     In another embodiment, the water-sport garment is a wetsuit with shortened arm and leg portions, generally referred to as a spring suit. A spring suit comprises one or more panels of foam rubber affixed to one or more panels of waterproof breathable laminate. The foam rubber panels may be configured to cover one or more body parts where heat retention is desired, such as the chest, neck, shoulders, upper arms, under arms, back, torso, upper legs, or inner legs. The waterproof breathable laminate panels may be configured to cover one or more body parts where freedom of movement or heat dissipation is desired, such as the chest, neck, shoulders, upper arms, under arms, back, torso, upper legs, or inner legs. The foam rubber panels may have a thickness that ranges from 0.5 mm to 5.0 mm. The thickness of the inner and outer layers of knit fabrics in the waterproof breathable fabric may have a thickness that ranges from 54 to 60 g/m 2 . 
     In another embodiment, illustrated in  FIGS. 7A ,  7 B,  8 A and  8 B, one or more foam rubber panels are joined to one or more panels of waterproof breathable laminates to form a vest. The foam rubber torso portion  700  or  800  is affixed to foam rubber arm portions  701  or  801  by upper arm seams  702  or  802 . The torso portion  700  or  800  and arm portions  701  or  801  are also affixed to waterproof breathable laminate under arm portions  703  or  803  by under arm seams  704  or  804 . The foam rubber torso portion  700  or  800  and foam rubber arm portions  701  or  801  are additionally affixed to a waterproof breathable laminate neck portion  705  or  805 . A zipper  706  runs from the neck portion to the torso portion on the rear of the vest. Alternatively, the vest may have shortened arm portions  801  as illustrated in  FIGS. 8A and 8B . Alternatively, the vest may have no zipper as illustrated in  FIG. 8B . 
     In other embodiments of the vest, the chest and arm panels may be constructed out of a single panel of foam rubber. Additionally, the neck portion may comprise a panel of foam rubber. The number, size, thickness, or location of the foam rubber panels as well as the number, size, thickness, or location of the panels of waterproof breathable laminate may vary according to the desired heat retention, heat dissipation, or flexibility characteristics of the vest. 
     In another embodiment, the water-sport garment is a bootie designed to be worn on the foot, as illustrated in  FIG. 9 . The bootie  90  comprises a waterproof breathable laminate lower foot portion  900  affixed to a waterproof breathable laminate upper foot portion  904  at an upper foot seam  905 . The two panels are joined via flat lock stitching. The upper foot portion and lower foot portion are affixed to a foam rubber panel under foot portion  902  that extends over the rear of the wearer&#39;s foot up to the elastic binding portion  903 . An elastic binding portion  903  is affixed to an open end of the combination of the upper foot portion  904  and under foot portion  902 . 
     In other embodiments of the bootie, the lower and upper foot portions are constructed from a single piece of foam rubber. Alternatively, the lower or upper foot portions may comprise foam rubber panels in addition to the under foot portion. The number, size, thickness, or location of the waterproof breathable laminate panels and foam rubber panels may be varied according to the desired heat retention, heat dissipation, or flexibility characteristics of the bootie. The upper and lower foot portions may be joined at a seam with a flat lock stitch and tape, a heat weld, glue, a blind stitch, or any other suitable method for joining panels of fabric together. 
     Other embodiments of a water-sport garment include a hood designed to be worn on the head, a glove designed to be worn on the hand, a bib, and shorts. 
     The panels of waterproof breathable laminate in some embodiments comprise a synthetic knit fabric outer layer affixed to a waterproof breathable membrane affixed to a synthetic knit fabric inner layer. The synthetic knit fabrics may be nylon, polyester, or a mixture of nylon and polyester. The outer layer and the inner layer need not comprise the same synthetic fabric. The thickness of the synthetic knit fabric outer and inner layers is typically in the range of 54 to 60 g/m 2 . The thickness of the outer and inner layer need not be the same. The waterproof breathable membrane preferably comprises thermoplastic polyurethane film. Additionally, the interior and exterior of the panels of waterproof breathable laminate may be treated with a durable, water-repellant chemical. 
     Preferred embodiments of wetsuit include chest and torso portions using neoprene that is 3 mm thick, and arm and leg portions that are 2 mm thick. The waterproof breathable fabric is preferably located under the arms, close to the neck, between the legs, and on the back. The waterproof breathable fabric is preferably 57 g/m 2  in those locations. 
     In addition, while several variations of the disclosure have been shown and described in detail, other modifications, which are within the scope of this disclosure, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combination or sub-combinations of the specific features and aspects of the embodiments can be made and still fall within the scope of the disclosure. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosure. Thus, it is intended that the scope of at least some of the disclosed embodiments herein disclosed should not be limited by the particular disclosed embodiments described above.