Patent Publication Number: US-6668384-B1

Title: Seamless front flap assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     DESCRIPTION 
     1. Field of the Invention 
     The present invention relates to a seamless front flap assembly. Specifically, the present invention relates to a seamless front flap assembly for a front shell of a waterproof garment. 
     2. Description of the Related Art 
     FIGS. 1-3 show a conventional waterproof jacket. The jacket is made by stitching a plurality of the impregnated man-made shell fabrics together and has two opposite front panels. The front flap assembly for the jacket is constructed by first stitching an outer flap and an inner flap respectively with each of the front panels. A zipper tape is further located below the outer flap and stitched therein, while the other zipper tape is located above the inner flap and stitched therein. Based on the above structure, when the two zipper tapes are engaged to form a zipper, the outer flap and the inner flap enclose the zipper tapes such that water cannot pass through the zipper tapes rendering the waterproof effect. However, as shown by the broken lines in FIG. 2, water can still penetrate into the front panels through the needle holes of the stitching and eventually the jacket cannot be 100% waterproof. 
     To eliminate the above problem, for the shell fabrics, thermal tapes are provided under the stitching to ensure the waterproof effect. Since the thermal tape cannot be positioned on the front flap portion of the jacket for appearance reasons, instead of the stitching, glue has been used to join the outer and inner flaps to the zipper tapes. However, the glued front flap portion usually has a strong smell and the quality thereof is not stable. Further, the production output is low and the cost incurred is high. The above factors make the glued waterproof jacket less competetive in the market. 
     FIGS. 4-6 show another conventional seamless front flap assembly is widely used in the current outdoor waterproof jacket. In this instance, an outer flap is respectively stitched on each of the opposite front panels, with the upper one used to block the water and the lower one served as a gutter. A zipper tape is positioned below the respective outer flap and further stitched to the front panel. To prevent the water from penetrating into the needle holes of the stitching between the outer flap and the front panel, a thermal tape is positioned under the stitching. 
     However, with two flaps positioned on the top of the zipper tapes by stitching, the jacket not only consumes more fabrics, the front of the jacket is also stressed by the flaps and makes the wearer feel uncomfortable. Even though this type of jacket is waterproof, the front of the jacket is never clean and neat. 
     FIGS. 7-9 show a seamless front flap assembly disclosed in the pending U.S. Ser. No. 10/213,199, where improvements have been made to prevent water from penetrating into the front panels through the needle holes of the stitching. 
     This invention is related to an improved version of the pending U.S. Ser. No. 10/213,199 featuring an extra piece of fabric to provide additional anchoring for the zipper tapes. 
     BRIEF SUMMARY OF THE INVENTION 
     An objective of the present invention is to provide a seamless front flap assembly for a garment, which is waterproof. 
     Another objective of the present invention is to provide a seamless front flap assembly for a garment, which makes the front of the garment look neat and elegant. 
     The other objective of the present invention is to provide a seamless front flap assembly for a garment, which features extra pieces of fabric to provide additional anchoring for the zipper tapes. 
     A further objective of the present invention is to provide a seamless front flap assembly for a garment, which features a lower outer flap to serve as a gutter to enhance the water blocking effect. 
     To achieve these objectives, the seamless front flap assembly in accordance with the present invention for a garment having a first front panel and a second front panel in a side-by-side configuration, the assembly comprises: a top storm flap including: an upper fabric; a lower fabric stitched to the upper fabric of the top storm flap; and a thermally meltable compound for adhering the upper fabric to the lower fabric of the top storm flap; a bottom storm flap including: an upper fabric; a lower fabric stitched to the upper fabric of the bottom storm flap; and a thermally meltable compound for adhering the upper fabric to the lower fabric of the bottom storm flap; a first zipper anchoring flap including: an upper fabric stitched to the lower fabric of the top storm flap; and a lower fabric stitched to the upper fabric of the first zipper anchoring flap; a second zipper anchoring flap including: an upper fabric stitched to the lower fabric of the bottom storm flap; and a lower fabric stitched to the upper fabric of the second zipper anchoring flap; a zipper including: a first zipper tape and a second zipper tape, each zipper tape being stitched to the first zipper anchoring flap and the second zipper anchoring flap, respectively. 
    
    
     The structure and objectives of the present invention can be more readily understood by persons skilled in the art from the following description of the preferred embodiments taken in conjunction with the accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front elevation view of a conventional jacket; 
     FIG. 2 is a cross-sectional view taken along Lines  2 — 2  in FIG. 1; 
     FIG. 3 is a cross-sectional view of FIG. 2, wherein the jacket is in an open state; 
     FIG. 4 is a front elevation view of the other conventional jacket; 
     FIG. 5 is a cross-section view taken along Lines  5 — 5  in FIG. 4; 
     FIG. 6 is a cross-sectional view of FIG. 5, wherein the jacket is in an open state; 
     FIG. 7 is a front elevation view of jacket including a prior seamless front flap assembly; 
     FIG. 8 is a cross-sectional view taken along Lines  8 — 8  in FIG. 7; 
     FIG. 9 is a cross-sectional view of FIG. 7, wherein the jacket is in an open state; 
     FIG. 10 is a front elevation view of a jacket in accordance with the present invention; 
     FIG. 11 is a cross-sectional view taken along Lines  11 — 11  in FIG.  10 ; and 
     FIG. 12 is a cross-sectional view of FIG. 10, wherein the jacket is in an open state. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 10-12 show the jacket with a seamless front flap assembly in accordance with a preferred embodiment of the present invention. As shown, the jacket  1  comprises a first front panel  11  and a second front panel  12  in a side-by-side configuration. 
     As best seen in FIG. 11, the seamless front flap assembly in accordance with the preferred embodiment of the present invention comprises a top storm flap  2 , a bottom storm flap  3 , a first zipper anchoring flap  4 , a second zipper anchoring flap  5 , and a zipper  6 . 
     The top storm flap  2  includes an upper fabric  21  having a free end  21   a  extending from the first front panel  11 , a lower fabric  22  having a free end  22   a  stitched to the free end  21   a  of the upper fabric  21  by concealed stitching  23  and a fixing end  22   b , and a thermally meltable compound  24  (such as a thermal meltable polyurethane resin in the form of a glue film), provided at the fixing end  22   b  of the lower fabric  22  for adhering the upper fabric  21  to the lower fabric  22 . 
     The bottom storm flap  3  includes an upper fabric  31  having a free end  31   a  extending from the second front panel  12 , a lower fabric  32  having a free end  32   a  stitched to the free end  31   a  of the upper fabric  31  by concealed stitching  33  and a fixing end  32   b , and a thermal meltable compound  34  (such as a thermally meltable polyurethane resin in the form of a glue film) provided at the fixing end  32   b  of the lower fabric  32  for adhering the upper fabric  31  to the lower fabric  32 . If desired, the free ends  31   a ,  32   a  of the upper fabric  31  and lower fabric  32  may be folded over towards the upper fabric  31  and stitched to the upper fabric  31  at opposing ends to form a gutter  35  to provide additional water blocking effect. 
     The first zipper anchoring flap  4  includes an upper fabric  41  having a free end  41   a  and a fixing end  41   b  stitched to the fixing end  22   b  of the lower fabric  22  of the top storm flap  2 , a lower fabric  42  having a free end  42   a  stitched to the free end  41   a  of the upper fabric  41  by concealed stitching  43 . Preferably, a thermal tape  44  is positioned to the fixing end  41   b  of the upper fabric  41  where the fixing end  41   b  is stitched to the fixing end  22   b  of the lower fabric  22  of the top storm flap  2  to enhance the waterproof effect. 
     The second zipper anchoring flap  5  includes an upper fabric  51  having a free end  51   a  and a fixing end  51   b  stitched to the fixing end  32   b  of the lower fabric  32  of the bottom storm flap  3 , and a lower fabric  52  having a free end  52   a  stitched to the free end  51   a  of the upper fabric  51  by concealed stitching  53 . Preferably, a thermal tape  54  is positioned to the fixing end  51   b  of the upper fabric  41  where the fixing end  51   b  is stitched to the fixing end  32   b  of the lower fabric  32  of the bottom storm flap  3  to enhance the waterproof effect. 
     The zipper  6  includes a first zipper tape  61  and a second zipper tape  62 , each having a tooth side  63  and a fixing side  64  stitched to the free ends  41   a ,  42   a  of the first zipper anchoring flap  5  and the free ends  51   a ,  52   a  of the second zipper anchoring flap  6 , respectively. 
     As shown in FIGS. 11 and 12, the lower fabrics  42 ,  52  of the first and second zipper anchoring flaps  4 ,  5  may each include a free end  42   b ,  52   b  being stitched to a lining of the jacket  1 . 
     Based on the above structure, and by using a thermal welding machine to heat the thermally meltable compound  24 ,  34 , and the thermal tapes  44 ,  54 , the molten and then cured compound  23 ,  33  will adhere the upper fabrics  21 ,  31  to the lower fabrics  22 ,  32 , while the molten and then cured thermal tapes  44 ,  54  will adhere to the stitching at the fixing ends  41   b ,  51   a  of the upper fabrics  41 ,  51 , respectively. As such, the seamless front panel assembly in accordance with a preferred embodiment of the present invention is constructed. 
     When the tooth side  63  of the zipper tapes  61 ,  62  are engaged with each other, the bottom storm flap  3 , preferably extending beyond where the tooth sides  63  engage to further enhance the waterproofing effect, and the top storm flap  2  extends above the bottom storm flap  3 . 
     If the free ends  31   a ,  32   a  of the upper fabric  31  and lower fabric  32  are folded over towards and stitched to the upper fabric  31  at opposing ends to form a gutter  35  as shown in FIGS. 11 and 12, the top storm flap  2  extending above the bottom storm flap  3  helps to cover up the needle holes of the stitching. 
     Preferably, additional matching fasteners  8 , such as snap buttons or mechanical loop-hook fasteners, may be provided to the lower fabric  22  of the top storm flap  2  and the top layer fabric  31  of the bottom storm flap  3  such that the top storm flap  2  may be properly attached to the bottom storm flap  3  upon engagement of the zipper tapes  61 ,  62 . 
     As such, there will be no stitching found on the upper fabric  21  of the top storm flap  2  and the front panels  11 ,  12 , whereby no water can penetrate into the front panels  11 ,  12 . 
     To further improve the waterproof effect, the first and second front panels  11 ,  12 , the outer and bottom storm flaps  2 ,  3 , the first and second zipper tapes  61 ,  62  may be made of woven or knit man-made fabric (such as nylon, polyester, TC, CN), or impregnated fabrics (such as PU, PTFE, PVC, or rubber coated/laminated fabrics). However, it should be noted that while applying the present invention to other types of jackets, the shell fabrics for the jacket can also be non-impregnated, especially highly breathable fabrics, which makes the jacket fashionable with a neat seamless outer appearance. 
     In accordance with the present invention, the seamless front flap assembly for a garment is waterproof and provides additional zipper anchoring flaps to help fix the zipper so as to render a neat and elegant appearance for the front of the garment. The gutter provided by the lower outer flap also helps to enhance the water blocking effect. 
     The structure of the present invention is not limited to the above embodiments. For example, the zipper can be replaced by snap-on buttons, mechanical loop-hook fasteners, etc. Although the invention has been described with reference to the preferred embodiments, it will be obvious to persons skilled in the art that various changes and modifications may be made without departing from the scope of the invention as recited in the claims.