WATER-SPORT GARMENT WITH BREATHABLE FABRIC PANELS

Abstract

A water-sport garment constructed with waterproof, breathable fabric panels and waterproof, non-breathable fabric panels. The waterproof, breathable fabric is constructed of one layer of a waterproof, breathable membrane with an inner and outer layer of synthetic knit fabric. The synthetic knit fabric is treated with a durable water repellant coating to prevent water absorption yet retain heat dissipation properties. The waterproof, breathable fabric is affixed to a conventional waterproof, non-breathable fabric used in the construction of water-sport garments. Construction of garments using panels of the waterproof, breathable fabric results in greater flexibility for the wearer, due to the waterproof, breathable fabric's improved stretchiness, as well as improved comfort for the wearer due to heat dissipation from areas of high heat generation during highly aerobic water-sports activities.

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'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'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'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'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'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'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'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/m²±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'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'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'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'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/m².

In another embodiment, illustrated in FIGS. 7A, 7B, 8A and 8B, 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'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/m². 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/m² 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.

Claims

1. A form-fitted garment for water-sport activity, the garment comprising:

at least one panel of foam rubber material having an inner laminate of fabric; and

at least one panel of breathable laminate having an outer knit fabric affixed to a waterproof breathable membrane affixed to an inner knit fabric;

wherein the at least one panel of foam rubber material and the at least one panel of waterproof breathable laminate are affixed in an edge-to-edge relationship.

2. The form-fitted garment of claim 1, wherein the inner knit fabric of the at least one panel of breathable laminate is treated with a durable water repellant.

3. The form-fitted garment of claim 1, wherein the garment comprises a wetsuit.

4. The form-fitted garment of claim 1, wherein the at least one panel of foam rubber material and the at least one panel of waterproof breathable laminate are affixed in an edge-to-edge relationship with a flat lock stitch.

5. The form-fitted garment of claim 1, wherein the waterproof, breathable membrane comprises thermoplastic polyurethane film.

6. A waterproof breathable wetsuit comprising:

a plurality of foam rubber panels having an inner laminate of fabric;

a plurality of breathable laminate panels having an outer knit fabric affixed to a breathable membrane affixed to an inner knit fabric, the outer knit fabric and the inner knit fabric being treated with a durable water repellant; and

the plurality of breathable laminate panels and the plurality of foam rubber panels being affixedly joined by a seam.

7. The wetsuit of claim 6, wherein the plurality of breathable laminate panels are situated in areas where greater heat dissipation is desired.

8. The wetsuit of claim 7, wherein the areas where greater heat dissipation is desired comprise at least one of armpits, groin, back, neck, shoulders, back of the elbow, and back of the knee.

9. The wetsuit of claim 6, wherein the plurality of breathable laminate panels are situated in areas where less restriction of movement is desired.

10. The wetsuit of claim 9, wherein the areas where less restriction of movement is desired comprise at least one of armpits, groin, back, neck, shoulders, back of the elbow, and back of the knee

11. A method of manufacturing a waterproof breathable water-sport garment, the method comprising:

affixing one or more panels of foam rubber material having an inner laminate of fabric to one or more panels of breathable laminate having an outer layer of knit fabric affixed to a waterproof breathable membrane affixed to an inner knit fabric; and

treating the inner knit fabric and the outer knit fabric of the one or more panels of breathable laminate with a durable water repellant.

12. The method of claim 11, further comprising positioning the one or more panels of breathable laminate in areas where greater heat dissipation is desired.

13. The method of claim 11, further comprising positioning the one or more panels of breathable laminate in areas where less restriction of movement is desired.

14. A garment suitable for water sports, comprising:

one or more panels of foam rubber material having an inner and outer laminate of synthetic fabric; and

one or more panels of a waterproof, breathable layered fabric.

15. The garment of claim 1, wherein said garment comprises a wetsuit.

16. The garment of claim 1, wherein said panels of a waterproof, breathable layered fabric are thinner than said panels of foam rubber material.

17. The garment of claim 1, wherein said panels of a waterproof, breathable layered fabric are thinner than said panels of foam rubber material.

18. The garment of claim 1, wherein said waterproof, breathable layered fabric comprises at least a first layer of synthetic knit fabric and at least a second layer of a waterproof breathable membrane of expanded polytetrafluoroethylene.

19. The garment of claim 1, wherein said waterproof, breathable layered fabric comprises an inner layer of synthetic knit fabric, a middle layer of a waterproof breathable membrane of thermoplastic polyurethane (TPU) film, and an outer layer of synthetic knit fabric.

20. The garment of claim 6, wherein said inner and outer layers of the synthetic knit fabric are treated with a durable, water-repellant chemical.

21. A method of manufacturing a garment suitable for water sports, comprising:

affixing one or more panels of foam rubber material having an inner and outer laminate of synthetic knit fabric and one or more layers of a waterproof, breathable layered fabric wherein said waterproof breathable layered fabric comprises at least a first layer of synthetic knit fabric and at least a second layer of a waterproof breathable membrane to form a form-fitting garment.

22. The method of claim 8, further comprising the step of treating said at least first layer of synthetic knit fabric with a durable, water-repellant chemical.

23. The method of claim 8, further comprising the step of positioning said one or more layers of a waterproof, breathable layered fabric in areas of said garment where greater flexibility and movement is desired.

24. The method of claim 8, further comprising the step of positioning said one or more layers of a waterproof, breathable layered fabric in areas of said garment where greater heat dissipation is desired.

25. A garment suitable for water sports, comprising:

at least one panel of waterproof, breathable layered fabric wherein said layered fabric comprises at least a first layer of synthetic knit fabric and at least a second layer of a waterproof breathable membrane.