U.S. patent application number 09/819888 was filed with the patent office on 2002-02-28 for apparel worn on, in or under the water and a manufacturing method thereof.
Invention is credited to Colvin, James M., Kania, Bruce G..
Application Number | 20020023283 09/819888 |
Document ID | / |
Family ID | 26888997 |
Filed Date | 2002-02-28 |
United States Patent
Application |
20020023283 |
Kind Code |
A1 |
Kania, Bruce G. ; et
al. |
February 28, 2002 |
Apparel worn on, in or under the water and a manufacturing method
thereof
Abstract
An article of apparel designed to be worn by divers and swimmers
which is formed by placing a prefabricated male mold inside a
prefabricated female mode. Then a polymeric material is injected
into a gap formed between the male mold placed inside the female
mold. Also included is a built-in air bladder system to change a
buoyancy of the diver and swimmer.
Inventors: |
Kania, Bruce G.; (Bozeman,
MT) ; Colvin, James M.; (Hilliard, OH) |
Correspondence
Address: |
OBLON SPIVAK MCCLELLAND MAIER & NEUSTADT PC
FOURTH FLOOR
1755 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202
US
|
Family ID: |
26888997 |
Appl. No.: |
09/819888 |
Filed: |
March 29, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60193448 |
Mar 31, 2000 |
|
|
|
Current U.S.
Class: |
2/2.15 ;
2/2.16 |
Current CPC
Class: |
A41D 13/0125 20130101;
B63C 11/04 20130101 |
Class at
Publication: |
2/2.15 ;
2/2.16 |
International
Class: |
B63C 011/04; B63C
011/28 |
Claims
1. An article of apparel, comprising: a pre-molded polymeric
material formed by injecting the polymeric material into a gap
formed between a male mold placed inside a female mold.
2. The apparel according to claim 1, further comprising: fabric on
at least one side of the apparel.
3. The apparel according to claim 1, wherein at least one of an
ankle and wrist portion of the article of apparel is skin
tight.
4. The apparel according to claim 1, further comprising a built-in
airtight bladder.
5. The apparel according to claim 1, wherein the airtight bladder
member includes at least one of 1) the polymeric material, and 2)
fabric.
6. The apparel according to claim 1, wherein the fabric comprises a
fabric material that precludes or minimizes bleed-through of the
polymeric material.
7. The apparel according to claim 1, wherein the polymeric material
comprises a material selected from the group of block copolymer
gels.
8. The apparel according to claim 1, wherein the polymeric material
includes at least one of SEBS, SEPS, and SEEPS.
9. The apparel according to claim 2, wherein the fabric is bulkable
yarns with non-woven sheet substrates.
10. The apparel according to claim 2, further comprising: polymer
or metal coatings on a surface of the fabric.
11. The apparel according to claim 1, wherein the polymeric
material includes a thermal-regulating additive.
12. The apparel according to claim 1, further comprising at least
one pre-molded contour feature configured to receive an external
device.
13. The apparel according to claim 12, wherein the external device
includes at least one of a diving computer, an air tank, and a
diving knife.
14. The apparel according to claim 12, wherein the pre-molded
contour feature comprises a ring shape.
15. The apparel according to claim 1, further comprising: stretch
seams at predetermined locations on the article of apparel.
16. The apparel according to claim 1, wherein the article of
apparel comprises a diving suit.
17. The apparel as shown in the figures, and described in the
specification.
Description
CROSS REFERENCE TO A RELATED APPLICATION
[0001] This application is related to co-pending Regular U.S.
application Ser. No. 09/473,139,filed on Dec. 28, 1999, and
co-pending Provisional U.S. Application Ser. No. 60/183,599, filed
on Feb. 18, 2000, both of which are incorporated herein by
reference.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0002] The present invention relates to an article of apparel
designed and adapted to be worn by a human in, on or under the
water, and preferably to a wet suit, diving suit, dry suit, waders,
shorts, shirts, vests, hoods, socks, etc., made of or comprising a
polymeric material such as a gelatinous elastomer composition, and
a manufacturing method thereof. The present invention also relates
to an antimicrobial silver-containing layer applied to the article
of apparel.
BACKGROUND OF THE INVENTION
[0003] Apparel worn by swimmers, divers, and outdoorsmen, e.g., wet
suits, dry suits, exposure suits, diving suits, vests, shorts, etc.
generally provide the wearer with a layer of protection against
cold temperatures. Such apparel also, however, affects the overall
buoyancy of the wearer. Importantly, commonly available diving
apparel undergoes significant changes in buoyancy with changes in
depth/pressure, making it difficult for the wearer to maintain a
depth other than specifically targeted for the appropriate weight
belt. That is, for example with classical neoprene wet suits and
dry suits commercially available, less and less weight is required
as the diver descends more deeply into the water to maintain
position, and the amount of excess weight on the diver can become
significant when the diver proceeds to a depth greater than
originally anticipated. For example, there is a reduction of
approximately 40% in the amount of weight required to remain
neutrally buoyant at a depth of 33 feet as compared with the
surface. At 66 feet of depth, the amount of ballast must be further
reduced by approximately 30%. Accordingly, there is rarely a time
when their weight belt, etc. provides them with neutral buoyancy.
Instead, most divers expend excess energy and air to keep at the
desired depth. Becoming incapacitated in a negatively buoyant state
is extremely dangerous, for obvious reasons. Rising too rapidly
also can have serious consequences, such as the bends.
[0004] Another problem with conventional exposure suits is that
foam cells contained within the insulating material collapse due to
an increase in pressure as the diver descends. Thus, the diver's
buoyancy is further affected. Also, as the foam cells in the
insulating material collapse, the insulating value of the suit
decreases. Further, the foam cells eventually take a permanent
compression set and the suit eventually loses much of its buoyancy
and insulation value.
[0005] To solve the problem of a diver's buoyancy changing at
different depths due to the collapse of foam cells, Jonnes et al
(U.S. Pat. No. 3,660,849) discloses a wet suit which includes an
insulating layer formed from separated compartments or packets
containing microbubbles. The microbubbles are pressure resistant
and are used to reduce the amount of change in buoyancy.
[0006] However, a problem with the Jonnes et al invention is that
the diver still experiences a positive buoyancy effect due to the
wet suit. That is, the Jonnes et al wet suit is not neutrally
buoyant. Thus, the diver is required to wear an excessive amount of
weight to descend. As discussed above, the weight required for the
diver to descend changes at different depths.
[0007] To offset the effect caused by the weight belt, external air
systems are used to increase or decrease the buoyancy of the diver.
However, this increases the amount of equipment the diver must
wear, and further adds to the overall weight of the diver, while
using up the limited air supply.
[0008] Another problem with the Jonnes et al invention is that it
describes the use of block copolymers including
polystyrene-polyisoprene-- polystyrene and
polystyrene-polybutadiene-polystyrene. Such compositions have
fairly low strength, can degrade with exposure to oxygen or ozone
or UV light, are excessively tacky, tend to suffer from excessive
"bleeding" (migration of oil to the surface or onto adjacent
materials), and are rather difficult to process.
[0009] In addition, conventional diving suits are generally
manufactured by forming several patterns of an insulating material,
such as a neoprene foam material and in the process mating a fabric
layer onto the outside surfaces. The patterns are then bonded
together, for example, by sewing or passing a hot knife between
patterns so as to fuse the patterns together. Joints between
packets are then covered with a flexible elastomeric tape, and then
typically sewn.
[0010] A problem with this conventional manufacturing method is
that the joints between bonded insulating packets tend to separate
after continued use. Thus, the durability of the wet suit is
reduced. Yet another problem with the conventional manufacturing
method is that an excessive amount of steps is required, thus
reducing production efficiency.
[0011] Another problem with conventional exposure suits is that
elbow areas, knee areas, and other body joints do not properly
stretch. That is, the conventional exposure suit generally contains
a neoprene foam material with a fabric layer on the outside
surfaces. The fabric layer covers the entire outer surface, thereby
inhibiting free motion of body joints, such as knee joints or elbow
joints. In addition, the neoprene foam material does not
sufficiently stretch. Thus, the user is inhibited from freely
moving when wearing a conventional exposure suit. Further, because
conventional exposure suits do not stretch appropriately, exposure
suits must be made in many different sizes to accommodate different
body shapes.
[0012] Yet another problem with conventional exposure suits is they
are generally not properly disinfected. That is, after a user wears
a suit, he or she generally washes the suit off with water.
However, this does not properly remove all of the bacterial
associated with conventional exposure suits. In addition, many
users rent diving suits, which have not been properly disinfected
after a previous user has used the suit. For example, a user who is
diving for extended periods of time may urinate within the diving
suit. Clearly, this creates bacterial problems for the next user to
wear the suit.
[0013] Still another problem with conventional exposure suits is
the extra equipment needed for diving, etc., is not integrated
within the diving suit. That is, any extra equipment is either
carried by hand or attached with a separate belt.
[0014] Still yet another problem with conventional exposure suits
is air becomes trapped in armpit areas, crotch areas, etc. This
effects a buoyancy of a diver, for example.
[0015] Consequently, there is a need for providing a novel diving
suit which is simple and inexpensive to manufacture, one which is
neutrally or near neutrally buoyant, one which is durable and
user-friendly, and one which includes a built-in air bladder
system. There is also a need for a seamless diving suit and a
manufacturing method thereof, such as a one piece diving suit,
which does not contain joints that easily separate. It is also
desirable that such a suit not alter in buoyancy or insulating
value at common depths, such as 120 ft. or less.
[0016] Further, there is a need for an exposure suit which is
effective against a broad spectrum of sepsis-causing bacteria and
odor-causing bacteria, an exposure suit which includes integrated
diving equipment, an exposure suit which includes stretch seams,
and an exposure suit having a mechanism to release trapped air.
SUMMARY OF THE INVENTION
[0017] Accordingly, one object of the present invention is to solve
the aforementioned problems.
[0018] Another object of the present invention is to provide an
article of apparel designed to be worn by a human above, in, on or
under the water, referred to herein as a "diving suit" which is
neutrally (or near neutrally) buoyant.
[0019] Yet another object of the present invention is to provide a
diving suit having a built-in air bladder system; ideally one which
allows a diver to alter attitude and depth.
[0020] Still another object of the present invention is to provide
a seamless diving suit or a diving suit with minimal seams.
[0021] Yet another object of the present invention is to provide a
simple, cost efficient method of manufacturing a neutrally buoyant,
or near neutral buoyant seamless diving suit having a built-in air
bladder system (buoyancy control device, BCD). This BCD can be
positioned anywhere within the diving suit.
[0022] Another object of the present invention is to provide a
diving suit which is effective against a broad spectrum of
microorganisms, such as sepsis-causing bacteria and odor-causing
bacteria.
[0023] Still another object of the present invention is to provide
a diving suit which includes integrated attachments and/or pockets
for integrating diving equipment into the diving suit.
[0024] Still another object of the present invention is to provide
a diving suit which includes stretch seams at elbow joints, knee
joints, etc, and a diving suit which appropriately stretches to
custom-fit a variety of body types.
[0025] These and other objects are accomplished by providing a
diving suit including a polymeric material. Also provided is a
method of manufacturing the diving suit including the steps of
placing a prefabricated male mold inside a prefabricated female
mode, and injecting the polymeric material into a gap formed
between the male mold placed inside the female mold. Alternately,
polymeric material can be placed in the female mold before
introduction of the male mold. The polymeric material may also
include an antimicrobial composition which is effective against a
broad spectrum of microorganisms. The diving suit may also include
stretch seams at appropriate locations to provide flexibility to
the user. Further, a silver layer may be applied to a skin-side of
the diving suit to combat a broad spectrum of microorganisms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] A more complete appreciation of the invention and many of
the attendant advantages thereof will be readily obtained as the
same becomes better understood by reference to the following
detailed description when considered in connection with the
accompanying drawings, wherein:
[0027] FIG. 1 is a perspective view of a male mold used to
manufacture the diving suit according to the present invention;
[0028] FIG. 2 is a perspective view of a female mold used to
manufacture the diving suit according to the present invention;
[0029] FIG. 3A is a vertical cross-section illustrating one example
of applying inner and outer fabrics to the diving suit, as well as
adjusting a size of the diving suit according to the present
invention;
[0030] FIG. 3B is a vertical cross-section illustrating another
example of applying inner and outer fabrics to the diving suit, as
well as adjusting the size of the diving suit according to the
present invention. Also illustrated is a method producing
skin-tight ankle and wrist portions, for example, of the diving
suit;
[0031] FIG. 4 illustrates an integral air bladder system of the
diving suit according to the present invention;
[0032] FIG. 5 is a perspective view of the front of the diving suit
according to the present invention;
[0033] FIG. 6 is a perspective view of the back of the diving suit
according to the present invention;
[0034] FIG. 7A is a perspective view of a tank harness for the
diving suit according to the present invention;
[0035] FIG. 7B is a perspective view of the tank harness shown in
FIG. 7A attached to the diving suit according to the present
invention;
[0036] FIG. 8 is a perspective view of a seamless cuff of the
diving suit according to the present invention;
[0037] FIG. 9 is a perspective view of an attachment mechanism for
attaching the tank harness shown in FIG. 7A to the diving suit;
[0038] FIG. 10 is a perspective view of padded and flexible areas
of the diving suit according to the present invention;
[0039] FIG. 11 is a perspective view of surface mounted and
embedded attachment mechanisms of the diving suit according to the
present invention;
[0040] FIG. 12 is a perspective view of a seamless wrist portion of
the diving suit according to the present invention;
[0041] FIG. 13 is a perspective view of an air-pocket release
system for the diving suit according to the present invention;
[0042] FIG. 14 is a graph comparing a neoprene diving suit with a
diving suit according to the present invention;
[0043] FIGS. 15A-15C are cross-sectional views of multilayer
compositions which may be applied to the diving suit according to
the present invention; and
[0044] FIGS. 16A and 16B show additional multilayer compositions
which may be applied to the diving suit according to the present
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] Throughout the description of the present invention the term
"diving suit" will be used. However, it is to be understood that
the present invention relates to any type of article of apparel
worn by swimmers and divers (e.g., wet suit, dry suit, etc.),
fishermen (e.g., waders, overalls, socks, gloves, hoods, etc.),
boaters, sailors, lifeguards, longshoremen, captains, mates,
etc.
[0046] Referring now to the drawings, wherein like reference
numerals designate identical or corresponding parts throughout the
several views, FIG. 1 illustrates a male mold 202 which is to be
inserted into a female mold 210 (shown in FIG. 2) to manufacture a
diving suit according to the present invention. The male mold 202
may be a sand cast or fabricated aluminum mold, and is machined to
dimensions of the female mold 210 minus a desired wet suit
thickness. That is, a gap corresponding to the desired wet suit
thickness is formed between the male mold 202 and female mold 210.
Also illustrated is an arm portion 205 and a leg portion 207 of the
male mold 202. A trimline 204, indicated by a dotted line,
illustrates a portion of the diving suit to be trimmed and
accommodated with a zipper, for example. Also illustrated is an
inner fabric 206 covering a portion of the male mold 202.
[0047] FIG. 2 illustrates the female mold 210 used to produce the
diving suit according to the present invention. The female mold 210
may be a sand cast or fabricated aluminum mold, similar in
composition to the male mold 202. Preferably, the female mold 210
includes two portions 217 and 218 secured with rivets 219. The
female mold 210 includes the two portions 217 and 218 to facilitate
machining the female mold 210 to the desired thickness of the
diving suit. Also illustrated is an arm portion 213 and leg portion
215 corresponding to the arm portion 205 and leg portion 207 of the
male mold 202, as well as an outer fabric 216 covering an inner
surface of the female mold 210.
[0048] Prior to inserting the male mold 202 into the female mold
210, the inner fabric 206 is pulled over the male mold 202, and the
outer fabric 216 is placed inside the female mold 210. The inner
fabric 206 and outer fabric 216 preferably include an elastomeric
material which easily stretches. In addition, it should be noted
that the diving suit may be manufactured without the inner fabric
206 and the outer fabric 216 or with only one of the inner fabric
206 and the outer fabric 216.
[0049] Then, the male mold 202 having the inner fabric 206 on an
outer surface thereof is inserted into the female mold 210 having
the outer fabric 216 on an inner surface thereof. Thus, a gap 230
(as shown in FIGS. 3A and 3B) is formed between the inner fabric
206 and the outer fabric 216. A polymeric material may then be
injected into the gap 230 to form a seamless diving suit. In
another embodiment the polymeric material can be added to the
female mold and the male mold can be inserted.
[0050] Turning now to FIGS. 3A and 3B. FIG. 3A illustrates one
example of applying the inner fabric 206 and the outer fabric 216
to the diving suit, as well as lengthening an arm portion 205, 213
and/or leg portion 207, 215 of the diving suit.
[0051] To apply the inner fabric 206, an inner fabric molding 222
is disposed within the arm portion 205 and/or leg portion 207 of
the male mold 202, thus securing the inner fabric 206 to an outer
surface of the male mold 202. To apply the outer fabric 216, an
outer fabric molding 224 is disposed within the arm portion 213
and/or leg portion 215 of the female mold 212, thus securing the
outer fabric 216 to an inner surface of the female mold 212.
Therefore, using the inner fabric molding 222 and the outer fabric
molding 224, the inner fabric 206 and the outer fabric 216 are
secured, and form the gap 230. In addition, the inner fabric 206
and the outer fabric 216 are preferably applied prior to injecting
the polymeric material. However, the inner fabric 206 and the outer
fabric 216 may be applied to the diving suit after the molding
process is completed (i.e. by glueing or sewing the fabrics to the
molded polymeric material).
[0052] To lengthen the arm portion 205, 213 and/or leg portion 207,
215 of the diving suit, a length adjuster 220 may be inserted in
the female mold 210. A thickness of the inner fabric molding 222
and the outer fabric molding 224 may also be used to adjust the arm
portion 205, 213 and/or leg portion 207, 215 of the diving
suit.
[0053] FIG. 3B illustrates another example of applying the inner
fabric 206 and the outer fabric 216, as well as shortening a length
of the arm portion 205, 213 and/or leg portion 207, 215 of the
diving suit according to the present invention. Also illustrated is
one example of forming skin tight wrist and ankle portions, for
example, of the diving suit (i.e., forming a dry suit).
[0054] The inner fabric 206 and the outer fabric 216 in FIG. 3B are
applied to the diving suit in a similar manner to that shown in
FIG. 3A. That is, the inner fabric molding 222 is disposed within
the arm portion 205 and/or leg portion 207 of the male mold 202,
thus securing the inner fabric 206 to the male mold 202. To apply
the outer fabric 216, an alternative outer fabric molding 232
(which is thicker than the outer fabric molding 224 shown in FIG.
3A) is also disposed within the arm portion 213 and/or leg portion
215 of the female mold 212. Because the alternative outer fabric
molding 232 is thicker than the outer fabric molding 224, the
length adjuster 220 does not need to be included. This results in
shortening a length of the arm portion 205, 213 and/or leg portion
207, 215 of the diving suit.
[0055] Thus, using the appropriate combination and placement of the
inner fabric molding 222, outer fabric molding 224, alternative
outer fabric molding 232, limb adjuster 220, etc., the inner fabric
206 and the outer fabric 216 can be applied to the diving suit.
Further, a length of the arm portion 205, 213 and/or leg portion
207, 215 is easily adjusted.
[0056] FIG. 3B also illustrates one example of producing skin-tight
ankle and wrist portions of the diving suit. That is, the diving
suit is sealed at the wrist and ankle portions, and thus a dry suit
is produced. A neck portion, waist portion, etc. of the diving suit
may also be sealed in a similar manner. This is accomplished by
providing a thickened area. See e.g., area 234 in FIG. 3B.
Therefore, after the polymeric material is injected, the diving
suit will seal tightly against the diver's skin at the wrist and
ankle portions. The polymeric materials useful herein mimic the
skin and provide an effective water barrier.
[0057] As discussed above, FIGS. 3A and 3B illustrate a method of
adjusting a length of the arm portions 205, 213 and/or leg portions
207, 215 of the diving suit. However, a chest portion, neck
portion, waist portion, etc. (not shown) may also be adjusted using
a similar method. Further, the size and shape of the components
(e.g., inner fabric molding 222, etc.) are not limited to that
shown in FIGS. 3A and 3B. In addition, the components used to apply
the inner fabric 206 and the outer fabric 216 and to change the
size of the diving suit should have dimensions (weight, thickness,
etc.) set to achieve the desired result. An important feature of
the invention is that the inner fabric 206 and the outer fabric 216
are easily applied, and that the size of the diving suit may be
adjusted using the prefabricate male mold 202 and female mold 210.
That is, according to the present invention, it is not necessary to
use different molds to manufacture different sizes of diving
suits.
[0058] In addition, the inner and outer fabrics may be applied only
at predetermined areas of the wet suit. Thus, a stretch seam may be
formed at predetermined locations on the wet suit. In more detail,
the Polymeric material according to the present invention is
extremely elastic and may stretch up to 2500% of its original
shape. The inner and outer fabrics tend to reduce the stretchable
feature of Polymeric. Therefore, by allowing certain locations of
the wet suit to include inner and outer fabrics and other certain
areas to not have inner and outer fabrics, stretch seams may be
formed at the locations where the inner and outer fabrics do not
exist.
[0059] For example, a neck portion of the diving suit may be
configured to not have an inner or outer fabric. Thus, this neck
portion will be extremely elastic and function as one size that
"fits all." Obviously, other portions of the diving suit may be
configured to not have inner and outer fabric, such as the waist
area of the diving suit. In addition, only one fabric (i.e., the
inner or outer fabric) may be applied to certain areas of the wet
suit. Further, an elastic inner and outer skin may also be used at
certain areas to form stretch seams. The elastic skin is preferably
elastic enough to not significantly reduce the stretchability of
the polymer used. For example, a stretchable fabric may be one sold
under the trademark LYCRA. Rubber based fabrics may also be used.
Thus, by using a very stretchable fabric, a stretch seam may be
formed and the polymer material is protected from UV light via the
stretchable fabric.
[0060] FIG. 4 shows a built-in air bladder system 240 according to
the present invention. The air bladder system 240 includes a valve
246 to regulate an ingress/egress of air to an airtight bladder
member 256. The valve 246 may be threadedly engaged or glued, for
example, into the diving suit after the molding process. The
airtight bladder member 256 includes a bladder fabric 248 glued or
sewn, for example, to the inner fabric 206 or outer fabric.
[0061] Further, fitting members 252 and 253 are disposed between
the inner fabric 206 and outer fabric 216. The fitting members 252
and 253 may be sewn or glued, for example, to the inner fabric 206
and the outer fabric 216 prior to injecting the Polymeric material.
As shown, an entry point 254 is formed in the diving suit between
the fitting members 252 and 253 and is configured to receive the
bladder valve 246.
[0062] A description of the bladder valve 246 used to regulate the
ingress/egress of air to the airtight bladder member 256 will now
be given. However, it is to be understood that other types of
valves may be used in the diving suit according to the present
invention.
[0063] The bladder valve 246 includes an inlet 242, an outlet 244
and an extending member 255. The inlet 242 receives air from an
external air source to fill the airtight bladder member 256. Then,
the airtight bladder member 256 would bulge the diving suit
outwards and a buoyancy of the diver would increase. The extending
member 255 of the bladder value 46 may contain threads so that the
bladder valve 246 may be threadedly engaged into the diving suit.
Alternatively, the extending member 255 may be glued into the
diving suit. Air is released from the airtight bladder member 256
through the outlet 244 by pressing a release knob 250. The release
knob 250 includes a first member 247, a spring 248 and a second
member 249, as shown in FIG. 4. When the release knob 250 is in a
non-activated state, air is maintained within the airtight bladder
member 256.
[0064] The air bladder system 240 is an integral part of the diving
suit according to the present invention. Thus, the diver is not
required to carry excess equipment. However, the diving suit
according to the present invention may be manufactured without the
air bladder system 240. Further, the air bladder system may be
positioned at any desired portion of the diving suit. For example,
the air bladder system may be positioned at a side portion of the
diver between the armpit and hip. Also, multiple airtight members
may be used. For example, an airtight bladder member may be placed
on both sides of the diver between the armpit and hip. Both
airtight bladder members may be activated by a single valve, or
each airtight bladder member may have its own valve. The bladder
valve placement generally is restricted to placement of the
airtight member. However, the valve may be a hand held mechanism
connected to the airtight bladder member via appropriate
tubing.
[0065] When the appropriate components (e.g., fabric moldings,
length adjuster, etc.) are set in their desired positions and the
male mold is inserted, the Polymeric material may be injected to
form the diving suit. After the Polymeric material has cooled, the
female mold is released from the male mold 202, or vice versa.
Thus, the diving suit having the inner fabric 206 and the outer
fabric 216 is produced. Then, excess material may be trimmed from
the diving suit. That is, the diving suit may be trimmed along the
trimline 204 to accommodate a zipper, for example.
[0066] The diving suit may also include a silver layer on a
skin-surface thereof to combat bacteria from forming. This feature
will be discussed in more detail later.
[0067] In addition to the manufacturing methods described above,
the present invention diving suit can also be manufactured by
sewing together flat sheets of polymeric material or by gluing such
flat sheets together. In addition, the polymeric material in sheet
or piece form can be joined to manufacture the invention diving
suit by the traditional hot knife method, or a combination of these
methods.
[0068] The polymeric material used in making the present invention
diving suit can be any useful polymeric material known in the art.
The polymeric material preferably is not foamed and preferably
contains no microbubbles, hollow glass spheres, etc., and
preferably is not a solid/polymer composite material in which the
solid and polymer have different densities, buoyancies, etc.
Rather, the polymeric material used herein is preferably a single
polymeric composition which, itself, may comprise one or more
polymers and one or more solvents, additives, etc. Preferably, the
polymeric material is homogeneous at room temperature.
[0069] The polymeric materials useful herein include polyesters,
polyethers, polycarbonates, polyamides, polyurethanes, silicones,
rubbers (natural and synthetic), etc. The polymers described in
U.S. Pat. Nos. 5,830,237 and 5,603,122 (both incorporated herein by
reference), are useful herein. Particularly useful are those gels
described in these two patents having the described Shore A
durometer characteristic and/or a Shore 00 durometer of from
1-100.
[0070] A particularly preferred class of polymeric materials useful
herein are polymeric gels formed of block copolymers and extending
oils such as mineral oil, paraffin oil, etc. Such block copolymers
include diblock, triblock, etc. copolymers and specifically include
SEP, SEBS, SIS, SEEPS, SEPS, etc. Useful polymers and gels are also
described in the following U.S. patents, all incorporated herein by
reference: U.S. Pat Nos. 5,710,206, 5,655,947, 5,624,294,
5,633,286, 5,475,890. 5,508,334, 5,336,708, 5,334,646, 5,324,222,
5,262,468, 5,239,723, 5,153,254, 5,760,117, 4,618,213, 4,369,284,
5,441,560, 4,680,233, 4,942,270, 5,177,143, 4,716,183, 4,852,646,
5,149,736, 5,104,930, 5,442,004, 5,541,250, 5,618,882, and
5,313,019. Preferably, the gel comprises SEBS and oil. Examples of
SEBS are S8004, S8006, and S8007 (all manufactured by Kuraray Co.).
More preferably, the gel includes SEPS and oil. Examples of SEPS
are S2002, S2005, S2006, S2007, S2043, S2063 and S2104 (all
manufactured by Kuraray Co.). Most preferably, the gel includes
SEEPS and oil. Examples of SEEPS are S4033, S4044, S4055, S4077,
and S4099 (all manufactured by Kuraray Co.) The gel may include any
combination of SEBS, SEPS, and SEEPS. All of these compositions can
be made to be stronger, more stable, less tacky, exhibit better oil
retention, and/or easier processing than the compositions described
in the Jonnes patent. In addition, the gel and/or fabric can
include a thermal-regulating additive for absorbing and/or
releasing heat. An example of a thermal-regulating additive is
microcapsules filled with phase change material (e.g., paraffinic
hydrocarbons) or plastic crystals with appropriate thermal storage
properties, such as one sold under the trademark THERMASORB from
Frisby Technologies. Such thermal-regulating additives can cool the
body when it is hot and heat the body when it is cold.
[0071] The mineral oil may be present in from 0-95% by weight based
on total gel weight, more preferably 70-90% by weight, but also
including all of any positive amount including 5, 10, 15, 20, 25,
30, 35, 40, 45, 55, 60, 65, 70, 75, 80, 85, and 90% by weight and
all values and ranges in between all these listed values. The gel
preferably has a durometer (Shore A) of approximately 0-20 and
preferably a durometer that matches or approximates (within about
.+-.100%) that of human skin. Preferably, the oil is present on an
equal weight basis, or in a weight ratio of 1/4, with regard to the
amount of polymeric material present. More preferably, the gel
durometer is from 1-100 Shore 00, most preferably 5-35. The
polymeric material present is preferably a styrene
isoprene/butadiene block copolymer or a
styrene-ethylene/butadiene-styrene block copolymer. Examples of
suitable polymeric materials include C-Flex 1970-W5 (R70-339-000),
C-Flex 1960-W5 (both manufactured by Consolidated Polymer
Technologies, Largo, Fla., U.S.A.), Kraton G1654 (manufactured by
Shell Chemical Co.), Septon 4033, 4044, 4055, 4077, and 4099
(manufactured by Kuraray), DYNAFLEX G6703, G6708, G6713 and G2706
(manufactured by GLS Corp.). For the C-Flex materials a
particularly preferred ratio is 1 part oil per 2 parts C-Flex
material.
[0072] Preferred ratios of polymer to mineral oil are about 1/1-4/1
using C-Flex 1970-W5 or 1960-W5, one part Kraton G1654: 2.75 parts
mineral oil, and 14 parts Kraton G1654: 15 parts C-Flex R70-306 (or
R70-190 or R70-251 or any mixture thereof): 40 parts mineral oil.
The C-Flex R70-339-000, R70-306, -190 and -251 materials are also
preferred herein and are products of Consolidated Polymer
Technologies. They are blends of S-EB-S block copolymer or SIB
block copolymer with mineral oil. 10 parts Kraton G1654 and 11
parts C-Flex R70-306 and 27 parts Duoprime 70 oil is also
preferred. A highly preferred gel is 62.5% C-Flex 1970-W5, and
37.5% Carnation mineral oil. 55-65% C-Flex 1970-W5 and 45-35% oil
is also preferred. Also preferred is a composition of 26-65 wt %
styrene-isoprene/butadiene block copolymer and 35-74% by weight
mineral oil. Here, 27, 28, 29, 30, 35, 40, 45, 50 and 55 wt % SIB
can be used with oil ranging from 73, 72, 71, 70, 65, 60, 55, 50
and 45 wt %. All %'s are percent by weight unless otherwise
indicated.
[0073] The preferred polymers useful herein and listed above
(C-Flex, Kraton, Septon, and DNYAFLEX materials), in addition to
being styrene-isoprene/butadiene or
styreneethylene/butadiene-styrene block copolymers (mixed with
mineral oil in the case of at least the C-Flex 1970-W5,
R70-339-000, R70-306, -190 and -251 materials) also include
styrene/butadiene-styrene and any thermoplastic elastomer having
the Shore A and/or Shore 00 characteristics listed above and
capable of being blended with mineral oil. Mixtures of all
mentioned polymers may be used. The mineral oil used herein is
preferably purified mineral oil and is preferably USP grade.
Carnation mineral oil is preferred. The optimum ratios of polymer
to oil are best determined by a modest degree of experimentation in
view of the particular selection of these materials and the
intended application.
[0074] The material used to make the diving suit may also be
urethane or any other material that is neutrally buoyant (or near
neutrally buoyant).
[0075] In a preferred embodiment the polymeric material of the
invention is coated on one or both sides thereof with fabric, such
as spandex, nylon, etc. It is preferred that the fabric is a
stretch fabric so that an intimate fit can be achieved with
standard sized suits. Fabrics described in U.S. Pat. Nos. 5,830,237
and 5,603,122 are useful herein, and both of these patents are
incorporated by reference. Preferred fabrics have a weave, etc.
that does not allow, or minimizes bleed-through of the polymeric
material during manufacture. Also preferred fabrics have good bond
strength with the gel and have good abrasion resistance. One
example of a fabric which has appropriate stretch, bleed-through,
bond strength, and abrasion resistance is "fiber-on-end fabrics"
(bulkable yarns with non-woven sheet substrates), such as one sold
under the trademark WEARFORCE from Xymid, LLC. Such coating can be
accomplished by lining the molds described in the Figures with
fabric prior to addition of polymeric material, or by pouring
polymeric material on fabric and then assembling the invention
diving suit, for example. The polymeric material is preferably
liquid (pourable) due to temperature, state of crosslinking etc. In
addition, the invention suit can be assembled from the "flat sheet"
manufactured and sold by the Ohio Willow Wood Company.
[0076] Polymer or metal coatings can be used to improve properties
of apparel related to insulation, friction, cleanability, bonding,
suspension, water resistance, wear, etc. Examples of these coatings
includes ones sold under the trademarks SUPER COMPOSITE SKIN and
TITANIUM ALPHA provided by Yamamoto Corporation and PMC from
Smooth-On. Gloves, boots, waders, etc. that are made from the
invention material can have a non-slip material incorporated on any
surface that may benefit from additional friction. For example, gum
rubber could be directly incorporated into the bottom surface of
boots to improve traction. The invention diving suit preferably
provides a human wearer with comfort and fit, and is neutrally
buoyant or near neutrally buoyant. The neutral buoyancy of a
material according to the invention can be determined by immersing
the material in water and determining its rise or fall. In the most
preferred embodiment herein the invention diving suit is neutrally
buoyant or near neutrally buoyant at the surface, at a depth of 33
feet, and at a depth of 66 feet. Neutral buoyancy occurs when the
weight of the diving suit equals the weight of an equal volume (to
the suit) of water. Near neutral buoyancy is within 30, 25, 20, 15,
10, 5, 4, 3, 2, 1 or less than 1% of this weight, including all
numbers and ranges between these numbers. Another preferred
buoyancy for the invention diving suit is that which is equal to
human buoyancy.
[0077] In another preferred embodiment, the present invention
diving suit has a particular density (weight/area) that provides
neutral or near neutral buoyancy. This density may range from 1-48
oz. per 9 square inches of diving suit material, including 1, 2, 3,
4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 5, 16, 17, 18, 19, 20, 21,
22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38,
39,40, 41, 42, 43, 44, 45, 46, 47, 48 oz. including all numbers
between these numbers, all subranges between these numbers, and all
ranges between these ranges. It is within the skill of the ordinary
artisan to determine the proper weight, density, etc. of the diving
suit material to provide human, neutral or near neutral buoyancy in
view of the present disclosure.
[0078] In yet another preferred embodiment of the present
invention, the diving suit includes specially molded contour
features. For example, the diving suit may be molded to include a
compartment that lies between the fabric layers of the diving suit
and which is configured to form fit around, for instance, a diving
computer, covering all but the readout display while encasing and
protecting the computer. Similar contour features may accommodate
an air tank attachment and stabilize the air tank directly into the
diving suit. Likewise, the diving suit may be molded to include
appropriate diving clips and D-rings, and a compartment to hold a
knife, etc. For example, a contoured ring (i.e., molded ring) with
built in snap fasteners on a wrist portion of the diving suit may
be included in the diving suit to allow a standardized dive
computer to be attached to the diving suit. The diving suit of the
present invention may also be molded to be thicker on a side
corresponding with an appropriate fabric stretch direction to
achieve limited water ingress at apertures of the diving suit.
[0079] In still another preferred embodiment of the present
invention, the diving suit may include an antimicrobial composition
(e.g., silver layer) on a skin surface thereof. This feature will
be discussed in more detail later with reference to FIGS. 15-16.
Turning now to FIGS. 5-14.
[0080] FIG. 5 is a front perspective view of the diving suit
according to the present invention. As shown, the diving suit 2
includes a high stretch form-fit collar 4, padded shoulder areas 6,
shoulder stretch seams 8, a kangaroo front pocket 10, auxiliary
hard mounts 12, an internal form-fitting belt 14, and integral
pockets 16. The diving suit 2 also includes a buoyancy control (BC)
hook-up 18, an automatic buoyancy control (BC) release valve 20, a
chest buoyancy control (BC) bladder 22, an LED chest light 24, a
high power, low power and buoyancy control (BC) emergency fill
lines 26, a thin wrinkle-free elbow joint area 28, a dive computer
30, an emergency buoyancy control (BC) fill valve 32, a buoyancy
control (BC) fill and purge control pad 34, a thigh stretch seam
36, a segmented knee guard 38, a knee stretch seam 40, and an
anklet sealed cuff 42.
[0081] The high stretch form-fit collar 4 shown in FIG. 5 does not
have fabric material on the outer or inner surfaces thereof. Thus,
because the polymeric material is super-flexible, the high stretch
form-fit collar 4 custom fits any user. That is, a single collar
size will "fit all" users. Alternatively, the collar 4 may include
a very stretchable fabric on the outer and/or inner surfaces, such
as LYCRA.
[0082] The shoulder pads 6 pad, for example, an air tank harness
attached to the diving suit. The shoulder pads 6 may be formed of
additional polymeric material or may be filled with water. That is,
the material used to provide the shoulder pads 6 are preferably
neutrally buoyant. Alternatively, the shoulder pads may be filled
with air from the buoyancy control system according to the present
invention. That is, the shoulder pads 6 may function similar to the
chest BC bladder 22.
[0083] The shoulder stretch seams 8, thin wrinkle-free joint area
28, thigh stretch seam 36, and knee stretch seam 48 are similar to
the high-stretch form-fit collar 4. That is, these additional
high-stretch areas are formed to not include fabric on the surfaces
thereof, so that they have a superb flexibility in the respective
areas (e.g., shoulder area, knee area, etc.). Alternatively, a very
stretchable fabric may be included in these areas. The stretchable
fabric should be sufficiently stretchable such that the flexible
areas provide a custom fit and do not significantly inhibit the
super flexibility characteristics of the polymer material.
[0084] The kangaroo front pocket 10 is integrally formed in the
diving suit and may be used to store, for example, diving
equipment. The pocket 10 may be formed between two outer fabrics or
between a single layer of fabric and the polymeric material, for
example.
[0085] The auxiliary hard mounts 12 are also integrally formed into
the diving suit and are used to attach, for example, a diving knife
or other necessary diving equipment. For example, a diving knife
may have a female socket connectable to a male auxiliary hard mount
12 by, for example, a ratchet mechanism in which the diving knife
may be ratcheted onto the auxiliary hard mount 12. Thus, the user
may easily attach/detach the diving knife to the auxiliary hard
mount 12, which is integrally formed into the diving suit. The
auxiliary hard mount 12 may be formed as part of the internal
form-fitting belt 14. That is, to support the attachment of diving
equipment to the auxiliary hard mount 12, a rigid structure (such
as the internal form-fitting belt) is required. Other mechanisms
may be used so that the auxiliary hard mount 12 is securely mounted
to the diving suit 2 so as to support tools attached thereto. The
internal form-fitting belt 14 is also used to secure a tank harness
(this feature will be described in more detail later).
[0086] The pockets 16 are also integrally formed into the diving
suit and may be used to store appropriate diving equipment, etc.
The pockets 16 may be formed in a similar fashion as the kangaroo
front pocket 10 (i.e., between two layers of fabrics, etc.). The BC
hook-up 18 is used to attach an air hose from an air tank. That is,
the air hose runs from the air tank to the BC hook-up 18. The chest
BC bladder 22 is filled with air from the air tank when the BC fill
and purge control pad 34 is activated. That is, the BC control pad
34 includes a fill button and a purge button. If the diver
activates the fill button, the BC bladder 22 is filled with air
from the tank. If the diver presses the purge button, air in the
chest bladder 22 is released. Thus, the user may change his or her
buoyancy using the integral buoyancy control system.
[0087] The air passages from the BC hook-up 18 may be formed using
air hoses, layers of fabric, or other appropriate methods so that
air is transferred from the air tank to the chest BC bladder 22.
Further, the BC control pad 34, fill and purge air into and out of
the chest BC bladder 22 via a mechanical and/or hydraulic mechanism
to the transfer air from the air tank to the chest BC bladder 22 or
from the chest BC bladder 22 to the outside.
[0088] The LED chest light 24 is also integrally formed in the
diving suit and provides illumination for diving expeditions, for
example. This is particularly advantageous because the diver does
not require a hand-held diving light. The chest light 24 may be
integrally formed in between an outer fabric in the polymeric
material, for example. The BC emergency fill line 26 is used to
fill the chest BC bladder 22, in an emergency or when the diver
does not have the air tank on. This can be accomplished by the
diver blowing air into the BC fill valve 32, which enters the chest
BC bladder 22 via the BC emergency fill line 26. The HP, LP and BC
lines 26 are three separate lines. The HP line is used to determine
the high pressure of the air tank and display this value on the
dive computer 2. The LP line is used for the other equipment, such
as the line in which the diver breathes from. The BC emergency fill
line is used to fill the chest BC bladder 22 as discussed above.
The dive computer 30 may also be integrally formed in the diving
suit and thus the user does not need to carry this computer as a
separate device.
[0089] The segmented knee guard 38 provides protection to the knee
without restricting the superb flexibility characteristic of the
knee stretch seam 40. The anklet seal cuff 42 form fits the user so
that water does not enter into the wet suit. That is, the sealed
cuff is formed to function as a dry suit (as previously discussed
with reference to FIG. 3B). Thus, water is prevented from entering
the anklet portion (and neck, wrist portions, etc.).
[0090] FIG. 6 is a perspective view showing a back portion of the
diving suit 2 according to the present invention. As shown, the
diving suit 2 includes a zipper 44, high stretch elbow guards 46,
the BC control pad 34, wrinkle-free knee joint area 48, back BC
bladder 50, tank harness mount 52, sealed wrist cuffs 54 and calf
stretch seam 56.
[0091] The zipper 44 is used to zip the diving suit together. The
zipper 44 may also be integrally molded into the diving suit or
glued, sewn, etc. Other closing mechanisms may be used, such as a
ziplock, shoestring, etc. The high stretch elbow guard 46 may
include a padded area having a thicker polymeric material so as to
provide padding for the elbows and may also be formed so as not to
have fabric on either surface thereof. Thus, the user is provided
with sufficient padding, while at the same time having an extremely
flexible elbow area. The elbow guard 46 may also include
stretchable fabric on either surface thereof.
[0092] The BC control pad 34 is used to control the air
intake/outtake of the back BC bladder 50 and the chest BC bladder
22 as discussed above. In addition, the tank harness 52 is
integrally molded into the diving suit 2 and is used to securely
fasten an air tank. This feature is discussed in more detail later.
The sealed wrist cuff 54 is similar the sealed anklet cuff 42 shown
in FIG. 5 and will also be discussed in more detail later. The calf
stretch seam 56 is similar to the thigh stretch seam 36 shown in
FIG. 5 and provides the diver with a custom fit. For example, the
calf stretch seam 56 stretches for a diver with large calves and
reduces in size for a user with smaller calves. Thus, a single
diving suit 2 may comfortably custom fit either diver.
[0093] The thin wrinkle-free knee area 48, as well as the
wrinkle-free elbow area 28 are similar to the stretch seams 36 and
56, but include a larger area in which the polymeric material does
not have a fabric on a surface thereof (or has a very stretchable
fabric) so that these areas are wrinkle-free. That is, the diver
may easily bend, for example, his or her elbow without the diving
suit crimping or wrinkling (and thereby inhibiting the free
movement of the divers's elbow, etc.)
[0094] FIG. 7A is a perspective view of a tank harness 57 for the
diving suit according to the present invention. As shown, the tank
harness 57 includes a donning handle 58 for carrying/storing the
air tank, a donning webbing 60, a harness release mechanism 62, a
harness 64, a tank strap 66, and a front clip 68. The donning
webbing 60 merges with the tank strap 66 at a front side of the
diving suit and attaches to the harness 64 at a back side thereof.
The donning webbing 60 provides additional support for the tank
harness 57. The harness release mechanism 62 is used to remove the
air tank and tank harness 57. That is, the diver may simply pull on
the harness release 62 to remove the air tank and tank harness. The
harness 64 is preferably a plastic material (neutrally buoyant) and
is situated on the user as shown in FIG. 7B, for example. The tank
strap 66 includes the front clip 68 and attaches to the internal
belt 14 shown in FIG. 5. Thus, with the tank harness 57 according
to the present invention, which is lightweight and flexible, the
user may easily attach and detach the air tank. FIG. 7B illustrates
the tank harness 57 attached to a diver wearing the diving suit
2.
[0095] FIG. 8 is a perspective view of a seamless cuff of the
diving suit according to the present invention, such as the anklet
cuff 42 shown in FIG. 5 or the wrist cuff 54 shown in FIG. 6. As
shown, the sealed cuffs 42, 54 include a variable thickness core 72
including the polymeric material. The anklet or wrist portion
includes a seamless portion 70 (i.e., there are no seams), and the
variable thickness core 72. Also shown is an outer fabric 76 and an
inner fabric 78. However, the sealed cuff 42, 54 does not include
the inner fabric 78. Thus, the sealed cuff may customly fit any
user. Alternatively, a fabric which is very stretchable may also be
used in the sealed cuff 42, 54. Further, the sealed cuffs 42, 54
prevent water from entering the diving suit.
[0096] FIG. 9 is a perspective view of an attachment mechanism for
attaching the tank harness 57 shown in FIG. 7A to the diving suit.
As shown, the harness 64 includes a stainless steel spring loaded
clip 84 which spring loads to an external button 88. The external
button 88 is embedded into the belt 14. FIG. 9 also illustrates the
spring loaded clip 84 and external button 90 as an exploded view.
Thus, the user may easily attach and detach the harness 64 to the
belt 14.
[0097] FIG. 10 is a perspective view of the shoulder pads 6 and
shoulder stretch seams 8, as well as a cross-sectional view of the
same. The shoulder pad 6 includes a multi-thickness molding 98
including a core polymeric material 110. Also shown are the
shoulder stretch seams 8, which include the core polymeric material
without fabrics on surfaces thereof. However, as shown, areas
outside the shoulder stretch seams 8 include an outer fabric 106.
Also shown is an inner fabric stretch area 114 corresponding to the
stretch seams 8 and which does not include an inner fabric. Thus, a
maximum elongation area occurs at the stretch seams 8, and a medium
elongation area occurs outside the stretch area 114. The maximum
elongation at the shoulder stretch seam 8 may be elongated up to
900%, for example. A low elongation area 104 comprises the core
material with fabric on both sides thereof.
[0098] FIG. 11 is a perspective view of the external button 88 used
for attaching the harness 64 to the belt 14. The belt 14 includes
polymeric material 116, a reinforcement portion 118, a urethane
embedded attachment 120, and webbing 122. The external button 88
may be surface mounted, such as the surface mounted attachment
button 124, or embedded such as the embedded attachment button 126.
The embedded attachment button 126 includes a layer of urethane or
other appropriate material covering the embedded flange portion 90
(see FIG. 9) of the external button 88. The webbing 122 provides
additional support to the external button 88. That is, because the
air tank is heavy, the harness will tend to pull on the external
button 88. Therefore, the webbing 122 may be used to further secure
the external button 88 to the belt 14.
[0099] FIG. 12 is a perspective view of a seamless wrist portion of
the diving suit according to the present invention. As shown, the
wrist portion includes a seamless portion 130 without an outer
fabric and without a seam. Thus, the wrist portion may be easily
moveable and will snugly fit a variety of different wrist sizes.
Also shown is a half finger style hand portion 132 of the diving
suit which may include optional webbing 134. The seamless wrist
portion is produced according to the method of the present
invention (as previously discussed).
[0100] FIG. 13 is a perspective view of an air-pocket release
system for the diving suit according to the present invention. As
shown, air pockets 140 develop in areas such as the armpit and
crotch of the diver. This changes the buoyancy of the diver.
Accordingly, the present invention provides a mechanism for
releasing these air pockets. The air-pocket release system includes
access/vent tubes 142 which are linked to the air pockets 140. The
diver may release the air within the air pockets 140 by activating
a built-in pump with a one way valve 144 which is contained in the
belt 14. That is, the user may turn a handle of the built-in pump
144 to evacuate air trapped in the air pockets 140. Also shown are
dry suit aperture closures 146. These are similar to the sealed
cuff wrist and anklet portions previously described. The access
tubes 142 may be flexible and collapsible. Other air passages may
also be used (such as air passages between two layers of fabric).
The air passages may also be on the external side of the suit or be
between the suit and diver's skin.
[0101] FIG. 14 illustrates a comparison between a neoprene diving
suit with a diving suit according to the present invention. In more
detail, FIG. 14 compares a 6 mil neoprene diving suit having fabric
on both sides, a 4 mil neoprene diving suit having no fabric, and a
4 mil thermoplastic diving suit according to the present invention
having fabric on one side. As shown, the buoyancy of a diver
wearing a 6 mil neoprene and 4 mil neoprene diving suit
significantly changes based on the depth dived. On the contrary,
the 4 mil thermoplastic diving suit according to the present
invention has a neutral buoyancy regardless of the depth the
individual is diving.
[0102] Buoyancy is defined as the lifting force exerted on any
object when immersed in a liquid substance. The sum total of the
buoyant force is equal to the weight of the liquid displaced by the
volume of the object. If the buoyant force is greater than the
immersion weight of the object, the object is said to be
"positively buoyant" (i.e., it will float). For the contrary
condition, when the buoyant force is less than the immersion
weight, the object will be "negatively buoyant" (i.e., it will
sink). For the condition where both forces are equal the object is
said to be at a "neutral" state.
[0103] For the enclosed buoyancy tests shown in FIG. 14, the upward
buoyant force is measured in the units of grams with what is
basically an inverted scale. That is, an entire assembly, including
a scale, is enclosed in a sealed pressure vessel. The pressure
vessel is then filled with water and when compressed air is added
into the vessel an "equivalent depth" is attained. As described
above, the upward buoyant force is directly related to the amount
of water displaced by the material sample. As the hydrostatic
pressure is increased, the material sample will compress in all
axes. As this compression occurs, the amount of water displaced
will decrease and therefore the sample will become less buoyant
resulting in less upward force and thus a decreased reading.
[0104] Turning now to a feature of the present invention in which a
silver bacteria fighting layer is applied to an inside of the
diving suit. Note, the inner fabric may be coated with this
composition or the polymeric material may itself be coated.
Further, the silver may be incorporated into the polymer.
[0105] Silver is effective against a broad spectrum of
microorganisms, including but not limited to sepsis-causing
bacteria and odor-causing bacteria. (For purposes of this detailed
description, a metal with "antimicrobial," "bactericidal" and/or
"bacteristatic" properties is broadly defined as a metal that is
active against at least one pathogenic agent, including but not
limited to bacteria, protozoa, fungi, rickettsiae, and viruses.
Bactericidal agents kill organisms, whereas bacteristatic agents
prevent their growth and multiplication.) The silver is preferably
in a mechanically stable form that remains bound to the polymeric
material when dry, but that releases useful amounts of silver ions
when moistened by a liquid such as water, perspiration, and so
forth. Thus, at least a portion of the silver contained is
eventually released into the surrounding areas. The silver itself
is nontoxic, nonhazardous, substantially nonallergenic and
nonirritating, and inert until activated by contact with a suitable
liquid (water, perspiration, etc.).
[0106] In addition, the diving suit may include layers of
additional useful materials, including but not limited to
moisture-impermeable layers, moisture-absorbing layers, inserts for
providing heat or cooling, and additional layers of the polymeric
material or the silver-containing layer. The composition can be
made by any convenient techniques known in the art, of readily
available materials.
[0107] The antimicrobial composition and the same applied to the
diving suit of the present invention will now be described with
reference to FIGS. 14A-14C and 15A-15B.
[0108] FIG. 14A is a cross-sectional view of a multilayer
composition 310, including a polymeric gel composition 76 (i.e.,
the core material of the diving suit) and a silver-containing layer
314. The polymeric gel composition 76 comprises a block copolymer
and, optionally, mineral oil as previously described. The silver
layer 314 may be added by coating the polymeric gel composition
with silver; alternatively, a silver-containing fabric 316 such as
silver nylon material may be attached to the polymeric gel
composition (FIG. 14B).
[0109] One or both sides of layer 76 may be coated with silver by
any convenient technique, including but not limited to vapor
coating, aerosolized deposition, sputter coating, chemical
deposition, plating, or other techniques known in the art.
Alternatively, the silver may be carried by a layer 316 that
incorporates or is coated with useful amounts of silver. For
example, layer 316 may comprise a woven, knitted, or nonwoven
silver-plated fabric. Alternatively, the fabric may be made of a
combination of silver-coated (or silver-impregnated) and plain
fibers. Suitable materials for layer 316 include silver-impregnated
warp knit nylon fabric, silver-impregnated nylon pile fabric, and
other fabrics made by Omnishield, Inc., Swift, Inc., Sauquoit
Industries, and other manufacturers. Other useful fabrics include
polyesters, polyethylenes, rayons, acrylics, and combinations
thereof that contain useful amounts of silver.
[0110] In one preferred embodiment of the present invention, layer
316 contains at least approximately 2 wt. % silver, more preferably
at least approximately 5-10 wt. % silver. However, it should be
noted that silver concentrations outside this range may also be
useful for some applications. Silver (or some other metal with
medically useful properties) is added to the fabric substrate of
layer 316 by vapor coating, aerosolized deposition, sputter
coating, chemical deposition, plating, or other suitable technique.
Individual fibers can be coated and then worked (woven, knitted,
crocheted, felted, blown, etc.) into a fabric; alternatively,
silver may be added to the finished fabric. Useful fabrics may
contain up to 100% silver-coated fibers. The silver of layers 314,
316 is in a highly purified form, that is, at least approximately
99.9% pure and preferably at least approximately 99.99% pure. The
metal content of layers 314, 316 as well as the thickness and
uniformity of the metal coating, may vary broadly depending on the
intended application. However, it should be understood that the
materials for layers 314, 316 are selected with a view to providing
the needed amounts of free silver to the skin. Other metals that
exhibit antibacterial and/or antifungal properties may also be
useful for the practice of the present invention, including but not
limited to gold, copper, aluminum, zinc, and combinations and
alloys thereof.
[0111] Layers 314, 316 not only contain a sufficiently high content
of silver (or other useful metal) to provide useful amounts of
silver ions for the intended application, but preferably have an
approximately uniform distribution of silver. Non-uniform
distributions may result in non-uniform treatment, since the amount
of silver supplied to different areas of the target site may
differ. The thickness of the silver coating may vary broadly.
Useful amounts of silver may be achieved with coatings no greater
than 1 or 2 micrometers thick.
[0112] The silver in layers 314, 316 is preferably in a form that,
when composition 310 is placed in contact with body tissues and
moistened by water or sweat between the skin of the user and the
diving suit, it releases silver ions by the passive dissolution of
silver in an ionic form from the metallic silver surface in a
process known as oligodynamic action. Thus, over a period of time,
at least a portion of the available silver migrates to the
immediately-adjacent tissues where it has useful antimicrobial and
antifungal effects.
[0113] While not wishing to be bound by theory, it is believed that
metallized (i.e., metal-containing, metal-coated, metal-plated)
materials wherein the metal atoms are firmly attached or bound to a
fabric substrate when dry, but are at least somewhat releasable in
ionic form when wetted with a suitable liquid, are especially
suitable for the practice of the present invention. For example,
layers 314, 316 may contain silver in the form of small crystals
which tend to release free silver ions when wetted by saline,
water, etc. Crystalline silver deposits of this type are believed
to have a greater effective surface area than conventional
silver-plated coatings, and therefore the capability of releasing
more silver ions per unit coating weight, in shorter periods of
time. However, other types of silver-containing materials may also
be useful.
[0114] Layer 316 may be attached to the polymeric gel composition
layer 76 by any convenient means, including but not limited to
heat/pressure bonding, crimping, embossing, sonic welding, needle
punching and biocompatible adhesives. Alternatively, hook-and-loop
or groove-and-rib type closures may be useful, particularly for
applications where a removable layer 316 is desired. These types of
closures are described in co-pending applications Ser. No.
09/431,991, filed Nov. 3, 1999, and Ser. No. 09/496,766, filed Feb.
3, 2000, the disclosures of which are incorporated herein by
reference.
[0115] Composition 310 may also include additional layers. For
example, composition 310 may have an outer layer of gas-permeable,
moisture-impermeable material (GORETEX or the like), the inner or
outer fabrics, a layer of moisture-absorbing material interposed
between layers 312 and 316, or a layer 318 of hook-and-loop fabric
such as VELCRO between layers 76 and 316 (FIG. 15C). Alternatively,
composition 310 may have a silver-containing layer such as layer
316 interposed between two layers 76, or comprise a layer 12 that
itself contains silver.
[0116] Silver ions released by layers such as above-described
layers 314 and 316 have been demonstrated to be effective against,
for example, odor-causing bacteria (including antibiotic-resistant
strains, Gram-positive strains, and Gram-negative strains), as
described in applications Ser. Nos. 09/431,991 and 09/496,766.
[0117] If desired, the composition 310 may include one or more
pockets 322 for holding removable heated or cooled inserts 324 as
shown in FIG. 16A. Alternatively, the composition 310 may have a
plurality of permanent inserts 332 (FIG. 16B). Inserts 324 and 332
are preferably made of a material with a high heat capacity, thus,
the inserts tend to retain their temperature when heated or cooled
and only slowly return to ambient temperature.
[0118] Composition 310 is inert until the silver of layer 314 or
316 is wetted by any of a variety of agents: water, sweat, etc.
Then, at least some free silver ions are released from layers 314
and 316 and migrate from composition 310 into the surrounding
region.
[0119] The silver layer 314, 316 may be applied to the inner
surface of the entire wet suit, or just to bacteria prone areas
such as a crotch area, armpit area, etc.
[0120] Obviously, numerous modifications and variations of the
present invention are possible in light of the above teachings. It
is therefore to be understood that within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
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