U.S. patent application number 15/286929 was filed with the patent office on 2018-04-12 for insulated vented garment formed using sections of non-woven polymer material.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to IUSTINIA KOSHKAROFF, LUKE A. PEZZIMENTI, KEVIN C. SZE.
Application Number | 20180098584 15/286929 |
Document ID | / |
Family ID | 60153469 |
Filed Date | 2018-04-12 |
United States Patent
Application |
20180098584 |
Kind Code |
A1 |
PEZZIMENTI; LUKE A. ; et
al. |
April 12, 2018 |
INSULATED VENTED GARMENT FORMED USING SECTIONS OF NON-WOVEN POLYMER
MATERIAL
Abstract
Aspects herein provide for a method of manufacturing a vented
insulated garment using sections of non-woven polymer material and
garments produced therefrom. The method generally comprises
positioning a section of non-woven polymer material between two
textile layers, and bonding the textile layers together at areas
adjacent to the section of non-woven polymer material to form
seams. The seams may be optionally perforated.
Inventors: |
PEZZIMENTI; LUKE A.;
(PORTLAND, OR) ; SZE; KEVIN C.; (PORTLAND, OR)
; KOSHKAROFF; IUSTINIA; (PORTLAND, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
60153469 |
Appl. No.: |
15/286929 |
Filed: |
October 6, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A41D 27/28 20130101;
A41D 1/02 20130101; A41D 27/24 20130101; A41D 2300/50 20130101;
A41D 2400/10 20130101; A41D 27/02 20130101; A41D 31/102 20190201;
A41D 31/065 20190201; A41B 1/08 20130101; A41D 2500/30 20130101;
A41D 1/06 20130101 |
International
Class: |
A41D 27/02 20060101
A41D027/02; A41B 1/08 20060101 A41B001/08; A41D 1/02 20060101
A41D001/02; A41D 1/06 20060101 A41D001/06; A41D 27/28 20060101
A41D027/28 |
Claims
1. A method of making an insulated garment, the method comprising:
providing a first panel of material; providing a second panel of
material; providing a section of thermally insulating fill
material; positioning the section of thermally insulating fill
material on the first panel of material; positioning the second
panel of material such that the section of thermally insulating
fill material is interposed between the first panel of material and
the second panel of material; securing the first panel of material
to the second panel of material at one or more areas adjacent to
the section of thermally insulating fill material; and forming the
garment using at least the first panel of material and the second
panel of material.
2. The method of claim 1, wherein the securing step comprises
applying an adhesive to an inner-facing surface of at least one of
the first panel of material or the second panel of material at the
one or more areas adjacent to the section of thermally insulating
fill material.
3. The method of claim 2, wherein the applied adhesive is activated
by one of heat energy or ultrasonic energy.
4. The method of claim 1, wherein the section of thermally
insulating fill material is positioned on the first panel of
material by affixing the section of thermally insulating fill
material along its perimeter edge to the first panel of
material.
5. The method of claim 1, further comprising perforating the one or
more areas adjacent to the section of thermally insulating fill
material to create a plurality of perforations on the one more
areas, the plurality of perforations extending through the first
panel of material and the second panel of material in the one or
more areas.
6. The method of claim 1, wherein one or more of the first panel of
material or the second panel of material is formed of a knit
textile.
7. The method of claim 1, wherein one or more of the first panel of
material or the second panel of material is formed of a woven
textile.
8. A garment comprising: at least a first garment panel comprising:
an inner panel; an outer panel; a first section of thermally
insulating fill material interposed between the inner panel and the
outer panel; and at least a first seam that joins the inner panel
to the outer panel at a first area adjacent to the section of
thermally insulating fill material.
9. The garment of claim 8, further comprising at least a second
seam that joins the inner panel to the outer panel at a second area
adjacent to the section of thermally insulating fill material,
wherein the first seam is spaced apart from and unconnected to the
second seam.
10. The garment of claim 9, where in the first seam and the second
seam define an open-ended chamber containing the first section of
thermally insulating fill material.
11. The garment of claim 8, wherein the garment comprises one or
more additional sections of thermally insulating fill material
interposed between the inner panel and the outer panel.
12. The garment of claim 8, wherein the first seam joining the
inner panel to the outer panel is created with an adhesive
activated by the application of energy.
13. The garment of claim 12, wherein the first seam is reinforced
by stitching.
14. The garment of claim 8, wherein at least one of the inner panel
or the outer panel is formed from a knit textile.
15. The garment of claim 8, wherein at least one of the inner panel
or the outer panel is formed from a woven textile.
16. A garment comprising: at least a first panel of material
comprising: an inner panel; an outer panel; a section of thermally
insulating fill material interposed between the inner panel and the
outer panel; a first seam that joins the inner panel to the outer
panel at a first area adjacent to the section of thermally
insulating fill material; and a second seam that joins the inner
panel to the outer panel at a second area adjacent to the section
of thermally insulating fill material, the first seam and the
second seam defining an open-ended chamber containing the section
of thermally insulating fill material.
17. The garment of claim 16, further comprising a plurality of
perforations located on at least the first seam, the plurality of
perforations extending through the first seam, and through the
inner panel and the outer panel.
18. The garment of claim 16, further comprising at least a second
panel of material, the second panel of material comprising a single
layer of material.
19. The garment of claim 18, wherein the garment comprises a pair
of pants having a torso portion, a first leg portion, and a second
leg portion, and wherein the first panel of material is positioned
at least at an upper anterior aspect of the first and second leg
portions.
20. The garment of claim 18, wherein the garment comprises a shirt
having a torso portion, a first sleeve portion, and a second sleeve
portion, and wherein the first panel of material is positioned at
least at an anterior aspect of the torso portion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application having attorney docket number
NIKE.260978/160358US01 and entitled "Insulated Vented Garment
Formed Using Sections of Non-Woven Polymer Material" is related by
subject matter to concurrently filed U.S. patent application Ser.
No. ______, having attorney docket number NIKE.260977/150999US01
and entitled "Insulated Vented Garment Formed Using Non-Woven
Polymer Sheets." The entirety of the aforementioned application is
incorporated by reference herein.
TECHNICAL FIELD
[0002] Aspects herein relate to an insulated vented garment and
methods for making an insulated vented garment.
BACKGROUND
[0003] Traditional ways of creating insulated garments comprise
creating chambers through, for example, stitching panels of
material together and blowing down or other synthetic fibers into
the chambers. This often requires specialized machinery and can be
messy. Moreover, traditional insulated garments may trap moisture
vapor produced by the wearer which may result in wearer
discomfort.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Examples of the present invention are described in detail
below with reference to the attached drawing figures, wherein:
[0005] FIG. 1 illustrates an exploded view of a first exemplary
construction for an insulated vented garment in accordance with
aspects herein;
[0006] FIG. 2 illustrates a top perspective view of a construction
detail for the first exemplary construction of FIG. 1 in accordance
with aspects herein;
[0007] FIG. 3 illustrates a top perspective view of the first
exemplary construction of FIG. 1 when in an as-assembled state in
accordance with aspects herein;
[0008] FIG. 4 illustrates a cross-sectional view taken along cut
line 4-4 of FIG. 3 in accordance with aspects herein;
[0009] FIGS. 5-6 illustrate front and back views respectively of an
exemplary insulated vented garment formed using, or instance, the
first exemplary construction of FIG. 1 in accordance with aspects
herein;
[0010] FIGS. 7-8 illustrate front and back views respectively of an
exemplary insulated vented garment formed, for instance, using the
first exemplary construction of FIG. 1 in accordance with aspects
herein;
[0011] FIGS. 9A-9B illustrate exemplary patterns for a seam in
accordance with aspects herein;
[0012] FIG. 10 illustrates a flow diagram of an exemplary method of
forming an insulated vented garment in accordance with aspects
herein;
[0013] FIG. 11 illustrates an exploded view of a second exemplary
construction for an insulated vented garment in accordance with
aspects herein;
[0014] FIG. 12A illustrates a top perspective view of a
construction detail for the second exemplary construction of FIG.
11 in accordance with aspects herein;
[0015] FIG. 12B illustrates a top perspective view of the second
exemplary construction of FIG. 11 when in an as-assembled state in
accordance with aspects herein;
[0016] FIG. 13 illustrates an alternative configuration for the
second exemplary construction in accordance with aspects
herein;
[0017] FIG. 14 illustrates a cross-sectional view taken along cut
line 14-14 of FIG. 12B in accordance with aspects herein;
[0018] FIG. 15 illustrates a front view of an exemplary insulated
vented garment formed, for example, using the second exemplary
construction of FIG. 11 in accordance with aspects herein;
[0019] FIG. 16 illustrates a front view of an exemplary insulated
vented garment formed, for example, using the second exemplary
construction of FIG. 11 in accordance with aspects herein; and
[0020] FIG. 17 illustrates a flow diagram of an exemplary method of
forming an insulated vented garment in accordance with aspects
herein.
DETAILED DESCRIPTION
[0021] The subject matter of the present invention is described
with specificity herein to meet statutory requirements. However,
the description itself is not intended to limit the scope of this
disclosure. Rather, the inventors have contemplated that the
claimed or disclosed subject matter might also be embodied in other
ways, to include different steps or combinations of steps similar
to the ones described in this document, in conjunction with other
present or future technologies. Moreover, although the terms "step"
and/or "block" might be used herein to connote different elements
of methods employed, the terms should not be interpreted as
implying any particular order among or between various steps herein
disclosed unless and except when the order of individual steps is
explicitly stated.
[0022] At a high level, aspects herein relate to methods of
constructing insulated vented garments and garments resulting
therefrom. Methods of constructing the insulated vented garment may
utilize non-woven polymer sheets or sections of non-woven polymer
material instead of materials such as down or loose poly-fill
fibers. As used throughout this disclosure, terms such as
"non-woven polymer sheet," "poly-fill sheet," "thermally insulating
sheet material," and "thermally insulating fill sheet" may be used
interchangeably herein. Further, as used throughout this
disclosure, terms such as "sections of non-woven polymer material,"
"sections of poly-fill material," "sections of thermally insulating
sheet material," and "sections of thermally insulating fill
material" may be used interchangeably herein. Besides being easier
to work with due to their cohesive structure, the use of non-woven
polymer sheets or sections of non-woven polymer material imparts
warmth to the finished garment. Moreover, the non-woven polymer
materials described herein are generally hypoallergenic, do not
require special laundering, have short dry times, and still provide
warmth even when wet. They also do not require specialized handling
or machinery when forming the garment which saves on manufacturing
costs.
[0023] In a first method of construction that utilizes non-woven
polymer sheets, one or more selected portions of the non-woven
polymer sheet may be removed to create openings or voided portions
in the non-woven polymer sheet. In an alternative aspect, the
non-woven polymer may be formed to have one or more openings or
voided portions. The non-woven polymer sheet is positioned between
a first and second panel of material. The first panel of material
is secured or bonded to the second panel of material in one or more
areas corresponding to the voided portions in the non-woven polymer
sheet. In an optional exemplary aspect, one or more perforations
may be formed in the bonded areas where the perforations extend
through the first panel of material and the second panel of
material. As described further below, the perforations may be
useful for allowing moisture vapor and/or excess heat produced by a
wearer to escape from inside of the garment. The first and second
panels of material may be used at least in part to form the
garment.
[0024] Garments produced using the first method may comprise, for
instance, at least one garment panel having an inner panel and an
outer panel. A non-woven polymer sheet may be positioned between
the inner and outer panels where the non-woven polymer sheet may
comprise a voided portion (i.e., a portion from which the non-woven
polymer sheet material has been removed or is absent). The garment
may further comprise at least one seam that joins the inner panel
to the outer panel at an area corresponding to the voided portion
of the non-woven polymer sheet. In aspects, the garment may
comprise multiple seams at areas corresponding to voided portions
of the non-woven polymer sheet where the seams may help to define a
plurality of chambers containing the non-woven polymer sheet. In an
optional aspect, the garment may further comprise one or more
perforations located on the seam, where the perforations extend
through the inner panel and the outer panel.
[0025] In a second method of construction that utilizes sections or
strips of non-woven polymer material, the section of non-woven
polymer material may be positioned between a first and second panel
of material. The first panel of material may be secured or bonded
to the second panel of material in one or more areas adjacent to
the section of non-woven polymer material. In an optional exemplary
aspect, perforations may be formed in the bonded area where the
perforations extend through the first panel of material and the
second panel of material.
[0026] Garments produced using the second method of construction
may comprise, for example, at least one garment panel having an
inner panel and an outer panel. A section of non-woven polymer
material may be positioned between the inner panel and the outer
panel. The garment may further comprise one or more seams that join
the inner panel to the outer panel at areas immediately adjacent or
next to the section of non-woven polymer material; the seams may
define a chamber that contains the section of non-woven polymer
material. In an optional aspect, perforations may extend through
the seam(s) such that they extend through the inner panel and the
outer panel.
[0027] In general, garments produced using the first and second
methods of construction are both insulating and breathable. This
may be advantageous for a wearer undergoing physical exertion as
these wearers often produce moisture in the form of perspiration.
Perspiration still occurs in cold weather and may increase when the
wearer is wearing a heat-insulating garment. By utilizing the
perforations as described herein, the moisture vapor may escape to
the exterior environment helping to keep the wearer comfortable. As
well, the interior temperature of the garment may be regulated by
facilitating a transfer of heat through the garment via the
perforations.
[0028] Additional advantages may be obtained by using non-woven
polymer sheets and/or sections of non-woven polymer material.
Because of their non-woven structure formed, for example, by
entangling fibers or filaments, they are able to maintain a
cohesive or unitary structure as opposed to, for instance, loose
poly-fill fibers and/or down. As such, they allow for the creation
of chambers that are positioned vertically and/or diagonally on a
garment. In other words, because there is little risk of drift of
the materials (as opposed to, for example, down and/or loose
poly-fill fibers that do not have a cohesive structure), the
chambers may assume orientations other than generally discrete
chambers having horizontal orientations. Further, the chambers can
assume more organic or curvilinear shapes because there is no need
to blow down or loose poly-fill fibers into the chambers. It is
known that it is often difficult to evenly distribute down or loose
poly-fill fibers into chambers that are curvilinear or that deviate
from a more traditional horizontally oriented chamber.
Additionally, since there is no need to contain loose fill
materials, the chambers described herein may be in the form of
"open-ended" chambers. That is, instead of a traditional chamber
that is defined on all sides by seam lines to create an enclosed
chamber, chambers described herein may comprise one or more sides
or regions that are not bounded by seam lines.
[0029] Accordingly, aspects herein provide for a method of making
an insulating garment, the method comprising providing a first
panel of material; providing a second panel of material; and
providing a thermally insulating fill sheet having one or more
voided portions. The thermally insulating fill sheet is secured to
at least the first panel of material, and the second panel of
material is positioned such that the thermally insulating fill
sheet is interposed between the first panel of material and the
second panel of material. The first panel of material is affixed to
the second panel of material in one or more areas corresponding to
the one or more voided portions in the thermally insulating fill
sheet and the garment is formed using at least the first panel of
material and the second panel of material.
[0030] In another aspect, a garment is provided comprising at least
a first garment panel. The first garment panel comprises an inner
panel, an outer panel, and a thermally insulating fill sheet
interposed between the inner panel and the outer panel, where the
thermally insulating fill sheet comprising at least one voided
portion. The garment further comprises at least one seam that joins
the inner panel to the outer panel at an area corresponding to the
voided portion of the thermally insulating fill sheet and a
plurality of perforations located on the at least one seam, where
the plurality of perforations extend through the at least one seam
and through the inner panel and the outer panel.
[0031] In yet another aspect, a garment is provided comprising at
least a first garment panel. The first garment panel comprises an
inner panel, an outer panel, and a thermally insulating fill sheet
interposed between the inner panel and the outer panel at a first
area, where the thermally insulating fill sheet comprises at least
a first voided portion and a second voided portion. The garment
further comprises at least a first seam that joins the inner panel
to the outer panel at a first location corresponding to the first
voided portion of the thermally insulating fill sheet and at least
a second seam that joins the inner panel to the outer panel at a
second location corresponding to the second voided portion of the
thermally insulating fill sheet, where the first seam is spaced
apart from and unconnected to the second seam. Additionally the
garment comprises an open-ended chamber formed between the inner
panel and the outer panel and defined by the first seam and the
second seam, where the chamber contains at least a portion of the
thermally insulating fill sheet.
[0032] Aspects herein further provide for a method of making an
insulated garment. The method comprises providing a first panel of
material, providing a second panel of material, and providing a
section of thermally insulating fill material. The section of
thermally insulating fill material is positioned on the first panel
of material and the second panel of material is positioned such
that the section of thermally insulating fill material is
interposed between the first panel of material and the second panel
of material. The first panel of material is secured to the second
panel of material at one or more areas adjacent to the section of
thermally insulating fill material and the garment is formed using
at least the first panel of material and the second panel of
material.
[0033] In another aspect a garment is provided. The garment
comprises at least a first garment panel comprising an inner panel,
an outer panel, a first section of thermally insulating fill
material interposed between the inner panel and the outer panel,
and at least a first seam that joins the inner panel to the outer
panel at a first area adjacent to the section of thermally
insulating fill material.
[0034] In an additional aspect a garment is provided. The garment
comprises at least a first panel of material comprising an inner
panel, an outer panel, and a section of thermally insulating fill
material interposed between the inner panel and the outer panel.
The garment further comprises a first seam that joins the inner
panel to the outer panel at a first area adjacent to the section of
thermally insulating fill material and a second seam that joins the
inner panel to the outer panel at a second area adjacent to the
section of thermally insulating fill material. The first seam and
the second seam define an open-ended chamber containing the section
of thermally insulating fill material.
[0035] As used throughout this disclosure, positional terms used
when describing, for instance, a garment, such as "anterior,"
"posterior," "inferior," "superior," "lateral," "medial," and the
like are to be given their common meaning with respect to the
garment being worn by a hypothetical wearer standing in anatomical
position. Unless indicated otherwise, terms such as "affixed,"
"coupled," "secured," and the like may mean releasably affixing two
or more elements together using for instance, structural
differences between the elements, releasable adhesives, snaps,
buttons, hook-and-loop fasteners, and the like. These terms may
also mean permanently affixing two or more elements together using,
for example, stitching, bonding, adhesives, welding, and the like.
Unless indicated otherwise, terms such as "proximate" or "adjacent"
may mean within 0 cm to 5.0 cm of a designated reference point.
[0036] First Exemplary Method of Construction and Garments Produced
Therefrom
[0037] Aspects herein contemplate a method of forming an insulated
vented garment using non-woven polymer sheets such as a thermally
insulating poly-fill sheet. Aspects herein further contemplate an
insulated vented garment formed using non-woven polymer sheets. As
used throughout this disclosure the term "non-woven" may be defined
as a mat or sheet-like structure formed by entangling fibers or
filaments of a material. In exemplary aspects, the non-woven
polymer sheet may comprise a single layer or multiple layers.
Further, in exemplary aspects, the polymer material may comprise
polyester fibers or filaments. The non-woven polymer sheet is
generally lightweight but provides good insulation due to heated
air being trapped between the entangled fibers.
[0038] Turning now to FIG. 1, an exploded view of a first exemplary
construction 100 for an insulated vented garment is provided in
accordance with aspects herein. The exemplary construction 100
comprises at least a first pliable textile layer 110, a non-woven
polymer sheet 112, and a second pliable textile layer 114. In
aspects, the first textile layer 110 may comprise an inner-facing
layer of the garment (i.e., the layer configured to face toward a
body surface of a wearer when the garment is worn), and the second
textile layer 114 may comprise an outer-facing layer of the garment
(i.e., the layer configured to face away from a body surface of a
wearer and toward the external environment when the garment is
worn). The first textile layer may comprise a first surface 116 and
an opposite-facing second surface 118, where the second surface 118
is configured to face toward the body surface of the wearer when
the garment is worn. The second textile layer 114 may comprise a
third surface 124 and an opposite-facing fourth surface 126, where
the third surface 124 is configured to face toward the external
environment when the garment is worn.
[0039] In exemplary aspects, the first textile layer 110 and the
second textile layer 114 may comprise a knitted, woven, or
non-woven textile. Further, the first textile layer 110 may be
formed of the same material (e.g., knit or woven material) as the
second textile layer 114, or the layers 110 and 114 may be formed
of different materials (i.e., the first textile layer 110 may be a
knit material and the second textile layer 114 may be a woven
material or vice versa). In exemplary aspects, one or more of the
layers 110 and/or 114 may be treated with a durable water repellant
(DWR) to make the resulting garment substantially impervious to
water. For instance, the second textile layer 114, since it is an
outer-facing layer, may be treated with a DWR finish. Further, it
is contemplated herein that first textile layer 110 may be finished
to provide a soft feel or hand to heighten wearer comfort since the
first textile layer 100 is configured to potentially come into
contact with the body surface of the wearer when the garment is
worn. For instance, the first textile layer 110 may be brushed to
impart a soft feel to the first textile layer 110. Any and all
aspects, and any variation thereof, are contemplated as being
within aspects herein.
[0040] It is further contemplated herein that one or more of the
first textile layer 110 and/or the second textile layer 114 may be
formed from fabrics having different weights. For instance, the
layers 110 and/or 114 may be formed of light fabrics (89 g/m.sup.2
to 30 g/m.sup.2) or even ultra-light fabrics (29 g/m.sup.2 or
lighter). However, it is contemplated herein that heavier fabrics,
such as fabrics with weights in the range of 90 g/m.sup.2 to 149
g/m.sup.2 or even 150 g/m.sup.2 to 250 g/m.sup.2 or higher may be
used for the layers 110 and/or 114 in accordance with aspects
herein.
[0041] The non-woven polymer sheet 112 is shown as being positioned
between the first textile layer 110 and the second textile layer
114. It is contemplated herein that the non-woven polymer sheet 112
may comprise any number of different weights. Continuing, the
non-woven polymer sheet 112 comprises a fifth surface 120 and an
opposite-facing sixth surface 122. The fifth surface 120 is
positioned adjacent to the fourth surface 126 of the second textile
layer 114 in the construction 100, and the sixth surface 122 is
positioned adjacent to the first surface 116 of the first textile
layer 110 in the construction 100.
[0042] The non-woven polymer sheet 112 is shown with a portion
removed to form an opening or a voided portion 132. In exemplary
aspects, this may be done using a mechanical cutting process,
ultrasonic cutting, laser cutting, water jet cutting, and the like
to form the voided portion 132 in the non-woven polymer sheet 112.
In an alternative exemplary aspect, the non-woven polymer sheet 112
may be pre-formed to have the voided portion 132. Any and all
aspects, and any variation thereof, are contemplated as being
within aspects herein. Although shown with just one voided portion
132, it is contemplated herein that the non-woven polymer sheet 112
may comprise multiple voided portions. Further, it is contemplated
herein, that the voided portion 132 may comprise any number of
different lengths and may have different shapes such as curvilinear
or organic shapes. Any and all aspects, and any variation thereof,
are contemplated as being within aspects herein.
[0043] The construction 100 depicted in FIG. 1 further comprises a
first adhesive material 128 and a second adhesive material 130. In
exemplary aspects, the first adhesive material 128 and the second
adhesive material 130 may comprise an adhesive tape formed to have
a shape corresponding to that of the voided portion 132 of the
non-woven polymer sheet 112. The first adhesive material 128 and
the second adhesive material 130 may be used to secure or bond the
first textile layer 110 to the second textile layer 114 at the
voided portion 132 of the non-woven polymer sheet 112. For
instance, the first adhesive material 128 may be positioned on the
first textile layer 110 and the non-woven polymer sheet 112 may be
positioned on the first textile layer 110 such that the voided
portion 132 is axially aligned with the first adhesive material
128. The second adhesive material 130 may also be positioned such
that it is axially aligned with the voided portion 132, and the
second textile layer 114 may be positioned adjacent to the first
textile layer 110. Then, the two layers 110 and 114 may be pressed
together with sufficient force and/or energy applied in an area
generally corresponding to the voided portion 132 to activate the
adhesive materials 128 and 130 to create a bond(s) between the two
layers 110 and 114. The adhesive materials 128 and 130 may be
activated by, for instance, heat, or ultrasonic energy, or any
other type of applied energy. By removing portions of the non-woven
polymer sheet 112 at areas where the first and second textile
layers 110 and 114 are bonded, a more secure bond may be
formed.
[0044] Once the first textile layer 110 and the second textile
layer 114 are bonded together, a seam is formed at the bonded area.
In other words, a seam is formed at the voided portion 132 of the
non-woven polymer sheet 112 as will be discussed further below. It
is contemplated herein, that only one of the adhesive materials 128
or 130 may be used herein to affix the first textile layer 110 to
the second textile layer 114. Any and all aspects, and any
variation thereof, are contemplated as being within aspects
herein.
[0045] The construction 100 further comprises one or more optional
perforations 134. In exemplary aspects, the perforations 134 are
made through the second textile layer 114 and the first textile
layer 110 in the area corresponding to the voided portion 132. To
put it another way, the perforations 134 are formed at the seam
area created when the first textile layer 110 is affixed or bonded
to the second textile layer 114 at the voided portion 132 of the
non-woven polymer sheet 112. The perforations 134 may be formed
using, for instance, a mechanical cutting process, a knitting or
weaving process, laser cutting, water jet cutting, ultrasonic
cutting, and the like. As stated above, the perforations 134 may be
used to allow moisture vapor or excess heat produced by the wearer
to exit the garment.
[0046] Turning now to FIG. 2, referenced generally by the numeral
200, a top perspective view of a portion of the construction 100 is
shown comprising the non-woven polymer sheet 112 positioned on the
first surface 116 of the first textile layer 110 in accordance with
aspects herein. Before affixing the first textile layer 110 to the
second textile layer 114 at the voided portion 132 of the non-woven
polymer sheet 112 as described above, the non-woven polymer sheet
112 may be secured to the first textile layer 110 to prevent
shifting of the non-woven polymer sheet 112 during manipulation of
the construction 100. For example, the non-woven polymer sheet 112
may be secured to the first textile layer 110 by stitching or
tacking a perimeter edge defining the voided portion 132 to the
first textile layer 110. This is indicated by reference numeral
210. Other methods of securing the non-woven polymer sheet 112 to
the first textile layer 110 are contemplated herein such as using
adhesives, a bonding process, spot welding, a melting process, and
the like. Moreover, although shown as secured to the first textile
layer 110, it is contemplated herein that the non-woven polymer
sheet 112 may alternatively be secured to the second textile layer
114 or to both the first textile layer 110 and the second textile
layer 114.
[0047] FIG. 3 illustrates a top perspective view of the
construction 100 in an as-assembled state in accordance with
aspects herein. As shown, the second textile layer 114 is
positioned adjacent to the first textile layer 110 such that the
third surface 124 of the second textile layer 114 is exposed. The
non-woven polymer sheet 112 is positioned between the first textile
layer 110 and the second textile layer 114. The voided portion 132
of the non-woven polymer sheet 112 is indicated by the dashed
lines. As described above, the first textile layer 110 is secured
or bonded to the second textile layer 114 at the voided portion 132
to form a seam 310. The perforations 134 extend through the seam
310. In other words, the perforations 134 extend through the first
textile layer 110 and the second textile layer 114 at the seam 310
in accordance with aspects herein.
[0048] A cross-section of the construction 100 taken along cut line
4-4 of FIG. 3 is shown in FIG. 4 in accordance with aspects herein.
Because the seam 310 is positioned at a location corresponding to
the voided portion 132 of the non-woven polymer sheet 112, the
non-woven polymer sheet 112 is not present in the seam 310.
However, all three layers--the first textile layer 110, the
non-woven polymer sheet 112, and the second textile layer 114--are
present in the areas adjacent to the seam 310. As further shown in
FIG. 4, the perforations 134 extend through the first textile layer
110 and the second textile layer 114 at the seam 310. As used
throughout this disclosure, portions of the construction 100 that
comprise the first textile layer 110, the non-woven polymer sheet
112, and the second textile layer 114 may be known as chambers. For
instance, the reference numeral 410 may indicate a first chamber
and the reference numeral 412 may indicate a second chamber, where
the first chamber 410 may be demarcated or separated from the
second chamber 412 by the seam 310.
[0049] Turning now to FIGS. 5 and 6, front and back views
respectively of a garment 500 having the construction 100 is shown
in accordance with aspects herein. The garment 500 is shown in the
form of a jacket although it is contemplated herein that the
garment 500 may take other forms such as a shirt, a pull-over
hoodie, a vest, a pant, a short, a body suit, a sock, a hat, a
shoe, and the like. The garment 500 comprises a torso portion 510
configured to cover the front and back torso of a wearer when the
garment 500 is in an as-worn configuration. The torso portion 510
may comprise an optional releasable fastener mechanism 522 such as
a zipper used to open and close the garment 500. The torso portion
510 defines at least a neck opening 516, a waist opening 518, and
first and second sleeve openings (not shown). The neck opening 516,
in turn, may be defined by a collar portion 520 of the garment 500.
The garment may optionally comprise a first sleeve portion 512
extending from the torso portion 510 at the first sleeve opening,
and a second sleeve portion 514 extending from the torso portion
510 at the second sleeve opening.
[0050] Some or all of the garment 500 may comprise the construction
100 described with respect to FIGS. 1-4. For instance, it is
contemplated herein that an entirety of the torso portion 510
including the collar portion 520 may be formed of the construction
100. In some aspects, the first and second sleeve portions 512 and
514 may also be formed from the construction 100.
[0051] It is also contemplated herein that the construction 100 may
be used on only portions of the garment 500. For instance, the
garment 500 may be zoned into different areas such as areas needing
a high amount of insulation, a moderate amount of insulation, and
areas needing a low amount of insulation. In exemplary aspects, the
zoning may be based on heat or sweat maps of the human body. Areas
needing a high amount of insulation may comprise, for instance, the
first and second sleeve portions 512 and 514. Areas needing a
moderate to high amount of insulation may comprise, for instance,
the front of the torso portion 510, and areas needing a moderate to
low amount of insulation may comprise, for example, the back of the
torso portion 510. These locations are exemplary only and it is
contemplated herein that the garment 500 may be zoned
differently.
[0052] Continuing, areas needing a high amount of insulation may be
formed from the construction 100 but the non-woven polymer sheet
112 in these areas may not comprise voided portions. Instead, a
continuous expanse of the non-woven polymer sheet 112 may be
positioned between the first and second textiles layers 110 and 114
to provide a higher level of insulation. As such, it is
contemplated herein that areas needing higher insulation may not
comprise seams, such as the seam 310, and may not comprise
perforations such as the perforations 134.
[0053] Areas needing a moderate amount of insulation may be formed
from the construction 100 where the non-woven polymer sheet 112
comprises the voided portions and the first and second textile
layers 110 and 114 are bonded together at locations corresponding
to the voided portions to create one or more seams. By having
voided portions in these areas, a lower amount of insulation may be
achieved as compared to having a continuous expanse of non-woven
polymer sheet. Perforations, such as the perforations 134 may be
formed on some or all of the seams to impart increased permeability
and breathability to the garment 500 in these areas.
[0054] Areas needing a low amount of insulation may also be formed
from the construction 100. In exemplary aspects, an increased
number of seams may be formed in these areas, and/or a greater
number of seams may comprise perforations for a higher level of
permeability and breathability. Alternatively, areas needing a low
amount of insulation may be formed without using the construction
100. For instance, these areas may not comprise the non-woven
polymer sheet 112 and instead may comprise just the first and
second textile layers 110 and 114, just one of the layers 110 or
114, or the areas may comprise a different textile such as, for
instance, a mesh material for greater permeability and
breathability. Any and all aspects, and any variation thereof, are
contemplated as being within aspects herein.
[0055] Referring particularly to the garment 500 shown in FIG. 5,
the garment 500 comprises a number of seams where the seams
represent areas where the first textile layer 110 is bonded or
secured to the second textile layer 114 at voided portions in the
non-woven polymer sheet 112. For instance, seams 528 may be located
on a front aspect of the torso portion 510 at a first lateral side
of the torso portion 510, seams 536 may be located on the front
aspect of the torso portion 510 at a second opposite lateral side
of the torso portion 510, and seams 524 and 526 may be located on
the front aspect of the collar portion 520. Although the seams 526,
528, and 536 are shown as being perforated, it is contemplated
herein that one or more of the seams 526, 528, and 536 may not be
perforated.
[0056] A close-up of perforations 531 located on the seams 536 is
shown in FIG. 5. In exemplary aspects, the perforations 531 may
comprise a number of different shapes and sizes. As shown, the
perforations 531 may comprise an alternating pattern of
larger-sized perforations and smaller-sized perforations. Moreover,
the perforations 531 may extend continuously along the seam 536 as
shown, or the perforations 531 may be placed intermittently along
the seam 536. As further shown in the close-up view of the seam
536, the seam 536 may optionally be reinforced with stitching 532.
The stitching 532 may be along one edge of the seam 536 or along
both edges of the seam 536. Any and all aspects, and any variation
thereof, are contemplated as being within aspects herein.
[0057] The seams 524 and 526 on the collar portion 520 of the
garment 500 comprise both perforated and unperforated seams. For
instance, the seams 524 are unperforated and the seam 526 is
perforated. Having both perforated and unperforated seams at the
collar portion 520 may help provide a moderate amount of insulation
while still imparting a breathable and permeable characteristic to
the collar portion 520.
[0058] The back of the garment 500 as shown in FIG. 6 may comprise
a different pattern of seams as compared to the front of the
garment 500. For instance, seams 618 may be located at a first
lateral side of the back of the torso portion 510, seams 620 may be
located at a second opposite lateral side of the back of the torso
portion 510, and an additional set of seams 612 and 614 may be
located at an upper central back of the torso portion 510. Seams
610 may also be located on the collar portion 520. Similar to the
seams located on the front of the torso portion 510, some or all of
the seams 610, 612, 614, 618, or 620 may be perforated.
[0059] In exemplary aspects, open-ended chambers may be formed
between adjacent seams. For instance, with respect to FIG. 6, an
open-ended chamber 616 may be formed between the seam 612 and the
seam 614. The chamber 616 is defined along two sides by the seams
612 and 614 but is undefined or open at each opposing end. The
creation of open-ended chambers, such as the chamber 616 is
possible due to the cohesive or unitary structure of the non-woven
polymer sheet 112. In other words, because of its non-woven
structure, the polymer sheet 112 does not have to be enclosed
within, for example, a four-sided chamber as opposed to, for
example, loose fill or down which may escape the chamber if not
enclosed. Moreover, use of the non-woven polymer sheet 112 enables
the creation of chambers, such as chamber 617 that is vertically or
diagonally oriented on the garment 500. Using vertically or
diagonally oriented chambers with, for example, loose fill or down
may be challenging as these materials have a tendency to settle due
to gravity.
[0060] The pattern of the seams shown on the front and back of the
garment 500 are exemplary only, and it is contemplated herein that
different seam patterns may be utilized in accordance with aspects
herein. Moreover, it is contemplated that seams may be present on
the sleeve portions 512 and 514 when the sleeve portions 512 and
514 are formed using the construction 100. The perforation patterns
shown in association with the seams on the garment 500 are also
exemplary, and it is contemplated herein that different perforation
patterns may be utilized in accordance with aspects herein. Any and
all aspects, and any variation thereof, are contemplated as being
within aspects herein.
[0061] FIGS. 7 and 8 illustrate front and back views respectively
of a garment 700 also formed using the construction 100 in
accordance with aspects herein. The garment 700 is in the form of a
short although it is contemplated herein that the garment 700 may
be in the form of a pant, a three-quarter pant, a capri, a tight,
and the like. The garment 700 comprises a torso portion 710 adapted
to cover a lower torso of a wearer when the garment 700 is worn, a
first leg portion 712, and a second leg portion 714. The torso
portion 710 along with the first and second leg portions 712 and
714 help to define at least in part a waist opening 716, a first
leg opening 718, and a second leg opening 720.
[0062] Similar to the garment 500, the garment 700 may be
configured to provide varying levels of insulation over different
portions of the garment 700. This may be based on heat or sweat
maps of the human body. For instance, a greater amount of
insulation may be needed in areas of the garment 700 adapted to
cover the anterior thigh area of a wearer, and lower amounts of
insulation may be needed over the back of the torso portion 710 of
the garment 700. As such, the construction over different parts of
the garment 700 may vary to include a non-woven polymer sheet
without voided portions, a non-woven polymer sheet with voided
portions, a non-woven polymer sheet with voided portions and
perforations, and/or parts of the garment 700 that do not include a
non-woven polymer sheet.
[0063] As stated, the garment 700 may be formed from the
construction 100. As such, some or all of the garment 700 may
comprise the first textile layer 110, the non-woven polymer sheet
112, and the second textile layer 114. One or more portions of the
non-woven polymer sheet 112 may be removed to form voided portions,
such as the voided portion 132 in FIG. 1. With respect to FIG. 7,
seams 722 and 724 may be formed in areas corresponding to voided
portions of the non-woven polymer sheet 112. In exemplary aspects,
seams 722 may be located over a front aspect of the first leg
portion 712, and seams 724 may be located over a front aspect of
the second leg portion 714. Although the seams 722 and 724 are
shown as comprising perforations, it is contemplated herein that
one or more of the seams 722 and/or 724 may not comprise
perforations. Both the seams 722 and 724 are shown in a near
vertical orientation although other orientations are contemplated
herein.
[0064] With respect to FIG. 8 which depicts a back view of the
garment 700, the garment 700 may further comprise seams 810 located
on a back aspect of the second leg portion 714 at a posterior knee
region, and seams 812 located on a back aspect of the first leg
portion 712 at a posterior knee region. Seam 814 may also be
located on a posterior aspect of the torso portion 710 adjacent to
the waist opening 716. As shown, some of the seams 810, 812, and
814 are perforated and some are not.
[0065] The placement and pattern of the seams on the garment 700 is
exemplary only and other patterns are contemplated herein.
Moreover, the perforation pattern shown for the garment 700 is
exemplary only and other perforation patterns are contemplated
herein. Any and all aspects, and any variation thereof, are
contemplated as being within the scope herein.
[0066] The seams shown for the garments 500 and 700 have generally
been shown as being linear. However, it is contemplated that seams
described herein may assume more organic or curvilinear shapes.
FIGS. 9A and 9B illustrate this aspect. For instance, seam 910 in
FIG. 9A comprises a wave-like form, and seam 912 in FIG. 9B
comprise an almost circular component. The seam 912 may define at
least in part a chamber 913. As seen, organic or curvilinear seam
patterns may be used to define, for example, chambers that also
have more organic or curvilinear shapes as compared to more
traditional horizontally oriented, straight-edged chambers. In this
aspect, the chamber 913 is defined by one seam line and may have
one open end. FIGS. 9A and 9B further illustrate perforations
located on the seams 910 and 912.
[0067] Turning now to FIG. 10, a flow diagram depicting an
exemplary method 1000 of forming an insulated vented garment using
non-woven polymer sheets or thermally insulating fill sheets is
provided in accordance with aspects herein. At a step 1010, a first
panel of material, such as the first textile layer 110, is
provided, and at a step 1012 a second panel of material, such as
the second textile layer 114, is provided. In exemplary aspects,
the first and second panels of material may comprise pliable
knitted, woven, or non-woven textiles.
[0068] At a step 1014, a thermally insulating fill sheet such as
the non-woven polymer sheet 112 is provided where the thermally
insulating fill sheet comprises one or more voided portions or
openings each defined by a perimeter edge. In one exemplary aspect,
the voided portions may be formed by removing selected portions of
the thermally insulating fill sheet using, for instance, a
mechanical cutting process, laser jet cutting, water jet cutting,
ultrasonic cutting, and the like. The portions removed from the
thermally insulating fill sheet may be based on, for instance, a
predetermined pattern. In an alternative exemplary aspect, the
thermally insulating fill sheet may be pre-formed to have the
voided portions.
[0069] At a step 1016, the thermally insulating fill sheet is
secured to one or more of the first panel of material and/or the
second panel of material. In exemplary aspects, this may occur by,
for example, tacking or stitching the perimeter edge defining each
of the openings or voided portions to the first and/or second panel
of material. Other ways of securing the thermally insulating fill
sheet to the first and/or second panels of material are
contemplated herein such as using adhesives, bonding, spot welding,
and the like.
[0070] At a step 1018, the first and second panels of material are
positioned adjacent to each other such that the sheet of thermally
insulating fill sheet is interposed between the first and second
panels. At a step 1020, the first and second panels of material are
secured to each other in areas corresponding to the openings or
voided portions in the thermally insulating fill sheet to form
seams. In exemplary aspects, this may occur by providing an
adhesive material, such as an adhesive sheet, that is formed (e.g.,
cut) to have a shape corresponding to the shape of an opening in
the thermally insulating fill sheet. The adhesive material is
positioned between the first and second panels of material such
that it is aligned with the respective opening or voided portion in
the thermally insulating fill sheet. The adhesive material is
activated by the application of, for example, heat, light,
ultrasound, pressure, and the like in the area corresponding to the
opening to bond the first panel of material to the second panel of
material. A similar process is contemplated for each of the
openings or voided portions formed in the thermally insulating fill
sheet. At a step 1022, the garment is formed using at least the
bonded assembly described above.
[0071] Additional method steps are contemplated herein. For
instance, perforations may be formed through some or all of the
seams to impart breathability characteristics to the garment in
addition to the insulation characteristics provided by the use of
the thermally insulating fill sheet. It is further contemplated
herein that the seams formed in the areas corresponding to the
openings or voided portions in the thermally insulating fill sheet
may be reinforced with stitching. The listing of the method steps
1000 is exemplary only, and it is contemplated herein that the
steps may take place in other orders unless specified
otherwise.
[0072] Another exemplary method of construction contemplated herein
comprises using non-woven polymer sheets that do not have voided
portions. In other words, the non-woven polymer sheets comprise
continuous expanses without openings or voided portions formed
therein. The non-woven polymer sheet is positioned between a first
and second textile layer such as the first and second textile
layers 110 and 114 of FIG. 1. However, instead of bonding the first
and second layers directly together at the voided portions of the
non-woven polymer sheet as described with respect to the
construction 100, the first and second textile layers as well as
the non-woven polymer sheet are bonded together in one or more
areas to form seams. With respect to this aspect, material for the
non-woven polymer sheet may be selected such that it melts and/or
acts as an adhesive when activated via, for instance, heat or the
application of energy. It is further contemplated herein that
additional adhesive materials may be used to further augment the
bond between the first and second textile layers and the non-woven
polymer sheet. Thus, in this aspect, a seam area would comprise the
first textile layer, the non-woven polymer sheet, and the second
textile layer. Any and all aspects, and any variation thereof, are
contemplated as being within aspects herein.
[0073] As described, aspects herein are directed to a method of
forming an insulated vented garment using non-woven polymer sheets
such as a thermally insulating poly-fill sheet. Aspects herein are
further directed to an insulated vented garment formed using
non-woven polymer sheets. The use of non-woven polymer sheets
provides an economical and efficient production method, and
garments produced using this type of construction may comprise
organically shaped or curvilinear chambers that can be positioned
on the garment to provide targeted insulation and venting
features.
[0074] Second Exemplary Method of Construction and Garment Produced
Therefrom
[0075] Aspects herein further contemplate a method of forming an
insulated vented garment using sections or strips of a non-woven
polymer material. Aspects herein also contemplate an insulated
vented garment formed using sections or strips of non-woven polymer
material. As used throughout this disclosure, the term "strips" or
"sections" of non-woven polymer material may be defined as
disparate or non-continuous portions of a non-woven polymer
material that are used in the construction of a garment where
adjacent disparate sections of non-woven polymer material may be
separated by a seam as described below. In some aspects, the
section may take the form of a narrow piece of non-woven polymer
material (e.g., a piece whose width is less than its length) which
is hereinafter known as a "strip" of non-woven polymer material.
However, it is contemplated herein that the term "section" may also
encompass other geometries such as square pieces of non-woven
polymer material, rectangular pieces of non-woven polymer material,
circular or triangular pieces of non-woven polymer material,
curvilinear or organically shaped pieces of non-woven polymer
material, and the like. Similar to above, the sections of non-woven
polymer material, when incorporated into a garment, may provide
good insulation due to heated air being trapped between the
entangled fibers while still being lightweight.
[0076] Turning now to FIG. 11, an exploded view of a second
exemplary construction 1100 for an insulated vented garment is
provided in accordance with aspects herein. The construction 1100
comprises a first pliable textile layer 1110, a second pliable
textile layer 1114, and a section of non-woven polymer material
1112. In exemplary aspects, the first textile layer 1110 may
comprise a first surface 1116 and an opposite second surface 1118,
and the second textile layer 1114 may comprise a third surface 1120
and an opposite fourth surface 1122. When the construction 1100 is
used in the garment, the third surface 1120 of the second textile
layer 1114 may comprise an outer-facing surface of the garment or
garment panel, and the second surface 1118 of the first textile
layer 1110 may comprise an inner-facing surface of the garment or
garment panel.
[0077] In exemplary aspects, the first textile layer 1110 and the
second textile layer 1114 may have a similar pattern shape.
However, it is also contemplated herein that the first textile
layer 1110 and the second textile layer 1114 may comprise different
pattern shapes. For example, the first textile layer 1110 may have
a pattern shape comprising a smaller surface area than the second
textile layer 1114. To describe it a different way, the first
textile layer 1110 may be applied to the second textile layer 1114
as sections or "patches" at one or more areas of the second textile
layer 1114. Thus, the insulation features described herein using
the first and second textile layers 1110 and 1114, and the section
of non-woven polymer material 1112 may be incorporated at one or
more discrete portions of a garment or apparel item. This will be
described further with respect to FIG. 13.
[0078] Similar to the construction 100, the first textile layer
1110 and the second textile layer 1114 may comprise a knitted,
woven, or non-woven textile. Further, the first textile layer 1110
may be formed of the same material (e.g., knit or woven material)
as the second textile layer 1114, or the layers 1110 and 1114 may
be formed of different materials (i.e., the first textile layer
1110 may be a knit material and the second textile layer 1114 may
be a woven material or vice versa). In exemplary aspects, one or
more of the layer 1110 and/or 1114 may be treated with a durable
water repellant (DWR) to make the resulting garment substantially
impervious to water. For instance, the second textile layer 1114,
since it is an outer-facing layer, may be treated with a DWR
finish. Moreover, the first textile layer 1110 may be finished such
that is has a soft feel or hand. Finishing may include, for
example, brushing the second surface 1118 of the first textile
layer 1100. Any and all aspects, and any variation thereof, are
contemplated as being within aspects herein.
[0079] It is further contemplated herein that one or more of the
first textile layer 1110 and/or the second textile layer 1114 may
be formed from fabrics having different weights. For instance, the
layers 1110 and/or 1114 may be formed of light fabrics (89
g/m.sup.2 to 30 g/m.sup.2) or even ultra-light fabrics (29
g/m.sup.2 or lighter). However, it is contemplated herein that
heavier fabrics, such as fabrics with weights in the range of 90
g/m.sup.2 to 149 g/m.sup.2 or even 150 g/m.sup.2 to 250 g/m.sup.2
or higher may be used for the layers 110 and/or 114 in accordance
with aspects herein.
[0080] The section of non-woven polymer material 1112 is shown as
having a curved strip-like shape. However, it is contemplated
herein that the section of non-woven polymer material 1112 may
comprise different shapes as described above. The section of
non-woven polymer material 1112 is further shown as being
positioned between the first and second textile layers 1110 and
1114. More specifically, the section of non-woven polymer material
1112 is shown as being positioned between the first surface 1116 of
the first textile layer 1110 and the fourth surface 1122 of the
second textile layer 1114.
[0081] Similar to the non-woven polymer sheet 112 in FIG. 1, the
section of non-woven polymer material 1112 is contemplated to have
a cohesive or unitary structure due to, for example, entanglement
of fibers used to form the section of non-woven polymer material
1112. In exemplary aspects, the section of non-woven polymer
material 1112 may be cut from a non-woven polymer sheet using, for
example, a mechanical cutting process, laser cutting, ultrasonic
cutting, water jet cutting, and the like. In other exemplary
aspects, the section of non-woven polymer material 1112 may be
formed to have the shape shown. Any and all aspects, and any
variation thereof, are contemplated as being within aspects
herein.
[0082] The construction 1100 further comprises a first adhesive
material 1124 and a second adhesive material 1126. In exemplary
aspects, the first adhesive material 1124 and the second adhesive
material 1126 may comprise an adhesive tape formed to have a shape
generally corresponding to the shape of the section of non-woven
polymer material 1112. The first adhesive material 1124 and the
second adhesive material 1126 may be used to bond the first textile
layer 1110 to the second textile layer 1114.
[0083] To assemble the construction 1100, the section of non-woven
polymer material 1112 may be secured to the first surface 1116 of
the first textile layer 1110, and the first and second adhesive
materials 1124 and 1126 may be positioned adjacent to the section
of non-woven polymer material 1112 on the first surface 1116 of the
first textile layer 1110. More particularly, the first adhesive
material 1124 and the second adhesive material 1126 may be
positioned on the first surface 1116 of the first textile layer
1110 adjacent to the section of non-woven polymer material 1112 on
opposing sides of the section of non-woven polymer material 1112.
As used with respect to this aspect, the term "adjacent" may mean
within 0.0 mm to 20.0 mm of an edge of the section of non-woven
polymer material 1112. The fourth surface 1122 of the second
textile layer 1114 may then be positioned adjacent to the first
surface 1116 of the first textile layer 1110. The two layers 1110
and 1114 may be pressed together with sufficient force and/or
energy applied in the areas generally corresponding to the adhesive
materials 1124 and 1126 to activate the adhesive materials 1124 and
1126 and cause a bond between the two layers 1110 and 1114. The
adhesive materials 1124 and 1126 may be activated by, for instance,
heat, or ultrasonic energy, or any other type of applied energy. In
the construction 1100, the first and second textile layers 1110 and
1114 are un-affixed or un-bonded in areas corresponding to the
section of non-woven polymer material 1112.
[0084] Once the first textile layer 1110 and the second textile
layer 1114 are bonded together, seams are formed at the bonded
areas. In other words, a seam is formed at an area corresponding to
the first adhesive material 1124 and a seam is formed at an area
corresponding to the second adhesive material 1126. It is
contemplated herein, that instead of positioning the first and
second adhesive materials 1124 and 1126 adjacent to the first
textile layer 1110, the adhesive materials 1124 and 1126 may be
positioned adjacent to the second textile layer 1114. It is further
contemplated herein that additional adhesive materials may be used
to bond the first and second textile layers 1110 and 1114 together
in areas adjacent to the section of non-woven polymer material
1112. Any and all aspects, and any variation thereof, are
contemplated as being within aspects herein.
[0085] The construction 1100 further comprises one or more optional
perforations 1134 and 1136. In exemplary aspects, the perforations
1134 may be made through the second textile layer 1114 and the
first textile layer 1110 in the area corresponding to the second
adhesive material 1126, and the perforations 1136 may be made
through the second textile layer 1114 and the first textile layer
1110 in the area corresponding to the first adhesive material 1124.
To put it another way, the perforations 1134 are formed at the seam
area created when the first textile layer 1110 is affixed or bonded
to the second textile layer 1114 using the second adhesive material
1126. And the perforations 1136 are formed at the seam area created
when the first textile layer 1110 is affixed or bonded to the
second textile layer 1114 using the first adhesive material 1124.
The perforations 1134 and 1136 may be formed using, for instance, a
mechanical cutting process, a knitting or weaving process, laser
cutting, water jet cutting, ultrasonic cutting, and the like. As
stated above, the perforations 1134 and 1136 may be used to allow
moisture vapor or excess heat produced by the wearer to exit the
garment.
[0086] Turning to FIG. 12A, referenced generally by the numeral
1200, a top perspective view of a portion of the construction 1100
is shown comprising the section of non-woven polymer material 1112
positioned on the first surface 1116 of the first textile layer
1110 in accordance with aspects herein. Before affixing the first
textile layer 1110 to the second textile layer 1114 using the first
and second adhesive materials 1124 and 1126 as described above, the
section of non-woven polymer material 1112 may be secured to the
first textile layer 1110 to prevent shifting of the section of
non-woven polymer material 1112 during manipulation of the
construction 1100. In an exemplary aspect, this may be done by
tacking or stitching the section of non-woven polymer material 1112
along its perimeter edge as indicated by the reference numeral
1210. However, other ways of securing the section of non-woven
polymer material 1112 to the first textile layer 1110 are
contemplated herein such as using an adhesive, bonding, spot
welding, and the like. It is also contemplated herein that instead
of securing the section of non-woven polymer material 1112 to the
first textile layer 1110, it may be secured to the second textile
layer 1114 or to both the first and second textile layers 1110 and
1114. Any and all aspects, and any variation thereof, are
contemplated as being within aspects herein.
[0087] FIG. 12B illustrates a top perspective view of the
construction 1100 in an as-assembled state in accordance with
aspects herein. As shown, the second textile layer 1114 is
positioned adjacent the first textile layer 1110 such that the
third surface 1120 of the second textile layer 1114 is exposed. The
section of non-woven polymer material 1112 is positioned between
the first and second textile layers 1110 and 1114 as indicated by
the dashed line. As discussed, the first textile layer 1110 and the
second textile layer 1114 are bonded or secured to each other at a
first seam 1310 corresponding to the second adhesive material 1126
and a second seam 1312 corresponding to the first adhesive material
1124. It is contemplated herein that the first textile layer 1110
and the second textile layer 1114 may be generally unsecured or
unaffixed to each other except at the seams 1310 and 1312. The
seams 1310 and 1312 are positioned adjacent to and on opposing
sides of the section of non-woven polymer material 1112 and help to
define a chamber 1314 containing the section of non-woven polymer
material 1112. To describe it another way, the chamber 1314 is
bounded or defined on at least two sides by the seams 1310 and 1312
but may not be defined by seams at the ends of the chamber 1314
(i.e., it is an open-ended chamber 1314). The creation of
open-ended chambers, such as the chamber 1314 is possible due to
the cohesive or unitary construction of the section of non-woven
polymer material 1112 as opposed to loose fill materials that may
need to be completely enclosed within a chamber to prevent
drift.
[0088] FIG. 12B further illustrates the optional perforations 1134
and 1136. The perforations 1134 are positioned at the first seam
1310 and extend through the first and second textile layers 1110
and 1114 in this area. Similarly, the perforations 1136 are
positioned at the second seam 1312 and extend through the first and
second textile layers 1110 and 1114 in this area.
[0089] As described above, it is contemplated herein that the first
textile layer 1110 may have a different pattern shape than the
second textile layer 1114 such that the first textile layer 1110
has a smaller surface area than the second textile layer 1114. This
is shown in FIG. 13, referenced generally by the numeral 1300,
which depicts a bottom perspective view of an alternative
configuration for the construction 1100 where the first textile
layer 1110 has a different pattern shape than the second textile
layer 1114. In this aspect, the first textile layer 1110 is defined
by perimeter edges 1352, 1354, 1356, and 1358, and the surface area
of the first textile layer 1110 is less than the surface area of
the second textile layer 1114. Besides being secured to the second
textile layer 1114 at the bonded seams 1310 and 1312, the first
textile layer 1110 may also be secured to the second textile 1114
along its perimeter edges 1352, 1354, 1356, and 1358. This may
through the use of an adhesive seam tape, bonding, stitching,
welding, and the like. In exemplary aspects, the remaining portions
of the first textile layer 1110 may remain un-affixed to the second
textile layer 1114.
[0090] The configuration shown in FIG. 13 enables the formation of
insulated and vented sections at various portions of a garment
formed using, for instance, the second textile layer 1114. For
instance, the second textile layer 1114 may be used to form a
garment such as a shirt. In areas needing a higher amount of
insulation, sections of the first textile layer 1110 may be used to
form the construction 1100 shown in FIG. 11. By limiting the areas
in which the first textile layer 1110 is used, a lighter-weight
construction may be achieved while still having needed insulation
features.
[0091] Continuing, a cross-section of the construction 1100 taken
along cut line 14-14 of FIG. 12B is shown in FIG. 14 in accordance
with aspects herein. The seams 1310 and 1312 are shown as being
positioned adjacent to the chamber 1314 containing the section of
non-woven polymer material 1112. In other words, the chamber 1314
comprises the first textile layer 1110, the section of non-woven
polymer material 1112, and the second textile layer 1114. As shown,
the seams 1310 and 1312 comprise just the first and second textile
layers 1110 and 1114. The perforation 1134 is shown as extending
through the first and second textile layers 1110 and 1114 at the
seam 1310, and the perforation 1136 is shown as extending through
the first and second textile layers 1110 and 1114 at the seam
1312.
[0092] Although the construction 1100 is shown comprising one
section of non-woven polymer material 1112, it is contemplated
herein that the construction 1100 may comprise multiple sections of
non-woven polymer material, where each section is separated from an
adjacent section of non-woven polymer material by a seam, where the
seam may comprise optional perforations. Any and all aspects, and
any variation thereof, are contemplated as being within aspects
herein.
[0093] Turning to FIG. 15, a front view of a garment 1500 having
the construction 1100 is shown in accordance with aspects herein.
The garment 1500 is shown in the form of a jacket although it is
contemplated herein that the garment 1500 may take other forms such
as a shirt, a pull-over hoodie, a vest, a pant, a short, a body
suit, a sock, a hat, a shoe, and the like. The garment 1500
comprises a torso portion 1510 configured to cover the front and
back torso of a wearer when the garment 1500 is in an as-worn
configuration. The torso portion 1510 may comprise an optional
releasable fastener mechanism 1511 such as a zipper used to open
and close the garment 1500. The torso portion 1510 defines at least
a neck opening 1516, a waist opening 1518, and first and second
sleeve openings (not shown). The neck opening 1516, in turn, may be
defined by a collar portion. The garment 1500 may optionally
comprise a first sleeve portion 1512 extending from the torso
portion 1510 at the first sleeve opening, and a second sleeve
portion 1514 extending from the torso portion 1510 at the second
sleeve opening.
[0094] Some are all of the garment 1500 may comprise the
construction 1100 shown in FIGS. 11-14. For instance, it is
contemplated herein that an entirety of the torso portion 1510 may
be formed of the construction 1100. In some aspects, the first and
second sleeve portions 1512 and 1514 may also be formed from the
construction 1100.
[0095] Similar to the garment 500, it is also contemplated herein
that the construction 1100 may be used on only portions of the
garment 1500. For instance, the garment 1500 may be zoned into
different areas such as areas needing a high amount of insulation,
a moderate amount of insulation, and areas needing a low amount of
insulation.
[0096] Continuing, areas needing a high to moderate amount of
insulation may be formed from the construction 1100. However, seams
formed in these areas may not be perforated. Areas needing a low
amount of insulation may also be formed from the construction 1100.
Seams in these areas may be perforated to increase permeability and
breathability in these areas. Alternatively, areas needing a low
amount of insulation may be formed without using the construction
1100. For instance, these areas may not comprise sections of
non-woven polymer material 1112 and instead may comprise just the
first and second textile layers 1110 and 1114, just one of the
layers 1110 or 1114, or the areas may comprise a different textile
such as, for instance, a mesh material for greater permeability and
breathability. Any and all aspects, and any variation thereof, are
contemplated as being within aspects herein.
[0097] Referring particularly to the garment 1500, the garment 1500
comprises a number of seams such as seam 1520 and seam 1522 located
on an upper aspect of the torso portion 1510 on a first lateral
side, and seam 1526 and 1528 located on an upper aspect of the
torso portion 1510 on a second opposite lateral side. In an
optional aspect, the seams 1520, 1522, 1526, and 1528 may be
reinforced with stitching. The stitching may be along one edge of
the seams 1520, 1522, 1526, and 1528 or along both edges of the
seams 1520, 1522, 1526, and 1528. Any and all aspects, and any
variation thereof, are contemplated as being within aspects
herein.
[0098] In exemplary aspects, the seam 1520 and the seam 1522 define
a first chamber 1524 comprising a section of non-woven polymer
material, and the seam 1526 and the seam 1528 defined a second
chamber 1530 comprising an additional section of non-woven polymer
material. The chambers 1524 and 1530 are shown as being defined on
two sides by seams but as being open at each end. Some or all of
the seams 1520, 1522, 1526, and 1528 may be perforated. For
instance, the seams 1520 and 1526 are shown as comprising
perforations 1532. Similar to the discussion of the perforations
with respect to the garment 500, the perforations 1532 may comprise
different sizes, shapes, and may be formed continuously or
intermittently along the seams 1520 and 1526. Any and all aspects,
and any variation thereof, are contemplated as being within aspects
herein.
[0099] Although the seams 1520, 1522, 1526, and 1528 and the
chambers 1524 and 1530 are shown in a generally horizontal
orientation, it is contemplated herein that the garment 1500 may
comprise seams and chambers that have a generally vertical
orientation or that assume a more curvilinear or organic shape such
as the exemplary shapes shown in FIGS. 9A and 9B. Moreover, the
placement of the seams 1520, 1522, 1526, and 1528 and the chambers
1524 and 1530 shown in FIG. 15 is exemplary only and other patterns
are contemplated herein such as the pattern shown in FIG. 5 for the
garment 500. Although not shown, it is further contemplated that
the back of the garment 1500 may also comprise seams, chambers,
and/or perforations. For instance, the back of the garment 1500 may
have a pattern of seams, chambers, and/or perforations similar to
that shown for the garment 500 in FIG. 6. Any and all aspects, and
any variation thereof, are contemplated as being within aspects
herein.
[0100] FIG. 16 illustrates a front view of a garment 1600 also
formed using the construction 1100 in accordance with aspects
herein. The garment 1600 is in the form of a short although it is
contemplated herein that the garment 1600 may be in the form of a
pant, a three-quarter pant, a capri, a tight, and the like. The
garment 1600 comprises a torso portion 1610 adapted to cover a
lower torso of a wearer when the garment 1600 is worn, a first leg
portion 1612, and a second leg portion 1614. The torso portion 1610
along with the first and second leg portions 1612 and 1614 help to
define at least in part a waist opening 1616, a first leg opening
1618, and a second leg opening 1620.
[0101] Similar to the garment 700 of FIGS. 7 and 8, the garment
1600 may be configured to provide varying levels of insulation over
different portions of the garment 1600. As such, the construction
over different parts of the garment 1600 may vary to include areas
having sections of non-woven polymer material, areas without
sections of non-woven polymer material, seams with perforations,
seams without perforations, no seams, and the like.
[0102] As shown in FIG. 16, the garment 1600 comprises seams 1622
and 1624 located on the first leg portion 1612 such that they are
configured to be positioned adjacent to a right anterior thigh area
of a wearer when the garment 1600 is worn. The seams 1622 and 1624
define at least in part a chamber 1626 comprising a section of
non-woven polymer material. Similarly, the garment 1600 further
comprises seams 1628 and 1630 located on the second leg portion
1614 such that they are configured to be positioned adjacent to a
left anterior thigh area of a wearer when the garment 1600 is worn.
Some or all of the seams 1622, 1624, 1628, and 1630 may be
perforated. For example, seam 1624 and seam 1630 are shown as
comprising perforations in FIG. 16.
[0103] Although the seams 1622, 1624, 1628, and 1630 and the
chambers 1626 and 1632 are shown in a generally horizontal
orientation, it is contemplated herein that the seams 1622, 1624,
1628, and 1630 and the chambers 1626 and 1632 may assume a more
vertical orientation or they may assume a more curvilinear or
organic aspects. Moreover, the placement of the seams 1622, 1624,
1628, and 1630 and the chambers 1626 and 1632 shown in FIG. 16 is
exemplary only and other patterns are contemplated herein such as
the pattern shown in FIG. 7 for the garment 700. Although not
shown, it is further contemplated that the back of the garment 1600
may also comprise seams, chambers, and/or perforations. For
instance, the back of the garment 1600 may have a pattern of seams,
chambers, and/or perforations similar to that shown for the garment
700 in FIG. 8. Any and all aspects, and any variation thereof, are
contemplated as being within aspects herein.
[0104] Turning to FIG. 17, a flow diagram of an exemplary method
1700 of forming an insulated, vented garment using sections or
strips of non-woven polymer material or thermally insulating fill
material is provided in accordance with aspects herein. At a step
1710, a first panel of material, such as the first textile layer
1110, is provided, and, at a step 1712, a second panel of material,
such as the second textile layer 1114, is provided. In exemplary
aspects, the first and second panels of material may comprise
pliable knitted, woven, or non-woven textiles.
[0105] At a step 1714, a section of thermally insulating fill
material, such as the section of non-woven polymer material 1112,
is provided. The section of thermally insulating fill material may
be cut from a sheet of thermally insulating fill material, or the
section of thermally insulating fill material may be formed to have
a specific shape as needed for construction.
[0106] At a step 1716, the section of thermally insulating fill
material is positioned between the first and second panels of
material. In exemplary aspects, the section of thermally insulating
fill material may be secured to the first panel of material and/or
the second panel of material by stitching or tacking the section of
thermally insulating fill material along its perimeter edge to the
panel(s). Other ways of securing the section of thermally
insulating fill material to the first and/or second panels of
material are contemplated herein such as using adhesives, bonding,
spot welding, and the like.
[0107] At a step 1718, the first and second panels of material are
positioned adjacent to each other such that the section of
thermally insulating fill material is interposed or positioned
between the first and second panels. At a step 1720, the first and
second panels of material are secured to each other in areas
adjacent to the section of thermally insulating fill material to
form seams. In exemplary aspects, this may occur by providing an
adhesive material, such as an adhesive sheet, that is formed (e.g.,
cut) to have a shape corresponding to the general shape of the
section of thermally insulating fill material. The adhesive
material is positioned between the first and second panels of
material such that it is positioned adjacent to one or more edges
of the section of thermally insulating fill material. The adhesive
material is activated by the application of, for example, heat,
light, ultrasound, pressure, and the like in the areas adjacent to
the section of thermally insulating fill material to bond the first
panel of material to the second panel of material. A similar
process is contemplated for additional sections of thermally
insulating fill material. At a step 1722, the garment is formed
using at least the bonded assembly described above.
[0108] Additional method steps are contemplated herein. For
instance, perforations may be formed through some or all of the
seams to impart breathability characteristics to the garment in
addition to the insulation characteristics provided by the use of
the sections of thermally insulating fill material. It is further
contemplated herein that the seams formed in the areas adjacent to
the sections of thermally insulating fill material may be
reinforced with stitching. The listing of the method steps 1700 is
exemplary only, and it is contemplated herein that the steps may
take place in other orders unless specified otherwise.
[0109] As described, aspects herein are directed to a method of
forming an insulated vented garment using sections of non-woven
polymer material such as a poly-fill material. Aspects herein are
further directed to an insulated vented garment formed using
sections of non-woven polymer material. The use of sections of
non-woven polymer material provides an economical and efficient
production method, and garments produced using this type of
construction may comprise organically shaped or curvilinear
chambers that can be positioned on the garment to provide targeted
insulation and venting features.
[0110] Aspects of the present disclosure have been described with
the intent to be illustrative rather than restrictive. Alternative
aspects will become apparent to those skilled in the art that do
not depart from its scope. A skilled artisan may develop
alternative means of implementing the aforementioned improvements
without departing from the scope of the present invention.
[0111] It will be understood that certain features and
subcombinations are of utility and may be employed without
reference to other features and subcombinations and are
contemplated within the scope of the claims. Not all steps listed
in the various figures need be carried out in the specific order
described.
* * * * *