US20260033575A1
2026-02-05
19/286,850
2025-07-31
Smart Summary: Garments are designed with special pockets filled with air to keep the wearer warm. These air pockets can be inflated or deflated as needed. They are made by combining different layers of fabric and film to create sealed pockets within the garment. A pump can be used to add air, while a release system allows the wearer to let air out. This feature lets the wearer adjust the warmth of the garment easily. 🚀 TL;DR
Garments include one or more fluid-filled bladder chambers for providing thermal insulation to a wearer. The bladder chamber(s) may be convertible between a deflated condition and an inflated condition. The bladder chamber(s) may be integrally formed with the fabric forming the garment, e.g., with the bladder chamber(s) defined between an exterior laminated component (e.g., formed from a fabric layer and a film layer) and an interior component (e.g., including at least a film layer). The film layers are selectively fixed together, e.g., at a perimeter bond and/or one or more internal bonded regions, to form fluid-tight bladder chamber portions within the overall garment structure. The garments may be equipped with a pump (for adding air to the garment bladder chamber(s)) and/or a release system (for removing air from the garment bladder chamber(s)). In this manner, a wearer can change the garment between the deflated condition and the inflated condition.
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Materials specially adapted for outerwear characterised by special function or use Thermally protective, e.g. insulating
This application is a U.S. Non-Provisional application and claims priority benefits based on: (a) U.S. Provisional Patent Appln. No. 63/677,693 filed Jul. 31, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders,” (b) U.S. Provisional Patent Appln. No. 63/677,708 filed Jul. 31, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders,” (c) U.S. Provisional Patent Appln. No. 63/677,842 filed Jul. 31, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders,” (d) U.S. Provisional Patent Appln. No. 63/677,870 filed Jul. 31, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders,” (c) U.S. Provisional Patent Appln. No. 63/726,392 filed Nov. 29, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders,” (f) U.S. Provisional Patent Appln. No. 63/726,394 filed Nov. 29, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders,” (g) U.S. Provisional Patent Appln. No. 63/726,399 filed Nov. 29, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders,” and (h) U.S. Provisional Patent Appln. No. 63/726,427 filed Nov. 29, 2024 and entitled “Laminates, Bladders, and Garments Including Laminates and Bladders.” Each of U.S. Provisional Patent Appln. No. 63/677,693, U.S. Provisional Patent Appln. No. 63/677,708, U.S. Provisional Patent Appln. No. 63/677,842, U.S. Provisional Patent Appln. No. 63/677,870, U.S. Provisional Patent Appln. No. 63/726,392, U.S. Provisional Patent Appln. No. 63/726,394, U.S. Provisional Patent Appln. No. 63/726,399, and U.S. Provisional Patent Appln. No. 63/726,427 is entirely incorporated herein by reference.
The present invention relates to laminates, bladders made from laminates, garment components and garments including such laminates and bladders, and/or methods of making and/or using such laminates, bladders, garment components, and/or garments. In some aspects of this technology, garment components and garments will include inflatable bladder chambers configured to provide thermal insulation for the wearer.
Conventional articles of apparel for providing warmth include garments such as jackets, vest, coats, and the like. Such garments typically are made from heavy materials, such as wool, fleece, or the like, and/or include insulation, such as down, polymeric fillers, etc. While potentially effective at keeping the wearer warm, some conventional garments of these types can restrict motion, e.g., particularly if worn during athletic activities.
Some conventional garments of these types can become heavier and/or experience reduced effectiveness, e.g., particularly when worn in wet conditions and/or when the fabric or insulation otherwise becomes damp or wet. These factors can result in decreased effectiveness of the garment, especially for wearers engaged in athletic activities.
This Summary is provided to introduce some general concepts relating to this technology in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the invention.
Aspects of this technology relate to laminates, bladders made from laminates, garment components and garments including such laminates and bladders, and/or methods of making and/or using such laminates, bladders, garment components, and/or garments, e.g., of the types described and/or claimed below and/or of the types illustrated in the appended drawings. In some aspects of this technology, the bladders will include inflatable bladder chambers configured to provide thermal insulation for a wearer. Such laminates, bladders, and garment components and garments including such laminates and bladders may include any one or more structures, parts, features, properties, and/or combination(s) of structures, parts, features, and/or properties of the examples described and/or claimed below and/or of the examples illustrated in the appended drawings.
Some more specific aspects of this technology relate to garments including one or more inflatable bladder chambers, e.g., for providing thermal insulation to a wearer. The bladder chamber(s) may be convertible between a deflated condition and an inflated condition. In other words, a bladder chamber may be in a deflated condition or may be in an inflated condition and may be configured to transition between conditions when a fluid (e.g. air) is introduced into the bladder chamber or released from the bladder chamber. Thus, the bladder chamber may switch from an inflated condition to a deflated condition and may switch from a deflated condition to an inflated condition.
The bladder chamber(s) may be formed by the elements forming the garment itself. Exemplarily, the bladder chamber(s) may be defined between an exterior component of the garment and an interior component of the garment. In other words, the bladder chamber may not comprise any element extraneous to the garment. For instance, the bladder chamber may not comprise any fluid container (such as a pouch or bag), e.g. made from a plastic material, that is formed externally to the garment and then inserted into the garment.
In particular, the exterior component may comprise a first layer (and optionally may constitute only the first layer) and the interior component may comprise a second layer (and optionally may constitute only the second layer), and a bladder chamber may comprise a space between the first and second layers. The space may be substantially empty and/or at atmospheric pressure when the bladder chamber is in a deflated condition and/or the space may be filled with air at a pressure above atmospheric pressure when the bladder chamber is in an inflated condition.
Exemplarily, the exterior component may be a laminated component (e.g., formed from the first layer and an additional layer) and the interior component may comprise only the second layer or may be a laminated component comprising one or more other layers besides the second layer (i.e., the interior component includes at least the second layer). The layers may face one another and may be selectively or partly fixed together, e.g., at a perimeter bond and/or one or more internal bonded regions, to form one or more fluid-tight bladder chambers between the layers and within the overall garment structure.
Exemplarily, the first and second layers may be film layers (also referred to herein as “films”). A film layer may be a portion of material with a thickness in the order of hundreds or tens of microns, e.g. between about 20 microns and 120 microns, such as about 30-60 microns. Such film layers may have a single layer construction or a multi-layer construction with two or more layers.
A film layer may be made of a material comprising plastic, e.g., a thermoplastic elastomer, a polyurethane, and/or a thermoplastic polyurethane. A film layer may be such that it prevents or substantially limits the passage of air through it, i.e., it may be air impermeable. In some examples, a film layer may constitute a single layer. In other examples, a film layer may comprise a plurality of (sub-) layers and may constitute a multi-layer structure.
A laminated component for forming a bladder chamber in a garment may comprise a film layer and at least one additional layer. The additional layer may be a fabric layer (also referred to herein as “fabric”). A fabric layer may be obtained via mechanical manipulation of yarn. In particular, the fabric layer may be obtained by interlooping yarn and, more specifically, it may be a knit fabric layer. Interlooping particularly may include forming yarn(s) into loops, each (or part) of which is only released after a succeeding loop has been formed and intermeshed with it.
Exemplarily, the fabric layer may be formed from a drawn textured yarn. Exemplarily, the fabric layer may have a double jersey knit structure.
The fabric layer and the film layer may be joined to form the laminated component, e.g., by means of an adhesive. The adhesive may be applied to a surface of the fabric layer and/or to a surface of the film layer. The adhesive may be applied discontinuously or intermittently.
Exemplarily, the adhesive between the fabric layer and the film layer may comprise a plurality of spaced-apart adhesive regions. In other words, the adhesive may comprise a plurality of adhesive regions physically separated from each other, i.e. not contacting each other. The spaced-apart adhesive regions may be formed as “dots” of adhesive in some particular examples.
Alternatively, in some specific examples, the adhesive between the fabric layer and the film layer may comprise a full layer of adhesive (e.g., a continuous layer of adhesive of constant or varying thickness). In some examples, the adhesive between the fabric layer and the film layer may comprise a substantially full layer of adhesive (e.g., of constant or varying thickness), such as a layer of adhesive covering at least 90% of a surface area between interfacing surfaces of the film and fabric.
The peel strength between the fabric layer and the film layer may be at least about 0.85 kg/cm, and in some examples, at least about 0.9 kg/cm, at least about 0.95 kg/cm, at least about 1 kg/cm, or even at least 1.05 kg/cm. Peel strength may be measured using International Standard ISO 2411.
As mentioned, the exterior component may be a laminated component. Additionally or alternatively, the interior component may be a laminated component.
When both are laminated components, the exterior laminated component may have the same properties, materials, and/or constructions as the interior laminated component. Alternatively, the exterior laminated component and the interior laminated component may differ in one or more of properties, materials, and/or construction features.
In some examples of this technology, garments of the types described above may be equipped with a pump (for adding air to the garment bladder chamber(s)) and/or a release system (for removing air from the garment bladder chamber(s)). With this additional equipment, a wearer can change the garment between the deflated condition and the inflated condition and, in at least some examples, control the pressure within the bladder chamber(s). By changing between the deflated condition and inflated condition, the wearer can control the thermal insulation characteristics of the garment.
While aspects of this technology are described in terms of laminates, bladders made from one or more laminates, garment components and garments including one or more of such laminates and bladders, additional aspects of this technology relate to methods of making and/or using such laminates, bladders, garment components, and garments.
The foregoing Summary, as well as the following Detailed Description, will be better understood when considered in conjunction with the accompanying drawings in which like reference numerals refer to the same or similar elements in all of the various views in which that reference number appears.
FIGS. 1A-1H illustrate various views and various features of garments in accordance with some examples of this technology.
FIGS. 2A and 2B illustrate features and methods of making laminated components used in some examples of this technology.
FIGS. 3A-3C illustrate features and methods of making one example garment component in accordance with some aspects of this technology.
FIGS. 4A and 4B illustrate features and methods of making another example garment component in accordance with some aspects of this technology.
FIGS. 5A-5C illustrate features and methods of making additional example garment components in accordance with some aspects of this technology.
FIGS. 6-10 illustrates features of making garments or garment components in accordance with some examples of this technology.
FIGS. 11A-11H illustrate features and examples of different arrangements of internal bonded regions in accordance with different examples of this technology.
FIG. 12 illustrates another example garment component structure in accordance with some aspects of this technology.
FIG. 13 illustrates another example garment component structure in accordance with some aspects of this technology.
FIGS. 14A-14C illustrate another example garment component structure in accordance with aspects of this technology.
FIGS. 15A-15D illustrate features of another example garment structure in accordance with aspects of this technology.
FIGS. 16A-16C illustrate features of another example garment structure in accordance with aspects of this technology.
FIGS. 17A-17H illustrate features of another example garment structure and method of making it in accordance with aspects of this technology.
FIG. 18 illustrates features of a cuff component that may be included in garment structures in accordance with some examples of this technology.
FIGS. 19A and 19B illustrate features of a drawstring component that may be included in garment structures in accordance with some examples of this technology.
FIGS. 20A-20F illustrate features of seam structures including fluid passageways and methods of making the seam structures that may be used in garment structures in accordance with some examples of this technology.
FIGS. 21A and 21B illustrate features of differences in a tubular garment component in accordance with some examples of this technology when deflated and inflated.
FIG. 22 illustrates features relating to mounting other garment components to garment components with inflatable bladder chambers in accordance with some examples of this technology.
FIG. 23 illustrates features of incorporating a pocket component in garments in accordance with some examples of this technology.
FIG. 24 illustrates features of internal bonded regions spacings in accordance with some examples of this technology.
In the following description of various examples of laminates, bladders, garment components, and garments according to the present technology, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example structures and environments in which aspects of this technology may be practiced. It is to be understood that other structures and environments may be utilized and that structural and functional modifications may be made to the specifically described structures, functions, and methods without departing from the scope of the present disclosure.
This application and/or claims use the adjectives, e.g., “first,” “second,” “third,” and the like, to identify certain components and/or features relating to this technology. These adjectives are used merely for convenience, e.g., to assist in maintaining a distinction between components and/or features of a specific structure. Use of these adjectives should not be construed as requiring a specific order or arrangement of the components and/or features being discussed. Also, use of these specific adjectives in the specification for a specific structure does not require that the same adjective be used in the claims to refer to the same part (e.g., a component or feature referred to as the “third” in the specification may correspond to any numerical adjective used for that component or feature in the claims).
This application describes components (e.g., garment components (including fabric components and laminated components), bladder components, film layers, and the like) that are “bonded” together. The term “bonded” (and derivatives thereof) means that the components are joined securely to one another. The term “bonded” encompasses bonds formed using adhesives or cements (including hot melt adhesives) as well as bonds formed in an “adhesive-free” manner, i.e., without use of a separate adhesive component.
“Adhesive-free” bonds include: bonds formed by fusing or melting components together (e.g., if the components include compositions that are compatible to mix and join together to form a bond, such as two components including a thermoplastic polyurethane (“TPU”) component); bonds formed by welding techniques (e.g., RF welding, ultrasonic welding, high-frequency welding, laser welding, impulse welding, etc.); bonds formed by heat scaling (e.g., by applying heat and optionally, pressure); etc. Some adhesive-free bonds may form a seamless joint between the two previously separate components (e.g., the materials may mix and join together and then re-harden with no discernible junction).
The term “melt bond” and variations thereof, as used herein, mean bonds formed where localized melting of each component occurs (e.g., melting of the thermoplastic polymer present in each component), the melted components combine together, and then the combined components harden to thereby “fuse” and “bond” the two components together. Such melt bonded joints are adhesive-free and may be seamless.
The term “engaged with” is used herein as a generic term and includes both adhesive based bonds and adhesive-free bonds within its scope as well as other potential types of engagement that fix two (or more) components together in a “non-bonded” manner (including through the use of mechanical connectors or fasteners, through the use of sewing or stitching, etc.).
The term “fluid impervious” as used herein means that the noted component (e.g., a film, a laminated component, a bonded region, a seam, a surface, a bladder, a garment component, a garment, etc.) is capable of stopping or reducing a rate at which air passes from one side of the component to the other side of the component. “Fluid impervious” bladders, garment components, and/or garments in accordance with at least some examples of this technology will maintain an inflated condition (holding air at a pressure above atmospheric pressure) for at least 10 minutes. While some gas may leak out of or diffuse through a “fluid impervious” component over time, the component may be considered “fluid impervious” if it can maintain an inflated condition (with the contained air at a pressure above atmospheric pressure) for at least about 10 minutes.
Some more specific aspects or examples of this technology relate to garments including one or more fluid-filled bladder chambers for providing thermal insulation to a wearer. The bladder chamber(s) may be convertible between a deflated condition and an inflated condition. The bladder chamber(s) may be formed by the elements forming the garment, e.g., with the bladder chamber(s) defined between an exterior laminated component (e.g., formed from a fabric layer and a film layer) and an interior component (e.g., including at least a film layer, but which also may be a laminated component (e.g., formed from a fabric layer and a film layer)). The film layers are selectively fixed together, e.g., at a perimeter bond and/or one or more internal bonded regions, to form fluid-tight bladder chamber portions between the film layers and within the overall garment structure
Garments in accordance with aspects of this technology may include various features to help maintain soft feel and/or suitable drape properties. In some garment examples according to this technology, the garment will include an exterior laminated component (formed from a fabric layer and a film layer) and an interior layer (optionally also a laminated component, but at least including a film layer).
In the exterior laminated component, the fabric layer may be fixed to the film layer by an adhesive applied at spaced-apart locations between the fabric and film layers. The intermittently applied adhesive layer can reduce stiffness of the exterior laminated component to provide a more flexible, soft feeling fabric with excellent hand feel and drape properties.
Additionally or alternatively, the interior component may comprise a laminated component, optionally with an adhesive applied at spaced apart locations between the fabric and film layers of that laminated component. The intermittently applied adhesive layer can reduce stiffness of the interior laminated component to provide a more flexible, soft feeling fabric with excellent hand feel and drape properties.
As an alternative to spaced-apart adhesive application described above, the adhesive may be applied continuously between the fabric and film in the interior laminated component and/or the exterior laminated component, which can improve peel strength and reduce delamination of the film from the fabric. Further, lamination with the adhesive applied continuously can improve air holding ability of a baffle made with the exterior laminated component and the interior laminated component.
In some examples, the application of the adhesive (e.g., amount of adhesive) between the fabric and film in the laminated component(s) may be configured to maintain hand-feel and drape. Additionally or alternatively, the thicknesses of the fabric and film layers in the laminated component(s) may be selected to maintain hand-feel and drape.
The exterior laminated component and the interior layer may include very thin films (e.g., less than 120 micron thick) forming the bladder chamber portions, e.g., to help maintain better flexibility of the laminated components.
Still additional aspects of this technology relate to methods of making and/or using the laminates, bladders, garment components, and garments of the types described above.
Given the general description of features, examples, aspects, structures, and methods according to examples of this technology provided above, a more detailed description of specific example laminates, bladder structures, garment components, garments, and methods in accordance with this technology follows.
FIGS. 1A-1H show various features of garments 100 in accordance with some aspects of this technology. More specifically: FIG. 1A provides a front view of a garment 100 including one or more garment components 102 that include an inflatable bladder chamber 110 (a sealed and fluid impervious chamber configured to contain a fluid under pressure); FIG. 1B provides a back view of the garment; FIG. 1C provides a close-up of one side of a bonded region 120 within a bladder chamber 110; FIG. 1D provides a partial sectional view through a bonded region 120 within a bladder chamber 110; FIG. 1E provides a partial cross-sectional view of a bladder chamber 110 of a garment component 102 showing bonded regions 120 and inflatable chamber portions 110D; FIG. 1F provides a partial cross sectional view of a bladder chamber 110 of a garment component 102 showing other potential features; and FIGS. 1G and 1H provide views illustrating features of incorporating a securing system 140 into garments 100 according to some examples of this technology.
The specific example garment 100 of FIGS. 1A and 1B is formed as a jacket or coat, but other types of garments may be formed in other specific examples of this technology, such as a jacket with a hood, a vest, a shirt, another type of upper body garment, another type of garment including an upper body portion, a lower body portion, a footwear upper (e.g., a boot or booties for an upper, a cuff region of an upper, etc.), etc. The garments 100 may be converted between a deflated condition (with inflatable bladder chamber 110 and bladder chamber portions 110D substantially emptied and/or flat) and an inflated condition (with inflatable bladder chamber 110 and bladder chamber portions 110D containing a gas (air) under pressure).
When in the inflated condition, garments 100 in accordance with aspects of this technology will provide increased thermal insulative properties as compared to the same garment 100 in the deflated condition.
In some examples, the level of inflation of a garment 100 (e.g., the volume of air introduced, the pressure of the air within the bladder chamber 110, etc.) may be varied and/or controlled. As some more specific examples, different levels of inflation of a garment 100 may correlate to different thermal resistivities associated with the garment 100 and/or different thicknesses of the layer of air provided in the bladder chamber 110D. In any of these matters, a wearer may be able to control and vary the level of thermal resistivity of the garment 100.
Garments 100 in accordance with at least some aspects of this technology may be washable and reusable. The garments 100 may be formed from one or more garment components 102 that include an inflatable bladder chamber 110 or a portion thereof, as will be described in more detail below. The garments 100 may be made from different numbers of garment components 102 that include an inflatable bladder chamber 110, e.g., including from one such garment component 102 (e.g., forming a front, back, and sides of the garment 100) to ten or more such garment components 102. When made from multiple garment components 102 including inflatable bladder chambers 110, at least some of the inflatable bladder chambers 110 of the different garment components 102 may be interconnected and in fluid communication.
Garment components 102 that include an inflatable bladder chamber 110 may be made from two laminated components in some examples of this technology—an exterior laminated component 110A and an interior laminated component 110B. Note FIGS. 1D-IF.
The exterior laminated component 110A and the interior laminated component 110B may be joined together in a manner so as to provide inflatable bladder chamber portions 110D and bonded regions 120. Bonded regions 120 may be provided at the exterior edge of a garment component 102 (e.g., at an outer perimeter of the garment component 102 and/or the bladder chamber 110) to provide fluid-impervious engagement between the exterior laminated component 110A and the interior laminated component 110B.
Additional bonded regions 120 may be provided at interior locations within the inflatable bladder chamber 110 (e.g., to control the bladder chamber 110's shape when inflated).
Garment components 102 having the inflatable bladder chamber 110 may extend over any desired portion or proportion of the garment 100 construction. In some specific examples, the garment component 102 and/or its inflatable bladder chamber 110 may: (a) form an entire garment 100 structure; (b) form an upper body garment including at least a front portion and/or a back portion; (c) form and connect a front bladder chamber portion located in a front portion of the garment 100 and a rear bladder chamber portion located in a back portion of the garment 100; (d) extend around at least one side (e.g., extend continuously around at least one flank side) of the garment 100 to form and connect a front bladder chamber portion located in a front portion of the garment 100 and a rear bladder chamber portion located in a back portion of the garment 100; (e) extend over at least one shoulder region (e.g., extend continuously over at least one shoulder region) of the garment 100 to form and connect a front bladder chamber portion located in a front portion of the garment 100 and a rear bladder chamber portion located in a back portion of the garment 100; (f) form and connect one or more sleeve portions and/or sleeve bladder portions of the garment 100, e.g., connected with a front garment portion (and its bladder chamber portion) and/or a rear garment portion (and its bladder chamber portion); and/or (g) form and connect a collar or hood garment portion and/or a collar or hood bladder portion of the garment 100, e.g., connected with a front garment portion (and its bladder chamber portion) and/or a rear garment portion (and its bladder chamber portion).
At the bonded regions 120, the facing surfaces of the exterior laminated component 110A and the interior laminated component 110B are bonded together, e.g., by an adhesive bond or in an adhesive-free manner (e.g., by a melt bond, weld bond, or fused bond). Note FIGS. 1D-1F.
As some more specific examples, exterior laminated component 110A may be joined to interior laminated component 110B, e.g., by an adhesive provided between them at the bonded regions 120 (e.g., an adhesive bond bonding facing fabric surfaces, facing polyurethane or thermoplastic polyurethane film surfaces, other facing laminate component 110A, 110B surfaces, etc.) and/or by an adhesive-free bond (e.g., welded, melt bonded, and/or fuse bonded, for example, between facing surfaces of thermoplastic polyurethane film materials in the laminate components 110A, 110B). These interfacing surfaces are shown at reference number 114 in FIGS. 1D-1F. In particular, the interfacing surfaces 114 may be surfaces of two film layers, one comprised in the exterior laminated component 110A and the other comprised in the interior laminated component 110B.
At the inflatable chamber portions 110D, however, the facing surfaces of the exterior laminated component 110A and the interior laminated component 110B are not bonded together such that an inflatable chamber portion 110D is defined between the facing surfaces of the exterior laminated component 110A and the interior laminated component 110B. Note, for example, inflatable chamber portions 110D defined between surfaces 110AS and 110BS in FIGS. 1D-1F.
FIGS. 1A-1D show bonded regions 120 at interior locations within the inflatable bladder chamber 110 of this specific example having a circular shape, with circles of constant sizes arranged in staggered columns that extend in a top-to-bottom direction of the garment 100. In this illustrated example, the bonded regions 120 are evenly spaced throughout the overall garment structure 100. As shown in FIGS. 1A and 1B, the garment 100 of this example extends from a bottom opening 100B (e.g., waist opening) to a top opening 100N (e.g., neck opening) of the garment 100, and the bonded regions 120 are distributed (and particularly substantially evenly distributed) around the garment 100 structure from the bottom opening 100B to the collar component 102C.
The bonded regions 120 may be provided in any desired numbers, sizes, shapes, patterns, orientations, distributions, and the like and may be present in a wide variety of different aesthetic appearances. As some additional examples, the bonded regions 120 substantially may be round, square, rectangular, polygonal, oval, star shaped, cross shaped, or irregularly shaped in different specific examples of this technology.
In some specific examples, at least some of the individual interior bonded regions 120 may have a diameter or diagonal dimension of at least 5 mm (and in some examples, at least 6 mm or even at least 8 mm) and/or a continuous bonded area of at least 19.6 mm2 (and in some examples, at least 28 mm2 or even at least 50 mm2). At least 25% of the interior bonded regions 120 of a garment component 102 and/or an overall garment 100 structure may have sizes within the above ranges (and in some examples, at least 50%, at least 75%, or even at least 90% of the interior bonded regions 120 of a garment component 102 and/or an overall garment 100 structure may have sizes within the above ranges).
Further, a single garment 100 need not have all of the bonded regions 120 of the same number, size, shape, pattern, and/or orientation. The bonded regions 120 at interior locations within the bladder chamber 110 may be sized, shaped, and/or positioned to control a shape of the bladder chamber 110 (and thus a shape of the garment component 102) when it is in an inflated condition. FIGS. 15A-15D, 16A, 16B, and FIGS. 17C-17F show further examples of garments 100 in accordance with aspects of this technology in a deflated condition (e.g., FIGS. 15C, 15D, 16A, 17C, 17E) and in an inflated condition (e.g., FIGS. 15A 16B, 17D, 17F). A wide variety of bonded region 120 features are possible in various different specific examples of this technology.
FIGS. 1A and 1B show an example of a garment component 102 having an inflatable bladder chamber 110 engaged with another garment component. For example, a garment component 102 forming a front of the garment 100 may be engaged with a hood or collar member 102C (or another garment component that does not have an inflatable bladder chamber 110).
Such engagements specifically may be accomplished using a sewn seam 108, with the seam 108 stitching through the hood or collar member 102C (or other garment component) and through a portion of a bonded region 120 of garment component 102 (e.g., through a perimeter edge bonded region 120 of garment component 102). Additionally or alternatively, such engagements may be accomplished using one or more of adhesive, adhesive-free bonding (e.g., formed by welding techniques, such as ultrasonic welding techniques and/or RF welding techniques), mechanical fasteners, etc.
As another example shown in FIGS. 1A and 1B, garment component 102 forming a front of the garment 100 may be engaged with another garment component that includes an inflatable bladder chamber 110, such as a garment component 102D forming a back portion of the garment 100.
Such engagements specifically may be accomplished using an adhesive bond or an adhesive-free bond (e.g., formed by welding techniques, such as ultrasonic welding techniques and/or RF welding techniques) between the garment components 102, 102D (e.g., by bonding their outer perimeter bonded regions 120 together, e.g., at shoulder seams and/or side seams as shown at reference number 108A in FIG. 1B). Additionally or alternatively, such engagements may be accomplished using one or more of a sewn seam, one or more mechanical fasteners, etc.
Additional examples and features of attaching two garment components (e.g., 102, 102D) with inflatable bladder chambers 110 are described in more detail below. FIGS. 1A and 1B further show that two garment components 102 and 102D having inflatable bladder chambers 110 may be engaged with a single additional garment component (e.g., hood or collar member 102C, sleeve components 102, etc.). In this illustrated example, seam 108 extends to connect hood or collar member 102C with both the front garment component 102 and the back garment component 102D.
FIGS. 1C and 1D show close-up views of an interior bonded region 120 of garment 100. FIG. 1C shows the exterior side of this example (formed from exterior laminated component 110A) and FIG. 1D shows a cross-sectional view through the center of the interior bonded region 120. As shown in FIGS. 1C and 1D, the exterior side of this example bonded region 120 forms a recessed region 120R with respect to a main surface 120SX area around that bonded region 120. Thus, at the outer surface, the bonded region 120 may be at least partly “debossed” (or recessed) with respect to the main surface 120SX area around that bonded region 120.
As further shown in FIG. 1D, the interior side of this example bonded region 120 may form a raised region 120S with respect to a main surface 120SI area around that bonded region 120 (e.g., a raised step that may extend all or partially around the bonded region 120). Thus, at the inner surface, the bonded region 120 may be at least partly “embossed” (or raised) with respect to the main surface 120SI area around that bonded region 120. This raised region 120S, when present on the interior of the garment 100, may help hold portions of the garment 100 off the wearer's body somewhat, e.g., when the inflatable bladder chamber 110 is in a deflated condition (e.g., for better breathability).
FIGS. 1C and 1D further show that the exterior side of the bonded region 120 at the perimeter 120P also may include a raised region 124X (raised with respect to the main surface 120SX) immediately adjacent the recessed region 120R at the exterior side. This raised region 124X at the exterior side of the perimeter edge 120P may be formed when the bonded regions 120 are formed. As examples, the raised region 124X at the perimeter edge 120P may be formed by one or more of: (a) adhesive material (e.g., adhesive material provided between the laminated components 110A, 110B, adhesive 116 material provided within one or both laminated components 110A, 110B, etc.), described in more detail below) flowing from beneath the press and gathering around the exterior side of the bonded region 120 when heat and pressure are applied; and/or (b) melted or softened material from one or both laminated components 110A, 110B flowing to and/or deforming at the raised region 124X when heat and pressure are applied.
The interior side of the bonded region 120 also may include a raised region 124I. This raised region 124I at the interior side may be formed by one or more of: (a) adhesive material (e.g., adhesive material provided between the laminated components 110A, 110B, adhesive 116 material provided within one or both laminated components 110A, 110B, etc.), described in more detail below) flowing from beneath the press and gathering around the interior side of the bonded region 120 when heat and pressure are applied; (b) melted or softened material from one or both laminated components 110A, 110B flowing to and/or deforming at the raised region 124I when heat and pressure are applied; and/or (c) pressing the laminated components 110A, 110B into a silicone press pad surface or other somewhat softened surface in the press when forming the bonded region 120.
As shown in FIGS. 1C and 1D, in at least some examples of this technology, an interior bonded region 120 may have: (a) a first thickness at a non-peripherical part of the bonded region (e.g., at its center where the interior laminated component 110B and the exterior laminated component 110A are pressed and fixed together) and (b) a second thickness at a periphery 120P of the bonded region 120, wherein the second thickness is different from (e.g., greater than) than the first thickness.
FIGS. 1A and 1F schematically show that this example garment 100 may include at least one pump component 130 for filling the inflatable bladder chamber 110 with air (or other desired gas). FIG. 1A shows the pump component 130 in broken lines because the pump component 130 may be located within a pocket 104 of the garment 100. The pump component 130 may be releasably attachable to fluid inlet port hardware that is fixed to one or more garment components 102 and opens into some portion of the bladder chamber 110.
If necessary or desired, an air intake 132 may be provided, e.g., defined through the pocket 104 (e.g., through garment component 102 and/or with the pump component 130), to provide air to be pumped or inserted into the inflatable bladder chamber 110.
Any desired type of pump component 130 may be provided, including a battery operated pump, a bulb type manual pump, a manually operated pump, etc. In some examples of this technology, a filter may be provided (e.g., at or with the air intake 132) to prevent dust, dirt, lint, moisture, or other undesired material from entering the pump component 130 (and thus the inflatable bladder chamber 110).
Additionally or alternatively, rather than (or in addition to) a pump 130, the garment 100's inflatable bladder chamber 110 could be inflated by a blow tube, e.g., attached or attachable at the air intake 132 or other air input port (e.g., an input port into inflatable bladder chamber 110).
FIGS. 1A and 1F also show that this example garment 100 may include at least one pressure release component 134, e.g., a pressure release valve, a closable opening (e.g., closed by a removable cap), etc., for releasing air (or other gas) from the inflatable bladder chamber 110. FIG. 1A shows the pressure release component 134 located at (e.g., within) a pocket 104 on the other side of the garment 100 from the pump component 130 (or other air input system).
If necessary or desired, at least one air outlet may be provided, e.g., defined through the pocket 104 (e.g., through garment component 102), but in some examples, the air released through the pressure release component 134 (e.g., through outlet 1340, see FIG. 1F) may be released to the interior of the pocket 104 or otherwise to the external environment.
As another example, the at least one pressure release component 134 may be provided on (e.g., mounted to) an interior layer of the garment (e.g., through interior laminated component 110B).
Any desired type of pressure release component 134 may be provided, including a battery operated valve, a manually operated valve, an outlet port covered by a removable cap, etc. The example of FIG. 1F shows a button 134A that may be pressed (against force applied by a spring 134S) to move a movable valve component (e.g., ball 134B) away from a fixed valve component (e.g., a valve seating area 134C) to open a fluid passageway through the fixed valve component to the fluid outlet 1340.
When the inflatable chamber portions 110D are inflated, the pressure of the gas within the inflatable chamber portions 110D pushes the movable valve component (e.g. ball 134B) against the fixed valve component (e.g., valve seating area 134C) to seal the pressure release valve and hold the gas within the inflatable chamber portions 110D.
Additionally or alternatively, one or more pressure release components 134 may include a valve-less pressure release structure in at least some example garment 100 structures. As a more specific example of such valve-less structures, the valve parts (e.g., valve 134B and valve seating area 134C) in one or more pressure release components 134 illustrated in FIG. 1F can be omitted and pressure release component 134 may comprise a cap that releasably secures to open and close a fluid outlet 1340, to thereby retain fluid within the bladder chamber 110 (when closed) and release fluid from the bladder chamber 110 (when open).
Additionally or alternatively, if desired, the garment 100 may include one or more relief valves 136 at one or more locations around the garment 100 structure. The relief valves 136 may be activated to release pressure when and if pressure within the inflatable chamber portion(s) 110D and/or local area exceeds a predetermined or predeterminable pressure value, e.g. becomes too high (e.g., above a “crack pressure” of the relief valve(s) 136).
Pressure may increase within the inflatable bladder portion(s) 110D at one or more local areas around the garment 100 or garment component 102, e.g., when external forces are applied to compress one or more inflatable chamber portions 110D and/or when external forces close off air access to some portion(s) of the inflatable bladder chamber 110.
For example, when a wearer sits down or falls down, some inflatable chamber portions 110D may become compressed and flattened, and the gas from those chamber portions 110D may flow into other chamber portions 110D. This will increase the pressure of the inflatable chamber portions 110D particularly at some local area(s) (and may cause a significant pressure spike at some local area(s)). One or more relief valve(s) 136 can operate to automatically open if the local pressure exceeds a predetermined or predeterminable threshold. Such relief valve(s) 136, when present, may help prevent separation of one or more interior bonded regions 120, may help prevent rupture of one or more of the inflatable chamber portions(s) 110D, and/or may help prevent breakage (e.g., bursting) of seams or seals, etc., and thereby increase the durability and life of the garment 100.
Any desired type of relief valve 136 may be provided. The example of FIG. 1F shows a relief valve 136 that includes a movable valve component (e.g., ball 136B) that is biased to seat against a fixed valve component (e.g., a valve seating area 136C) by a spring or other biasing member 136S. When fluid pressure in the local inflatable chamber portion 110D particularly exceeds the force applied to the movable valve component (e.g., ball 136B) by the biasing member 136S, the movable valve component moves away from the fixed valve component (e.g., valve seating area 136C) to open a fluid pathway through the relief valve 136 to the exterior environment (e.g., through valve outlet 1360).
Once the excess pressure within the local chamber portion 110D is sufficiently relieved (and/or the pressure spike has sufficiently abated), the biasing member 136S will force the movable valve component (e.g., ball 136B) back against the fixed valve component (e.g., valve seating area 136C) to again seal the relief valve 136 (and the inflatable chamber portion 110D).
FIGS. 2A and 2B show features of laminated components 110A, 110B and manners of making them in accordance with at least some examples of this technology. One layer of laminated components 110A, 110B constitutes a fabric 112. In other words, each one of laminated components 110A and 110B comprises a respective fabric layer 112.
Various different types of fabrics 112 may be used in different examples of this technology. As some specific examples, fabric 112 may be an ethylene polyester (PET) material, another polyester material, a recycled polyester material, or a nylon material.
Additionally or alternatively, fabric 112 may be at least one of a layer of a knit textile, a layer of woven textile, and a layer of nonwoven textile. Still additionally or alternatively, in some specific examples, the fabric 112 may have a knit structure formed from a drawn textured yarn or a fully drawn yarn, (e.g., including a double jersey knit structure). In other examples, the fabric 112 may include a woven structure formed from a drawn textured yarn or a fully drawn yarn. Exemplarily, the fabric 112 may be a knit fabric formed from a drawn textured yarn and including a double jersey knit structure.
The fabric 112 may have a durable water repellant (“DWR”) (or water resistant) coating at least partly applied to it (especially any fabric 112 layer that may be exposed at the exterior of a garment 100 in a final garment 100 structure). Such a coating may be applied before the lamination process described below in conjunction with FIG. 2A or at a later time.
Further, the DWR material may be at least partly applied to just one surface of the fabric 112 or to both surfaces, and/or the two opposite surfaces of a fabric 112 component need not have the same amount of DWR material applied to it. The DWR may be applied by dipping, spraying, printing, coating, and/or in other desired manners. Suitable DWR materials for fabrics are conventionally known and commercially available (e.g., fluoropolymer based materials).
In the process step shown in FIG. 2A, an adhesive 116 is applied to at least some portion of a surface 112A of the fabric 112. Any desired manner of applying the adhesive 116 may be used, including spraying, coating, printing, painting, etc. Also, any desired type of adhesive 116 may be used. In the example of FIG. 2A, the adhesive 116 is applied as a “full” layer on the surface 112A of the fabric 112. In the “full” examples, the adhesive 116 layer may have a constant thickness or a varying thickness. Other options will be described in more detail below, e.g., in conjunction with FIGS. 5A-5C. The bottom of FIG. 2A shows the fabric 112 with the adhesive 116 applied to it to form an adhesive infused fabric 112F.
Next, as shown in FIG. 2B, a film 118 is applied to the adhesive 116 side of the adhesive infused fabric 112F to form a laminated component, e.g., laminated component 110A and/or 110B. In this example, the adhesive 116 is a “full layer” (e.g., of constant or varying thickness) covering at least 90% (and up to 100%) of the surface area between the fabric 112 and the film 118. The term “substantially continuously” (and variations thereof) as used herein in this context means that adhesive 116 is applied between a fabric 112 and a film 118 to cover at least 90% (and up to 100%) of a surface area between facing and connected surfaces of the fabric 112 and the film 118 (e.g., the adhesive 116 extends “substantially continuously” to cover at least 90% of the interfacing surfaces of the film 118 and fabric 112).
The step of fixing the film 118 to the fabric 112 specifically can take place in any desired manner, including via conventional lamination techniques, via extrusion techniques, etc. The film 118 layer (e.g., a thermoplastic elastomer layer, such as a thermoplastic polyurethane layer or a polyurethane layer) may be directly extruded onto the fabric 112.
The film 118 may be made of any desired type of material that is capable of forming fluid impervious surfaces of an inflatable bladder chamber 110. In some more specific examples of this technology, the film 118 may comprise a layer chosen from at least one of a layer of a thermoplastic polyurethane material and a layer of a polyurethane material. Additionally or alternatively, in some specific examples, the film 118 may have a multi-layered structure, e.g., with one or more layers of thermoplastic polyurethane material and/or with one or more layers of polyurethane material.
In some examples of this technology, overall film 118 (e.g., the composite of all film 118 layers present) will be less than about 150 micron thick, and in some examples, less than about 120 micron thick, less than about 100 micron thick, less than about 80 micron thick, less than about 70 micron thick, less than about 60 micron thick, or even less than about 50 micron thick. As some additional examples, film 118 may be at least about 25 micron thick (with the upper end of the thickness range being within any of the ranges described above).
The method depicted in FIG. 2B shows the laminated component 110A, 110B particularly formed from a film 118 that constitutes a single layer. FIGS. 3A and 3B show an alternative film 118 structure and arrangement. More specifically, the film 118 shown in FIGS. 3A and 3B is itself a multi-layered construction.
In one particular example, one layer 118A of film 118 comprises a thermoplastic polyurethane layer and the other layer 118B comprises a polyurethane layer. These two layers 118A and 118B may be joined together (e.g., by an adhesive, by a lamination technique, by co-extrusion, by blowing techniques, etc.) to form film 118 as a composite film layer. The layers 118A and 118B may have different melt temperatures (e.g., with the polyurethane layer 118B having a higher melt temperature than the TPU layer 118A).
As another particular example of a multi-layered film 118 structure, one layer 118A of film 118 may comprise a thermoplastic polyurethane layer having a first melt temperature or melting point and the other layer 118B may comprise a thermoplastic polyurethane layer having a second melt temperature or melting point, wherein the second melt temperature or melting point is higher than the first melt temperature or melting point (e.g., at least 10 degrees C. higher, and in some examples, at least 20 degrees C. higher, or even at least 30 degrees C. higher). These two TPU layers 118A and 118B with different melting points may be joined together (e.g., by an adhesive, by a lamination technique, by co-extrusion, by blowing techniques, etc.) to form film 118 as a composite film layer or a multi-layer film. In such structures, the TPU layer 118B having the higher melt temperature may be directly engaged with the fabric 112 layer and the TPU layer 118A having the lower melt temperature may remain exposed. Thus, the TPU layer 118A having the lower melt temperature may form the interior surface of a bladder chamber 110 and will be available for forming bonded regions 120.
Separating a TPU layer 118A having a lower melt temperature from the fabric 112 with a TPU layer 118B having a higher melt temperature may enable use of somewhat lower processing temperatures when making the interior bonded regions 120 (e.g., when applying heat and pressure and/or when applying welding conditions (e.g., RF welding, etc.) discussed in more detail below). In at least some examples of such processing steps, the TPU layer 118B having the higher melt temperature may maintain a stable bond to the fabric 112 while the TPU layer 118A having the lower melt temperature bonds to a facing layer of TPU material in another laminated component 110A, 110B to form the bonded region(s) 120. These same melt temperature differential features (e.g., with a higher melt temperature layer 118B applied to the fabric 112 and a lower melt temperature layer 118A remaining exposed for forming bonds 120) may be provided with multi-layered films 118 formed of a polyurethane layer 118B and a TPU layer 118A and/or with multi-layered films 118 formed from two polyurethane layers 118A and 118B.
If necessary or desired, the exposed surfaces of one or both of film layers 118A and/or 118B may be covered with a release paper 118C. The release paper 118C, when present, may help avoid issues while shipping and/or storing the film 118 (e.g., to keep surfaces of the film layer(s) 118A and/or 118B clean, prevent undesired adhesion with itself when rolled, etc.).
Then, as shown in FIG. 3B, laminated components 110A, 110B specifically may be formed by laminating film 118 to fabric 112 with the layer 118B surface facing (and contacting) the adhesive 116 provided on the adhesive infused fabric 112F.
If present, release paper 118C provided on the layer 118B can be removed just prior to the lamination step of FIG. 3B. Additionally or alternatively, if present, any release paper 118C provided on the thermoplastic polyurethane layer 118A can be removed at an appropriate time (e.g., before, after, or during the lamination step of FIG. 3B).
As illustrated in FIG. 3B and in the cross-sectional view of FIG. 3C, laminated components 110A, 110B have thermoplastic polyurethane layer 118A exposed (or at least available to be exposed once any release paper 118C included thereon is removed) and available for forming bladder chambers 110 and bonding regions 120 in final garment component 102 structures, as will be described in more detail below.
In film 118 structures of the types shown in FIGS. 2A-3C, the overall film 118 (e.g., the single film layer 118 of FIG. 2B or the sum of layers 118A and 118B of FIGS. 3A-3C) will be less than about 150 micron thick, and in some examples, less than about 120 micron thick, less than about 100 micron thick, less than about 80 micron thick, less than about 70 micron thick, less than 60 micron thick, or even less than 50 micron thick. As some additional examples, film 118 (e.g., the single film layer 118 of FIG. 2B or the sum of layers 118A and 118B of FIGS. 3A-3C) may be at least about 25 micron thick or even at least about 30 micron thick (with the upper end of the thickness range being within any of the ranges described above).
In multi-layer film 118 examples: (a) the thermoplastic polyurethane film layer 118A may be at least about 10 micron thick or even at least about 20 micron thick and less than about 100 micron thick, and in some examples, less than about 75 micron thick, less than about 60 micron thick, less than about 50 micron thick, less than about 40 micron thick, less than about 35 micron thick, less than about 30 micron thick, or even less than about 25 micron thick and (b) the film layer 118B (i.e., the polyurethane film layer or the higher melt temperature thermoplastic polyurethane film layer) may be at least about 10 micron thick or even at least about 20 micron thick and less than about 100 micron thick, and in some examples, less than about 75 micron thick, less than about 60 micron thick, less than about 50 micron thick, less than about 40 micron thick, less than about 35 micron thick, less than about 30 micron, or even less than about 25 micron thick.
The two film layers 118A and 118B, when present, may have the same or different thicknesses (e.g., within the ranges described above). As one specific example, a two-layered film 118 of this type may have: (i) a thermoplastic polyurethane layer 118A having a thickness of about 25 micron and (ii) a polyurethane layer 118B or a higher melt temperature thermoplastic polyurethane layer 118B having a thickness of about 25 micron. These thickness measurements may comprise thicknesses measured before lamination of film 118 to a fabric 112 layer. Lamination to the fabric 112 may result in a “compressed” or reduced thickness of the film 118 layer. In some specific examples, an initial about 50 micron film 118 layer thickness prior to lamination to fabric 112 may be compressed or reduced to a thickness of about 32 micron (total film 118 thickness) after lamination and engagement with the fabric 112.
Film 118 “compression” of this type may occur when laminating single layer films (e.g., as shown in FIGS. 2A and 2B) and/or multi-layer films 118 (e.g., including layers 118A and 118B, e.g., as shown in FIGS. 3A-3C). As some specific examples, the film 118 thickness differential prior to lamination with fabric 112 v. after lamination with fabric 112 may be at least 10% smaller, and in some examples, at least 15% smaller, at least 20% smaller, at least 25% smaller, or even at least 30% smaller.
FIG. 4A illustrates features of a method of making a garment component 102 using laminated components 110A and 110B of the type shown in FIGS. 2A and 2B, i.e., each laminated component 110A, 110B with a single film 118 layer (e.g., a polyurethane film or a thermoplastic polyurethane film) in this specific example. FIG. 4A shows placement of an exterior laminated component 110A and an interior laminated component 110B in a press 400 so that their film 118 layers directly face one another (between press plates 400A and 400B).
An adhesive 402 particularly is applied between exposed surfaces of the films 118 (e.g., to the surface of the film 118 on either or both of laminated components 110A, 110B) in a pattern to form the bonded regions 120 at the desired locations of the garment component 102 (e.g., at an outer perimeter location and at one or more internal bonded region 120 locations). The adhesive 402 may be applied in any desired manner, including by printing, by application of two-sided tape to the surface of film 118, as a sheet of adhesive 402 material, etc.
Then, the laminated components 110A and 110B particularly are pressed together in the press 400, optionally with heating, to bond the film 118 layers of the laminated components 110A and 110B together at locations where the adhesive 402 is present to form bonded regions 120 at the locations where the adhesive 402 is present.
One or both of the press plates 400A, 400B may include a silicone pad (or other softened surface) at its outer surface. The silicone pad may help form the recessed regions 120R and raised regions 124X, 124I at the perimeter edge 120P of at least some bonded regions 120, as discussed above in conjunction with FIGS. 1C and 1D.
The method of FIG. 4A particularly works well with film 118 layers that will not form adhesive-free bonds under the pressing conditions being used (e.g., polyurethane films 118). The bottom of FIG. 4A shows the final composite product (e.g., garment 100 or garment component 102 in cross section), including an inflatable bladder portion 110D in the region between the bonded regions 120 formed with adhesive.
FIG. 4B shows a view similar to the partial cross-sectional view shown at the bottom of FIG. 4A if the process of FIG. 4A were performed with laminated components 110A and 110B having a multi-layer film 118 construction (e.g., a film 118 with two layers 118A and 118B of the types described above in conjunction with FIGS. 3A-3C). In this example, the thermoplastic polyurethane layers 118A of the films 118 (which may comprise the thermoplastic polyurethane films 118A having a lower melt temperature) directly face one another to form an inflatable bladder portion 110D in the region between the bonded regions 120.
If the two-layered film 118 of FIG. 4B is to be used in the method of FIG. 4A, the pressing conditions may need to be controlled (e.g., such as through the use of tooling) and/or other features may need to be present (such as adhesion blockers) so that all facing thermoplastic polyurethane layer 118A surfaces do not form an adhesive-free bond under the applied pressure.
In some examples of this technology, the fabric 112 may have a multi-layer construction. FIG. 4B shows an example in which the exterior laminated component 110A includes an additional fabric layer 112X applied to at least a portion of the outer surface of fabric layer 112 (such that additional fabric layer 112X forms the exterior-most layer of fabric 112 and garment component 102 in this example). Additional fabric layer 112X may be engaged with fabric layer 112 in any desired manner, such as by lamination techniques, by adhesive, by sewn seams, etc. Additional fabric layer 112X may provide additional strength or durability, water resistance, etc.
As one more specific example, in some examples of this technology, fabric layer 112 may be formed as a knit construction, and additional fabric layer 112X may be formed as a woven construction, e.g., to provide snag resistance. Additional fabric layers 112X of these types may be provided on any of the fabrics 112 described herein and/or in any of the laminate, bladder, and/or garment component structures described herein, including in any of the laminate, bladder, and/or garment component structures described herein in conjunction with FIGS. 1A-24.
Additionally or alternatively, if desired, the fabric 112 of the interior laminated component 110B may include an additional fabric layer 112X over at least some portion(s) of its exterior surface in other specific examples of this technology (e.g., providing a softer feel, providing moisture wicking, etc.).
As described above in conjunction with FIGS. 2A and 2B, in some examples of this technology, the laminated components 110A and 110B are formed with a full layer of adhesive 116 (or a substantially continuous layer of adhesive 116) joining fabric 112 to film 118. In some examples of this technology, however, a full layer of adhesive 116 will not be used to form laminated components 110A and/or 110B.
FIG. 5A illustrates a fabric 112 component having adhesive 116 applied to a surface 112A thereof at a stage similar to the stage shown in FIG. 2A. In this example, however, the adhesive 116 particularly is applied to the surface 112A “discontinuously” or “intermittently,” e.g., as a plurality of spaced-apart adhesive regions disposed throughout the fabric 112. The spaced-apart adhesive 116 regions may be applied to the surface 112A of the fabric 112 (or to the film 118) in any desired manner, such as by printing, by application of two-sided tape to the surface 112A or film 118, etc.
When present “intermittently” or “discontinuously,” the adhesive 116 covers less than 90% of the surface area between the fabric 112 and the film 118. In some examples of this technology, the adhesive 116 may be applied intermittently, in spaced-apart adhesive 116 regions, to cover less than 80% of a surface area between the film 118 and the fabric 112, and in some examples, less than 75%, less than 60%, less than 50%, less than 40%, or even less than 25% of this surface area. The distribution of adhesive 116 between the fabric 112 and film 118 (e.g., size, shape, and/or density of spaced-apart adhesive 116 regions) may be constant throughout the overall surface area of a laminated component 110A, 110B, or it may be varied at different regions of the overall surface area of a laminated component 110A, 110B. The “spaced-apart” adhesive 116 features can help provide a softer feel and improved drape for laminated components 110A, 110B formed from the fabric 112, adhesive 116, film 118 laminates (e.g., due to gaps between the adhesive 116 regions allowing more flexibility and producing less stiffness).
In some examples, the adhesive 116 regions will take the form of adhesive “dots,” e.g., substantially of round, oval, square, polygonal, or other desired shape(s). At least some of the spaced-apart adhesive 116 regions (or dots) may have a largest diagonal or diameter dimension D such that the spaced-apart adhesive 116 regions (e.g., dots) will be sized and shaped to contact at least 2 consecutive loops of a knit structure forming fabric 112 (and in some examples, at least 3 consecutive loops or even at least 5 consecutive loops), but particularly fewer than 10 consecutive loops of the knit structure forming fabric 112.
Specifically, the use of a drawn textured yarn with spaced-apart adhesive 116 regions of this size range helps the adhesive flow or sink into the knit structure to provide strong bonding and good peel strength (resistance to peeling or delamination).
Additionally or alternatively, the spaced-apart adhesive 116 regions (or dots) may be spaced from immediately adjacent neighboring adhesive 116 regions (or dots) by a spacing dimension S. Dimension D and dimension S in a specific laminated component 110A and/or 110B may be selected and balanced with respect to one another to provide a desired degree of drape or handfeel while still providing adequate peel strength. For example, smaller-sized adhesive 116 dots and/or greater adhesive 116 dot spacing will tend to produce laminated components 110A, 110B having better drape and handfeel properties (as the lower amounts of adhesive 116 may tend to make the laminated component 110A, 110B feel softer and more like the base fabric 112), but the lower amount of adhesive 116 may adversely impact peel strength (and make the laminated component(s) 110A, 110B more susceptible to delamination). On the other hand, larger adhesive 116 sized dots and/or smaller adhesive 116 dot spacing will tend to produce laminated components 110A, 110B having excellent pecl strength (and less susceptibility to delamination), but the laminated components 110A, 110B may tend to feel stiffer and have less favorable drape and handfeel properties.
The diameter or diagonal dimension D, the adhesive 116 region size ranges with respect to the number of consecutive loops, and/or the adhesive 116 region spacing dimension S described above may be present (or, in other words, apply) for at least about 25% of the spaced-apart regions of adhesive 116 in a garment 100 or garment component 102 structure, and in some examples, these ranges particularly may be present for at least about 40%, at least about 50%, at least about 75%, at least about 80%, or even at least about 90% of the spaced-apart regions of adhesive 116 in a garment 100 or garment component 102 structure.
Whether using a full adhesive 116 layer or spaced-apart adhesive 116 regions between the fabric 112 and film 118 layers, laminated components 110A and/or 110B in accordance with examples of this technology may be constructed to have desired drape and/or handfeel properties. In addition to adhesive 116 dot size and/or spacings, other garment structural features particularly can impact the drape and handfeel properties, such as adhesive 116 layer thickness (e.g., for full glue examples), adhesive 116 material, fabric 112 materials, fabric 112 thickness, film 118 thickness, number of layers in the film 118, etc. As some more specific examples of this technology, a laminated component 110A and/or 110B may have drape properties that are comparable to the drape properties of the fabric 112 layer when present alone (e.g., within a threshold amount of the drape properties of the fabric 112 when present alone).
In some examples of this technology, the laminated components 110A, 110B will have a peel strength between the fabric 112 and the film 118 layer of at least about 0.85 kg/cm, and in some examples, at least about 0.9 kg/cm, at least about 0.95 kg/cm, at least about 1 kg/cm, or even at least about 1.05 kg/cm. Peel strength may be measured using International Standard ISO 2411.
FIG. 5B provides a partial cross-sectional view of a garment 100 or garment component 102 similar to the view of FIG. 4A, but with an intermittent adhesive 116 layer connecting the fabric 112 and film 118 layers in both the exterior laminated component 110A and the interior laminated component 110B. FIG. 5C provides a partial cross-sectional view of a garment 100 or garment component 102 similar to the view of FIG. 4B but with an intermittent adhesive 116 layer connecting the fabric 112 and multi-layer film 118 layers in both the exterior laminated component 110A and the interior laminated component 110B. The garments 100 or garment components 102 shown in FIGS. 5B and 5C may be made in the same general manners as described above in conjunction with FIG. 4A. Use of an intermittent adhesive 116 layer between the fabric 112 and film 118—as shown in FIGS. 5A-5C—may help improve the softness, hand feel, and/or drape features of garments 100 and garment components 102 in accordance with some aspects of this technology (e.g., because less adhesive 116 is present to stiffen the laminate).
During pressing steps to form the garment components 102 of FIGS. 5A-5C, the exterior laminated component 110A particularly may be exposed to somewhat different heating and/or pressing conditions than the interior laminated component 110B, e.g., depending on the starting temperature, the dwell time under pressing conditions, and/or if just one press plate 400A or 400B is heated.
Differences in the pressing conditions particularly may cause the adhesive 116 in one laminated component 110A to soften (potentially melt and/or spread out) to somewhat a different degree than that of the other laminated component 110B. Thus, even if laminated components 110A, 110B have the same structures when the garment 100 and/or garment component 102 fabrication process starts, they may have somewhat different structures after heating and pressing occurs. Such features may be used, if desired, e.g., to particularly form the embossed and debossed features discussed above in conjunction with FIGS. 1C and 1D.
In some examples of this technology, intermittently applied regions of adhesive 116 may be provided between the film 118 and the fabric 112 in both the exterior laminated component 110A and the interior laminated component 110B. In such structures, the intermittently applied regions of adhesive 116 need not be applied in the same pattern in the exterior laminated component 110A as the pattern in the interior laminated component 110B. For example, the exterior laminated component 110A may have a different number, size, shape, spacing, density (e.g., adhesive 116 regions per square meter), average size, average spacing, average dispersion density, and/or arrangement of spaced-apart regions of adhesive 116 as compared to the number, size, shape, spacing, density, average size, average spacing, average dispersion density, and/or arrangement of spaced-apart regions of adhesive 116 of the interior laminated component 110B.
In particular, in some examples of this technology, the spaced-apart regions of adhesive 116 in the exterior laminated component 110A will not align with the spaced-apart regions of adhesive 116 in the interior laminated component 110B (e.g., in the vertical direction shown in FIGS. 5B and 5C), when the garment 100 or garment component 102 is supported on a horizontal base surface in a flat and unfolded orientation. In other words, the positions of the spaced-apart regions of adhesive 116 in the exterior laminated component 110A need not mirror and/or align with the positions of the spaced-apart regions of adhesive 116 in the interior laminated component 110B.
Asymmetries between the spaced-apart regions of adhesive 116 in the exterior laminated component 110A as compared to the interior laminated component 110B particularly may help improve the hand feel and/or drape properties by potentially providing less adhesive 116 material in a direct straight line direction from the exteriormost surface to the interiormost surface of the garment component 102 (e.g., allowing the laminated components 110A, 110B to flex more easily based on the flex properties of the fabric 112 layers).
The example method described above in conjunction with FIG. 4A uses a flat pressing technique in which: (a) adhesive 402 is applied to at least one film 118 at one or more locations where bonding is desired (to form one or more bonded regions 120) and (b) the pressing force (between plates 400A and 400B) is applied to the substantially entire portion of the laminated components 110A and 110B between the press plates 400A and 400B. The pressing force particularly may be uniform (or substantially uniform (e.g., with variations within about +5%)) over the substantially entire pressing area. This technique works well in situations where the facing surfaces of the films 118 will not bond together under the pressing conditions (e.g., if the facing surfaces of the films 118 are polyurethane materials, if no heating or low heating is used, if the facing films 118 will not form adhesive-free bonds, etc.).
The process of FIG. 4A (and FIG. 6 described below) also is advantageous because it does not require the production and use of tooling (e.g., tooling with at least one of the press plates to selectively apply pressing force only at the desired locations). Rather, pressing force can be applied to the substantially entire surfaces of the laminated components 110A, 110B between the press plates 400A, 400B.
FIG. 6 schematically shows that same general process from FIG. 4A, but the adhesive 402 is applied to one film 118 in shapes to produce one or more bonded regions 120: (i) forming a perimeter seam and (ii) forming one or more interior bonded regions having the general round shape shown in the garment 100 and garment component 102 of FIGS. 1A-1D.
FIG. 6 further shows that the adhesive 402 for the perimeter bonded region 120 of this example includes a gap or passage 120G. This gap 120G can be used to provide an unbonded region in the final garment 100 or garment component 102 structure, e.g., to provide a fluid passageway that will allow fluid to pass from the interior fluid chamber portion 110D of one garment component 102 to the interior fluid chamber portion 110D of another garment component 102, to provide an inlet for pumped fluid (e.g., from pump 130 of FIGS. 1A and 1F) to enter the inflatable bladder chamber 110, to provide an outlet to allow fluid to reach a pressure release component 134 and/or a relief valve 136 from FIGS. 1A and 1F, etc.
As shown in FIG. 6, the one or more individual laminated components 110A, 110B are placed in the press 400 between the press plates 400A and 400B (see arrow 602). Pressing force F, optionally together with heating, is applied to press the press plates 400A and 400B together with the laminate component(s) 110A and 110B between them (with the adhesive 402 applied to at least one film 118). After pressing, the garment 100 or garment component 102 (e.g., one garment component 102 of an overall garment 100 shown in FIG. 6) is removed from the press 400 (see arrow 604), e.g., for further processing (e.g., to combine with other garment components 102 to make garment 100).
The process of FIG. 6 also may be used with other laminated components 110A and/or 110B described above, such as laminated components 110A and/or 110B having “spaced-apart” regions of adhesive 116, laminated components 110A and/or 110B having a “full layer” of adhesive 116, laminated components 110A and/or 110B with multi-layer films 118, etc.
As evident from FIG. 6 and the discussion above, the adhesive 402 may be applied to one or both films 118 in any desired shapes and/or arrangements to produce any desired inflatable bladder chamber 110 size and/or shapes and/or any desired bonded region 120 pattern. Additional examples will be described in more detail below.
FIG. 7 shows features of another example method of making garments 100 and/or garment components 102 in accordance with some aspects of this technology. For some garments 100 and/or garment components 102, the facing surfaces of the film 118 layer may bond together (e.g., as a melt bond, weld bond, or other adhesive-free bond) under typical pressing conditions. This can happen, for example, with facing films 118 formed of thermoplastic polyurethane materials or having a hot melt material thereon. In such structures, a flat and full press technique of the types described above in conjunction with FIGS. 4A and 6 may not be suitable because the pressing step may completely bond the films 118 together, leaving no unbonded volume for the inflatable bladder chamber 110 and inflatable chamber portions 110D.
The example of FIG. 7 shows a technique in which a surface 406A of at least one of the press plates 400A, 400B (press plate 400B in this illustrated example) particularly includes tooling 702 thereon. The tooling 702 may be integrally or unitarily formed as part of the press plate 400B surface 406A, or it may be a separate element, e.g., attached to or provided on the press plate 400B surface 406A.
The tooling 702 may include one or more tooling surfaces 702A that are raised somewhat (e.g., about 0.5 mm or more) from the base surface 406A of the press plate 400B so that the laminated components 110A, 110B, when pressed together or relative to each other by the pressing force F, will have substantial force applied to them at the locations of (or corresponding to) the tooling surfaces 702A but little force (or no force) applied at areas not corresponding to the tooling surfaces 702A. In this manner, the melt or other adhesive-free bonds will be formed between the films 118 on the laminated components 110A, 110B at the locations of the tooling surfaces 702A (because the force F is applied there), but no melt or other adhesive-free bonds will be formed between the films 118 on the laminated components 110A, 110B at the locations away from the tooling surfaces 702A (because little or no force F is applied there).
In the specific example of FIG. 7, the one or more tooling surfaces 702A particularly are provided as components and shapes to produce bonded regions 120: (i) forming a perimeter seam and (ii) forming the one or more interior bonded regions having the general round shape shown in the garment 100 and garment component 102 of FIGS. 1A-1D.
FIG. 7 further shows that the tooling surfaces 702A for the perimeter bonded region 120 particularly include a gap or passage 720G. As described above in conjunction with FIG. 6, this gap 720G can be used to provide an unbonded region in the final garment 100 or garment component 102 structure, e.g., to provide a fluid passageway that will allow fluid to pass from the interior fluid chamber portion 110D of one garment component 102 to the interior fluid chamber portion 110D of another garment component 102, to provide an inlet for pumped fluid (e.g., from pump 130 shown in FIGS. 1A and 1F) to enter the inflatable bladder chamber 110, to provide an outlet to allow fluid to reach a pressure release component 134 and/or a relief valve 136 (e.g., shown in FIGS. 1A and 1F), etc.
As shown in FIG. 7, the individual laminated components 110A, 110B are placed in the press 400 between the press plates 400A and 400B (see arrow 700A), wherein at least one of the press plates 400A, 400B includes tooling 702. Pressing force F, optionally together with heating and/or other appropriate conditions (e.g., welding conditions), is applied to press the press plates 400A and 400B together or relative to each other with the laminate components 110A and 110B between them. After pressing, the garment 100 or garment component 102 (e.g., one garment component 102 of an overall garment 100 shown in FIG. 7) is removed from the press 400 (see arrow 700B), e.g., for further processing (e.g., to combine with other garment components 102 to make garment 100).
Melt bonds, welded bonds, fused bonds, or other adhesive-free bonds (shown at reference 704 in FIG. 7) particularly form the bonded regions 120 between the exterior laminated component 110A and the interior laminated component 110B.
The process of FIG. 7 also may be used with other laminated components 110A and/or 110B described above, such as laminated components 110A and/or 110B having “spaced-apart” regions of adhesive 116, laminated components 110A and/or 110B having a “full layer” of adhesive 116, laminated components 110A and/or 110B with multi-layer films 118 (e.g., provided that the facing film 118 surfaces are capable of forming an adhesive-free bond), etc.
As evident from FIG. 7 and the discussion above, the tooling 702 may be provided in any desired shapes and/or arrangements to produce any desired inflatable bladder chamber 110 size and/or shapes. While the process of FIG. 7 does require the use of tooling 702, it has other advantages, e.g., it does not require the use of adhesive (e.g., adhesive 402) between the film 118 surfaces to form the bonded regions 120.
FIGS. 8A and 8B illustrate another example multi-layered garment component 802 and its production process in accordance with some examples of this technology. Where the same reference numbers are used in FIGS. 8A and 8B as used in any of FIGS. 1A-7 above, the same or similar parts are being referenced (with any of the options or alternatives for those parts described herein), and much of the overlapping or duplicative description may be omitted.
In the example of FIGS. 8A and 8B, the exterior laminated component 110A and the interior laminated component 110B particularly include a fabric 112 and film 118 connected by adhesive 116, e.g., in any of the manners described above with respect to FIGS. 1A-7. The adhesive 116 may be a full layer or an intermittently applied layer, e.g., in any of the manners described above.
In the example of FIGS. 8A and 8B, however, each laminated component 110A and 110B includes another fabric 812 layer. These additional fabric 812 layers may have any of the compositions, structures, features, options, and/or alternatives for fabric 112 described above. The fabric 812 layer particularly is applied to (or arranged on) the surface of the films 118 opposite the fabric 112 and adhesive 116. The fabric 812 may be applied to the film 118 using an adhesive 816 and/or by lamination. Adhesive 816 may have any of the compositions, structures, features, options, and/or alternatives for adhesive 116 described above, including the full adhesive 116 or “spaced-apart” adhesive 116 region features.
As shown in FIG. 8A, in the final garment 100 and garment component 802 configuration, the additional fabric 812 layers in the exterior laminated component 110A and the interior laminated component 110B have surfaces substantially facing each other. These facing surfaces of fabric 812 are selectively bonded together at locations to form one or more bonded regions 120 (e.g., at the perimeter edge of the inflatable bladder chamber 110 or garment component 802 and/or at internal locations within a bladder chamber 110) so as to form bladder chamber portion(s) 110D between and/or around the bonded regions 120.
The bladder chamber portion(s) 110D particularly are provided between the facing surfaces of the fabric 812 layers (and fluid tightness or seal properties for the inflatable bladder chamber portions 110D are provided by the films 118 located outside the fabric 812).
The garment component 802 configuration of FIG. 8A may be made by any suitable method using an adhesive (e.g., adhesive 402) to form the bonded regions 120, including the methods described above in conjunction with FIG. 4A-6. FIG. 8B, however, illustrates yet another example method for forming garment component 802. In the example of FIG. 8B, the exterior laminated component 110A and the interior laminated component 110B are placed in a press, e.g., like press 400 described above in conjunction with FIGS. 4A and 6.
A sheet 820 of two-sided adhesive material (e.g., two-sided adhesive tape) particularly is placed between the facing surfaces of fabrics 812 (see arrow 822). Optionally, if desired, the sheet 820 may be applied to one of the exposed surfaces of fabric 812 (on laminated component 110A or 110B) before that laminated component 110A or 110B is placed in the press 400.
In the example of FIG. 8B, the sheet 820 is formed to include one or more cutout regions 820A. Thus, in FIG. 8B, the locations of the cutout regions 820A and the pathway 820B regions connecting the cutout regions 820A are shown, and the areas around the cutout regions 820A and pathway 820B regions correspond to two-sided adhesive material. In other words, the areas of the sheet 820 corresponding to cutouts 820A and pathway 820B regions constitute one or more through holes defined through the sheet 820 (with the remainder of the sheet 820 formed of two-sided adhesive).
Once the laminated components 110A, 110B and sheet 820 are in the press 400, force F may be applied between the press plates 400A and 400B (optionally with heating), to join the facing surfaces of fabric 812 together and form the garment component 802. The garment component 802 can be removed from the press (arrow 824) for further processing (e.g., incorporation into a garment 100).
The sheet 820 of this specifically illustrated example would produce a garment component 802 structure of the type shown at the bottom right of FIG. 8B, with: (i) the larger, generally spherical inflatable chamber portions 810D formed at the locations of the cutout regions 820A, (ii) the fluid passageways 810P connecting the inflatable chamber portions 810D formed at the locations of the pathways 820B, and (iii) bonded regions 120 formed at the locations where adhesive is present (e.g., around the perimeter, between the portions 810D and passageways 810P, etc.).
Alternatively, rather than a sheet 820 as described above, the garment component 802 structure shown in FIG. 8B could be formed using an adhesive that is printed or otherwise applied directly to at least one of the facing surfaces of fabric 812. Additionally or alternatively, if desired, a sheet 820 could be used in the processes described above and to make the garment components 102 described above in conjunction with FIGS. 1A-6 (i.e., to engage facing surfaces of film 118 in structures that do not include the extra layer of fabric 812).
Additionally, like the processes of FIGS. 4A-6, the process described above in conjunction with FIGS. 8A and 8B can be accomplished without the need for tooling in the press 400 to create the desired bonded regions 120. Rather, the process of FIG. 8B can be applied using a press 400 that applies pressure to the entire surfaces between the press plates 400A, 400B. The directly facing fabric 812 materials at locations corresponding to cutout regions 820A and pathways 820B particularly will prevent bonding at the locations corresponding to the inflatable chamber portions 810D and fluid passageways 810P.
FIG. 9 illustrates another example method for making a garment component 902, e.g., using laminated components 110A, 110B with an additional fabric 812 layer of the type shown in FIGS. 8A and 8B. Where the same reference numbers are used in FIG. 9 as used in any of FIGS. 1A-8B above, the same or similar parts are being referenced (with any of the options or alternatives for those parts described herein), and much of the overlapping or duplicative description may be omitted.
In the example of FIG. 9, rather than a sheet 820 of two-sided adhesive material, two-sided adhesive 920 material is applied to a surface of at least one of the fabric 812 layers as individual adhesive components 922 (e.g., as stickers applied to fabric 812 surfaces). See arrows 924.
In the example of FIG. 9, the individual adhesive components 922 are placed at the desired locations on the fabric(s) 812 to form the bonded regions via the adhesive components 922. One or more bladder chamber portions 110D will be formed at locations other than (e.g., outside of or around) the adhesive components 922.
Once the adhesive components 922 are applied to surface(s) of fabric 812 and the individual laminated components 110A, 110B are placed in the press 400, force F may be applied between the press plates 400A and 400B (optionally with heating), to join the facing surfaces of fabric 812 together via the adhesive components 922 to form the garment component 902. The garment component 902 can be removed from the press 400 (arrow 926) for further processing.
The adhesive components 922 of this specifically illustrated example particularly would produce a garment component 902 structure of the type shown at the bottom of FIG. 9, with: (i) the generally round bonded regions 120 formed at the locations of the adhesive components 922, and (ii) bladder chamber portions 110D extending around the bonded regions 120.
Additional two-sided tape 922P or other adhesive may be provided to produce the sealed outer perimeter edge 910P in the final garment component 902. A gap or passage 922G in the tape 922P around the perimeter provides a fluid passageway 814 to an inlet/outlet 814I/O in the final garment component 902 structure in this illustrated example.
Alternatively, rather than individual stickers or the like for adhesive components 922 as described above, the garment component 902 structure shown in FIG. 9 could be formed using an adhesive that is printed or otherwise applied directly to at least one of the facing surfaces of fabric 812.
Additionally or alternatively, if desired, one or more individual adhesive components 922, 922P could be used in the processes described above and to make the garment components 102 described above in conjunction with FIGS. 1A-6.
Additionally, like the processes of FIGS. 4A-6, the process described above in conjunction with FIG. 9 can be accomplished without the need for tooling in the press 400 to create the desired bonded regions 120. Rather, the process of FIG. 9 can be applied using a press 400 that applies pressure to the substantially entire surfaces between the press plates 400A, 400B. In this example, the directly facing fabric 812 materials at locations away from the adhesive components 922, 922P will prevent bonding at the locations corresponding to the inflatable chamber portions 110D.
The methods described above in conjunction with FIGS. 4A-6 and 8A-9 particularly use an added adhesive 402, 820, 920/922/922P material between layers of the laminated components 110A and 110B to form bonded regions 120. As described above, these methods have an advantage that no tooling was required to form the garment components 102, 802, and 902 and a flat and/or uniform pressing force and action over the substantially entire component surface could be used to form the bonded regions 120.
The methods described above in conjunction with FIG. 7 particularly did not require an additional adhesive material (e.g., an adhesive-free bond was formed, such as by fuse bonding, weld bonding, or melt bonding), but that method required use of tooling 702 to form the bonded regions 120. FIG. 10 illustrates an example of a method that allows a garment component 1002 to be produced without adding an additional adhesive to the composite product and/or without the need to use tooling to apply force at selected locations to form the desired one or more bonded regions 120.
In the example of FIG. 10, laminated components 110A and 110B of the types illustrated in FIGS. 2B, 3B, and/or 3C are used as the starting components with the facing surfaces of the film 118 formed from a material capable of forming fused bonds or melt bonds (e.g., adhesive-free bonds) under the applied heat and/or pressure and/or other conditions (e.g., thermoplastic polyurethane materials).
While FIG. 10 shows film 118 as a single layer, two-layer films 118 of the types described above in conjunction with FIGS. 3B and 3C may be used in some examples of this method (e.g., with the polyurethane layer 118B or the higher melt temperature thermoplastic polyurethane layer 118B fixed to the fabric 112 layer and the thermoplastic polyurethane layer 118A (e.g., the lower melt temperature thermoplastic polyurethane layer 118A) facing outward).
In this method, an adhesion blocker 1020 particularly is applied to a surface 118S of at least one of the facing film 118 layers. The adhesion blocker 1020 may be printed, coated, sprayed, painted, or otherwise applied to the surface 118S.
In some examples of this technology, the adhesion blocker 1020 may constitute an ink material or DWR material (or other suitable material) that is printed (e.g., ink jet printed, screen printed, etc.) or otherwise applied onto surface 118S of at least one film 118 layer. Additionally or alternatively, the adhesion blocker 1020 may constitute a one-sided adhesive tape or sticker applied onto surface 118S of at least one facing film 118 layer.
The blocker 1020 may be cured, if needed (e.g., UV cured). In the specific example illustrated in FIG. 10, the adhesion blocker 1020 is applied in a manner to leave the surface 118S of film 118 exposed in the form of circular regions 1020A. In the example of FIG. 10, on surface 118S, the adhesion blocker 1020 is the dark color and the exposed circular regions 1020A corresponding to the film 118 are the light color.
In the specific example of FIG. 10, the adhesion blocker 1020 is provided at one or more locations and shapes to leave exposed surface 118S of the film 118 at regions 1020A: (i) at the perimeter seam and (ii) within interior bonded regions 120 having the general circular shape shown in FIG. 10. The facing surfaces of the film 118 will bond at these locations that do not have the adhesion blocker 1020.
FIG. 10 further shows that the adhesion blocker 1020 particularly is applied to leave a gap 1020G in the perimeter bonded region 120. As described above in conjunction with FIG. 6, this gap 1020G can be used to provide an unbonded region in the final garment 100 or garment component 1002 structure, e.g., for a fluid inlet/outlet to allow fluid to pass from the interior fluid chamber portion 110D of one garment component 1002 to the interior fluid chamber portion 110D of another garment component, to provide an inlet 1024 for pumped fluid (e.g., from pump 130 in FIGS. 1A and 1F) to enter the inflatable bladder chamber 110, to provide an outlet to allow fluid to reach a pressure release component 134 and/or a relief valve 136 (e.g., shown in FIGS. 1A and 1F), etc.
As shown in FIG. 10, the individual laminated components 110A, 110B are placed in the press 400 between the press plates 400A and 400B (see arrow 1026A). Pressing force F, optionally together with heating and/or other bonding conditions, is applied to press the press plates 400A and 400B together with the laminate components 110A and 110B between them. After pressing, the garment 100 or garment component 1002 is removed from the press 400 (see arrow 1026B), e.g., for further processing (e.g., incorporation into a garment structure).
Melt bonds, welded bonds, fused bonds, or other adhesive-free bonds (shown at reference 1004 in FIG. 10) particularly form the bonded regions 120 between the exterior laminated component 110A and the interior laminated component 110B.
The process of FIG. 10 also may be used with other laminated components 110A and/or 110B described above, such as laminated components 110A and/or 110B having “spaced-apart” regions of adhesive 116, laminated components 110A and/or 110B having a “full layer” of adhesive 116, laminated components 110A and/or 110B with multi-layer films 118, etc. (e.g., provided that the facing surfaces are capable of forming an adhesive-free bond).
As evident from FIG. 10 and the discussion above, the adhesion blocker 1020 may be applied in any desired shapes and/or arrangements to produce any desired inflatable bladder chamber 110 size and/or shapes.
The final garment component 1002 of this specific example particularly includes an outer perimeter bond or seam 1028P (fluid impervious) and generally circular interior bonded regions 1028C. The process of FIG. 10 has advantages in that it does not require the use of adhesives between the laminated components 110A and 110B to form the inflatable bladder chamber 110 (adhesive-free bonding is accomplished) and it does not require the use of tooling (e.g., a flat or uniform press force can be applied across the laminated component 110A, 110B surfaces because the adhesion blocker 1020 prevents bonding at locations where bonding is not desired). Thus, an inflatable bladder chamber 110 configuration can be easily changed, e.g., by simply applying a different adhesion blocker 1020 pattern onto a film 118.
As noted above, systems and methods according to aspects of this technology may form bladder chambers 110, garment components 102, 802, 902, 1002, and garments 100 having many different sizes, shapes, and/or arrangements of bladder chamber portions 110D and bonded regions 120.
FIGS. 11A-11H provide some examples to illustrate the potential versatility of these systems and methods. In the examples of FIGS. 8A and 8B, the bonded regions 120 particularly were formed to leave unbonded regions for the inflatable chamber portions 810D that were generally spherical in shape and that were interconnected by a series of fluid passageways 810P. FIG. 11A provides a closer view of an example garment component 102 that has this general bladder configuration. The patterns of FIGS. 11A-11H need not include laminated components 110A and 110B of the specific construction shown in FIGS. 8A and 8B. Rather, the patterns of FIGS. 11A-11H may be provided in bladder configurations made having any of the laminate component 110A, 110B configurations and/or garment component configurations described above in conjunction with FIGS. 1A-10.
FIG. 11A further illustrates that this example garment component 802 includes: (i) a fluid passageway 814 leading to a fluid inlet/outlet 814I/O for garment component 802 (such as a fluid passageway 814 leading to another garment component, to a pump component 130, to a pressure release component 134, and/or to a relief valve 136 as shown in FIGS. 1A and 1F) and (ii) bonded region forming a fluid impervious outer perimeter 818 (e.g., except at fluid passageway 814).
FIGS. 11B-11C show structures similar to that of FIG. 11A (garment components 102 formed with bonded regions 120 located so as to leave one or more unbonded regions for the one or more inflatable chamber portions 810D that are generally spherical in shape and interconnected by a series of fluid passageways 810P). Where the same reference numbers are used in FIGS. 11B-11C as used in FIG. 11A (and the other figures), the same or similar parts are being referenced (with any of the alternatives or options for that part), and much of the overlapping description may be omitted.
In the example of FIG. 11B, at least some of the generally spherical chamber portions 810D particularly are somewhat larger and/or located closer together than in the example of FIG. 11A. Thus, the fluid passageways 810P are somewhat shorter, as compared to the example of FIG. 11A. FIG. 11B further illustrates that some of the generally spherical chamber portions 810D may be sized differently from others (with some generally spherical chamber portions 810D smaller than others).
In the example of FIG. 11C, on the other hand, the generally spherical chamber portions 810D are quite small as compared to the examples of FIGS. 11A and 11B and/or spaced quite close together. Thus, when this garment component 802 is inflated, it will produce less thickness in its top-to-bottom dimension (e.g., the dimension T from the outer surface of fabric 112 of the exterior laminated component 110A to the outer surface of fabric 112 of the interior laminated component 110B, as shown in FIG. 4A) than the thicknesses of the garment components 102 shown in FIGS. 11A and 11B.
FIGS. 11D-11H show structures similar to those of FIGS. 1A-1D, 6, 7, 9, and 10, e.g., garment components 102, 902, 1002 particularly formed with bonded regions 120 with circular or rounded shapes. Where the same reference numbers are used in FIGS. 11D-11H as used in FIGS. 1A-11C, the same or similar parts are being referenced (with any of the alternatives or options for that part), and much of the overlapping description may be omitted.
The garment components 102 shown in FIGS. 11D-11H particularly have bonded regions 1120 of distinct shapes (circular shaped in these figures), and the inflatable bladder portion 110D is formed around those bonded regions 1120. FIGS. 11D-11H further illustrate that these example garment components 102 include: (i) a fluid passageway 814 leading to a fluid inlet/outlet 814I/O for garment component 102 (such as a fluid passageway 814 leading to another garment component, to a pump component 130, to a pressure release component 134, and/or to a relief valve 136 as shown in FIGS. 1A and 1F) and (ii) a bonded region forming a sealed outer perimeter 818 (e.g., except at fluid passageway 814).
In the examples of FIGS. 11D-11F, the interior bonded portions—identified by reference number 1120 in these figures but also corresponding to some of the bonded regions identified by reference 120 in the discussion above—are formed as relatively small and discrete “dots.” These dots may be relatively small, e.g., having a greatest diagonal or diameter dimension of less than about 10 mm, and in some examples, less than about 8 mm, less than about 6 mm, less than about 5 mm, less than about 3 mm, or less than about 2 mm.
The specific garment component 102 example of FIG. 11E particularly has its interior bonded portions 1120 located somewhat closer together than the interior bonded portions 1120 of the example of FIG. 11D. Similarly, the specific garment component 102 example of FIG. 11F has its interior bonded portions 1120 located somewhat closer together than the interior bonded portions 1120 of the examples of FIGS. 11D and 11E.
Interior bonded portion 1120 spacing in this manner may be used to control a thickness T of the garment component 102 when inflated. In the examples of FIGS. 11D-11F, less than 25% of the surface area of the facing surfaces of the film 118 layers inside the sealed outer perimeter 818 are bonded together (adhesively or in an adhesive-free manner) to form the interior bonded regions 120/1120 of the interior bladder chamber portion 110D (and in some examples, less than about 20%, less than about 15%, or even less than about 10% of that surface area will constitute interior bonded regions 120/1120).
In the examples of FIGS. 11G and 11H, the interior bonded portions 1120 may have a greatest diagonal or diameter dimension of at least about 4 mm, and in some examples, at least about 5 mm, at least about 8 mm, at least about 10 mm, at least about 15 mm, or even larger.
In at least some examples of this technology, bonded regions 1120 will include at least some interior bonded region 1120 sizes that continuously cover an area of: (a) at least about 12.6 mm2, and in some examples, at least about 20 mm2, at least about 50 mm2, at least about 79 mm2, at least about 175 mm2, and/or (b) less than 700 mm2, and in some examples, less than 500 mm2, or even less than 400 mm2. At least 25% of the interior bonded regions 1120 of a garment component 102 and/or an overall garment 100 structure may have sizes within the above ranges (and in some examples, at least 50%, at least 75%, or even at least 90% of the interior bonded regions 1120 of a garment component 102 and/or an overall garment 100 structure may have sizes within the above ranges.
The specific garment component 102 example of FIG. 11G particularly has relatively small interior bonded portions 1120 that are closely spaced together (e.g., less than about 15 mm from all neighboring interior bonded portions 1120, and in some examples less than about 12 mm, less than about 10 mm, less than about 8 mm, or even less than about 5 mm from the neighboring interior bonded portions 1120). The garment component 102 of FIG. 11H, on the other hand, as compared to the garment component 102 of FIG. 11G, particularly has larger bonded portions 1120 (e.g., about 10 to 40 mm in diagonal or diameter dimension), and these bonded portions 1120 are spaced further apart (e.g., at least about 10 mm or at least about 15 mm apart from all neighboring bonded portions 1120).
Interior bonded portion 1120 size and spacing in this manner particularly also may be used to control a thickness T of the garment component 102 when inflated. In some examples (e.g., the examples of FIGS. 1A-1D, 11G and 11H), at least 25% of the area of the facing surfaces of the film 118 layers inside the sealed outer perimeter 818 are bonded together (adhesively or in an adhesive-free manner) to form the interior bonded regions 1120 of the interior bladder chamber portion 110D (and in some examples, at least 30%, at least 40%, or even at least 50% of that surface area will constitute interior bonded regions 1120).
In the garment components shown in FIGS. 11D-11F and 11H, when the bladder structure is in an inflated condition (as shown in these figures), one or more creases 1124 may be formed (e.g., in the exterior laminated component 110A and/or the interior laminated component 110B). The crease(s) 1124 may extend outward from the bonded region 1120, may span completely from one bonded region 1120 to an adjacent bonded region 1120, and/or may partially span from one bonded region 1120 to an adjacent bonded region 1120. When the bonded region 1120 particularly has a curved perimeter shape (e.g., circular, oval, elliptical, etc.), the crease 1124 or creases 1124 may extend outward from the curved perimeter shape, e.g., in a radial direction.
Additionally or alternatively, in some examples of this technology, a garment component (e.g., garment components 102, 902, 1002) may have a thickness dimension T (particularly the dimension T from the outer surface of fabric 112 of the exterior laminated component 110A to the outer surface of fabric 112 of the interior laminated component 110B, as shown in FIG. 4A) when inflated of no more than about 50 mm (and in some examples, no more than about 40 mm, no more than about 30 mm, no more than about 25 mm, or even no more than about 20 mm).
FIG. 12 illustrates a garment component 1202 (which could constitute a complete garment 100) in accordance with other examples of this technology. Where the same reference number is used in FIG. 12 as used in any of FIGS. 1A-11H discussed above, the same or similar parts are being referenced, and much of the overlapping or duplicative description may be omitted.
In the example of FIG. 12, the garment component 1202 includes an exterior laminated component 110A layer that may have any of the features described above in conjunction with FIGS. 2A-10, although an exterior laminated component 110A layer similar to those shown in FIGS. 2B, 4A, 5B, 6, and 7 is shown in the specific example illustrated in FIG. 12.
An inflatable bladder chamber portion 110D (or even a complete bladder chamber 110) may be formed between: (i) the film 118 layer of the exterior laminated component 110A and (ii) a layer 1210B of the garment component 1202 that directly faces the film 118 layer of the exterior laminated component 110A. In this illustrated example, the layer 1210B may include a film 1218 having: at least one polyurethane layer and/or at least one thermoplastic polyurethane layer.
Film 1218 may correspond to and/or have any of the features of films 118 described above. Alternatively, film 1218 may be made somewhat thicker than the thickness for layer 118 described above, e.g., if necessary to provide adequate strength and durability (and may be considered a “sheet” structure. In some examples of this technology, layer 1210B will be formed just by the film 1218.
In some examples of this aspect of the present technology, the film 1218 will remain exposed and will constitute an exposed surface (e.g. an interiormost layer) of the garment component 1202 (and optionally an exposed surface of a garment 100 including that garment component 1202). In such structures, the film 1218 may be formed from a transparent, partially transparent, or translucent material, e.g., permitting visual access to at least some portions of the interior of the bladder chamber portion(s) 110D.
Additionally, while the discussion of FIG. 12 above describes film 1218 as being located at the interior of the garment 100 (and the garment 100's interiormost layer), in other examples of this technology, if desired, the film 1218 may constitute an outer exteriormost surface or layer of the garment 100, and the component identified as exterior laminated component 110A in FIG. 12 may be replaced by interior laminated component 110B.
Use of a transparent, partially transparent (e.g., a colored transparent film, such as a film that is transparent to some visible light wavelengths but not all), semitransparent, or a translucent material as film 1218 in the example structure of FIG. 12 provides opportunities for producing interesting designs and/or aesthetics. As some examples, adhesives 402 and/or 116 may be visible through film 1218. Thus, these adhesives 402 and/or 116 may be applied in different colors and/or interesting patterns that can be viewed through film 1218. Additionally or alternatively, features may be provided within the bladder chamber portion 110D (e.g., provided on or with the laminated component 110A and/or 110B) that may be seen through film 1218). Still additionally or alternatively, the films 1218 themselves (e.g., including portions thereof) may be in different colors, e.g., to provide additional features for aesthetic designs.
FIG. 13 illustrates another example garment component 1302 (which could constitute a substantially complete garment 100) in accordance with some aspects of this technology. Where the same reference numbers are used in FIG. 13 as used in any of FIGS. 1A-12 discussed above, the same or similar parts are being referenced, and much of the overlapping or duplicative description may be omitted.
In the example of FIG. 13, the garment component 1302 includes fabric 112, film 118, and one or more bonding regions 120 of any of the types described above in conjunction with FIGS. 1A-12. The garment component 1302 structure of FIG. 13 differs from the other garment components described above in the manner in which the film 118 particularly is attached to the fabric 112 in the exterior laminated component 110A and/or in the interior laminated component 110B. In the examples described above (e.g., in conjunction with FIGS. 2A-5C), substantial portions, if not all, of the surfaces of the fabrics 112 are fixed to their corresponding films 118 by adhesive 116 (e.g., either with full layer adhesive 116 shown in FIGS. 2A-4B or with the spaced-apart adhesive 116 regions shown in FIGS. 5A-5C).
The garment component 1302 of FIG. 13, on the other hand, includes more limited connections between the facing surfaces of the fabric 112 and the film 118. For example, as shown in FIG. 13, the fabric 112 particularly may be fixed to the film 118 (e.g., by adhesive 116) primarily (and potentially only) at an outer perimeter region 110P of the fabric 112. The perimeter track 116P of the adhesive 116 between fabric 112 and film 118 is shown as broken lines in FIG. 13.
Additionally or alternatively, if desired, this limited connection between the fabric 112 and film 118 may be provided in the interior laminated component 110B. Interior bonded regions 120 between the films 118 may have any of the structures described above in conjunction with FIGS. 1A-11H. In this garment component 1302 structure, the films 118 forming the inflatable bladder chamber 110 may remain relatively free from the fabrics 112 (e.g., attached only at the outer perimeter region 110P) such that unbonded space 1300S is provided between the facing surfaces of the fabric 112 and film 118. This structure may provide a softer hand feel for the garment component 1302, e.g., because much of the outer layer of the garment component 1302 may feel like just the fabric 112 layer.
In some examples of the garment component 1302 shown in FIG. 13, one or more interior bonds 1306 particularly may be provided between the facing surfaces of the fabric 112 and film 118. Examples of such interior bonds 1306 (e.g., where additional adhesive 116 may be applied) are shown in broken lines in FIG. 13. These interior bonds 1306, when present, may be: (a) widely spaced-apart, e.g., at least about 50 mm from the perimeter track 116P and/or other interior bonds 1306 present, (b) relatively small (e.g., less than about 25 mm in its largest dimension (e.g., a diagonal or diameter dimension) and/or less than about 500 mm2 in area), and/or (c) take up a small percentage of facing surface areas of the fabric 112 and film 118 (e.g., less than 5% of this facing surface area).
When present, such additional one or more interior bonds 1306 may help better maintain the inflated bladder chamber 110 component in a desired position between the fabric 112 layers.
As described above in conjunction with FIG. 10, in some examples of this technology, an adhesion blocker 1020 may be applied to a surface of at least one film 118 to produce the inflatable bladder chamber portions 110D within an inflatable bladder 110. The described adhesion blockers 1020 particularly include ink materials, DWR materials, one-sided adhesive tape materials, sticker materials, or other materials, e.g., that may be printed or otherwise applied to a surface 118S of at least one film 118 layer.
FIGS. 14A-14C illustrate another example of adhesion blockers that may be used in at least some examples of this technology. Where the same reference numbers are used in FIGS. 14A-14C as used in the other figures described herein, the same or similar parts are being referenced (including any options or alternative features for that part described herein), and much of the overlapping or repetitive description may be omitted.
In the example of FIGS. 14A-14C, an exterior laminated component 110A and interior laminated component 110B are provided, e.g., of the types with two facing surfaces made from film 118 layers (e.g., film 118 layers that particularly will bond together under applied heat and pressure conditions and/or other bonding conditions (e.g., welding conditions), such as thermoplastic polyurethanes or polyurethanes that have a hot melt or other adhesive applied thereto and/or thermoplastic polyurethanes that can form adhesive-free bonds).
These laminated components 110A, 110B particularly may be fixed together under heat and/or pressure to form a garment component 1402. As some more specific examples: (a) the laminated components 110A, 110B may have any of the laminated component 110A, 110B structures shown in FIGS. 2B-7, and (b) the garment component 1402 may have any of the garment component 102 structures shown in FIGS. 4A-7.
The adhesion blockers 1420 of this example may include a fabric component applied to (fixed to) the film 118 layers at the desired locations for adhesion blocking (to thereby form at least some part of an interior chamber portion 110D). Any desired type of fabric may be used as an adhesion blocker 1420, provided that the exposed interiormost surface of the adhesion blocker 1420 on one laminated component 110A, 110B will not bond to the facing surface provided on the other laminated component 110A, 110B.
In this illustrated example, each of the laminated components 110A, 110B has a film 118 layer particularly made from a polyurethane material with a hot melt adhesive applied to its exposed surface or a thermoplastic polyurethane material at the exposed surface. These film 118 layers face one another and will bond to one another under the typically applied pressing conditions (e.g., under heat and pressure).
Thus, fabric type adhesion blockers 1420 particularly are applied to the exposed, facing surfaces of both laminated components 110A, 110B. In this manner, when heat and pressure and/or other bonding conditions are applied, at the adhesion blocker 1420 locations fabric will directly contact fabric, and these contacting fabric surfaces will not bond, thereby leaving an unbonded region as part of the inflatable bladder chamber 110.
Further, in the specific example illustrated in FIG. 14A, the adhesion blocker 1420 particularly is made of a laminated component corresponding to the structure of at least one of laminated components 110A and/or 110B. The laminated components of the adhesion blockers 1420 particularly are inverted from the orientation of the laminated component 110A, 110B to which it is attached, i.e., so that film 118 layer faces film 118 layer (and these film 118 layers can bond together) and so that the fabric 112 layer on one adhesion blocker 1420 (e.g., the adhesion blocker 1420 on laminated component 110A) faces the fabric 112 layer on the adhesion blocker 1420 provided on the other laminated component (e.g., the adhesion blocker 1420 on laminated component 110B).
In some examples of this technology, as shown in FIG. 14C, the adhesion blocker 1420 may form a location for one or more fluid passageways 1422, 1424 through the garment component 1402, e.g., through one of the laminated components 110A, 110B. As a more specific example, fluid passageway 1422 may be provided through one of the laminated components 110A, 110B (the exterior laminated component 110A in this illustrated example) as a pathway through which air from pump component 130 is introduced into the inflatable bladder chamber 110.
Appropriate hardware for attaching a fluid line (e.g., plastic tubing) and/or a pump component 130 to the laminated component 110A particularly may be provided at the fluid passageway 1422 (e.g., a coupling, another connector structure, etc.), and/or the adhesion blocker 1420 may provide additional reinforcement or support for engaging such hardware or component of the pump component 130.
Alternatively, if desired, the fluid passageway 1422 for the pump component 130 may be provided through the interior laminated component 110B.
Additionally or alternatively, one or more adhesion blockers 1020 of the types described above in conjunction with FIG. 10 may be used at a location corresponding to pump 130, e.g., in a similar manner as shown in FIGS. 14A-14C (e.g., replacing one or both of the facing fabric component(s) 1420 in FIGS. 14A-14C with at least one ink, adhesive tape, and/or sticker type adhesion blocker).
Additionally or alternatively, one or more fluid passageway 1424 may be provided through one of the laminated components 110A, 110B (the interior laminated component 110B in this illustrated example) as a pathway through which air from inside the inflatable bladder chamber portion 110D can exit the inflatable bladder chamber 110 (e.g., via release component 134 or a relief valve 136).
Appropriate hardware for attaching a fluid line (e.g., plastic tubing), release component 134, and/or relief valve 136 to the laminated component 110B particularly may be provided at the fluid passageway 1424 (e.g., a coupling, another connector structure, etc.), and/or the adhesion blocker 1420 may provide additional reinforcement or support for engaging such hardware or other component of the release component 134 and/or relief valve 136.
Alternatively, if desired, the fluid passageway 1424 for the release component 134 and/or relief valve 136 may be provided through the exterior laminated component 110A.
Additionally or alternatively, one or more adhesion blockers 1020 of the types described above in conjunction with FIG. 10 may be used at a location corresponding to release component 134 and/or relief valve 136, e.g., in a similar manner as shown in FIGS. 14A-14C (e.g., replacing one or both of the facing fabric component(s) 1420 in FIGS. 14A-14C with at least one ink, adhesive tape, and/or sticker type adhesion blocker).
FIGS. 1A, 1G, and 1H illustrate additional example features of example garments 100 in accordance with at least some aspects of this technology. FIGS. 1G and 1H schematically show two garment components-a front left garment component 102L and a front right garment component 102R.
The garment components 102L and 102R particularly may have structures corresponding to any of the garment components described above in conjunction with FIGS. 1A-14C, including bonded regions 120 selectively located to form (i) an outer perimeter seam 150A and (ii) one or more internal fixed regions 150B that define bladder chamber portions 110D.
In some examples of this technology, the bladder chamber portions 110D on the front left garment component 102L may be in fluid communication with the bladder chamber portions 110D on the right side garment component 102R, e.g., via fluid passageways 152 defined by the bonded regions 120 that connect with and extend around a back component or back portion of the overall garment 100 structure. This fluid communication is shown schematically in FIGS. 1G and 1H by arrow 154 (and example interconnections are described in more detail below).
In the example of FIG. 1A, the garment 100 particularly includes a securing system 140 or a connector system, such as a zipper or other slider type fastening system. FIGS. 1G and 1H schematically illustrate some examples of manners in which securing systems 140 may be engaged with a garment 100 in accordance with aspects of this technology.
For example, as shown in FIG. 1G, this example securing system 140 includes: (a) one portion 156A engaged with or otherwise provided with the perimeter seam 150A at one edge of garment component 102L, and (b) another portion 156B engaged with or otherwise provided with an adjacent perimeter seam 150A of garment component 102R.
In some examples, each of securing system portions 156A and 156B may constitute portions of a zipper fastener or other slider fastener component. The portions 156A and 156B of securing system 140 particularly may be provided as or on strips of material (e.g., fabric) that can be attached to the garment components 102L and/or 102R by a sewn seam (e.g., through perimeter seam 150A), by an adhesive, by an adhesive free seam (e.g., a welded seam), and/or by one or more mechanical fasteners (e.g., one or more rivets or other couplings extending through perimeter seam 150A).
FIG. 1H is a view similar to FIG. 1G, but a different securing system 140 structure and engagement are shown. In the example of FIG. 1H, at least some portions of the securing system 140 may be directly formed in or provided on the garment component(s) 102L and/or 102R having inflatable bladder chamber portions 110D.
The specific example of FIG. 1H includes a button type securing system 140 in which one or more button holes 158A are formed (as through hole openings) directly through the perimeter seam 150A of one garment component (garment component 102L in this example) and one or more corresponding buttons 158B are fixed (e.g., by sewing or mechanical fasteners) directly to the perimeter seam 150A of the other garment component (garment component 102R in this example). The one or more buttons 158B are shown in broken lines in FIG. 1H because they may be located on the other side of the surface shown in FIG. 1H. Alternatively, if desired, either the button hole(s) 158A and/or the button(s) 158B may be included with another component (e.g., such as mounted on a strip of material) that can be attached to garment component(s) 102L and/or 102R at the perimeter seam 150A.
Other types of securing systems 140 may be used and attached to garments 100 and garment components 102 in manners similar to those shown in FIGS. 1G and/or 1H in other specific examples of this technology.
As some additional examples, the securing system 140 may include: (i) one or more snap type fasteners (e.g., with the snap components engaged with a flap of material attached to perimeter seam 150A or with snap components directly fixed with perimeter seam 150A); (ii) one or more buckle type fasteners (e.g., with the buckle hardware engaged with a flap of material attached to perimeter seam 150A or with the buckle hardware directly fixed with perimeter seam 150A and with the buckle strap engaged with some portion of the garment 100 (such as one of garment components 102L and/or 102R)); and/or (iii) other types of fasteners; etc.
Additionally or alternatively, the securing system 140 may comprise a belt (e.g., extending through one or more belt loops provided with one or more of the garment components 102L, 102R, etc.).
FIGS. 15A-15D illustrate another example garment 1500 in accordance with some examples of this technology. This example garment 1500 comprises a vest structure, although jackets, shirts, and/or other garment structures may have features as shown in FIGS. 15A-15D. Where the same reference numbers are used in FIGS. 15A and 15B as used in the other figures described herein, the same or similar parts are being referenced (with any of the variations, options, or alternatives for that part), and much of the overlapping or repetitive description may be omitted. The example of FIGS. 15A-15D may be formed from one or more garment components 102 with an inflatable bladder chamber 110 and multiple bladder chamber portions 110D of any of the types described above in conjunction with FIGS. 1A-14C.
In the example garment structure 1500 of FIGS. 15A-15D, at the bonded regions 120, the facing surfaces of an exterior laminated component 110A and an interior laminated component 110B particularly are bonded together, e.g., by an adhesive bond or in an adhesive-free manner (e.g., by a melt bond, weld bond, or fused bond) in any of the manners described above.
FIGS. 15A-15D show the bonded regions 120 of this specific example substantially having an oval shape, with ovals of varying sizes arranged in staggered columns that extend from a top-to-bottom direction of the garment 1500. In this illustrated example, the bonded regions 120 specifically generally become smaller in surface area moving upward from the bottom opening 100B (e.g., waist opening) toward the top opening 100N (e.g., neck opening) of the garment 1500.
In the specific example of FIG. 15A, the largest bonded regions 120 are located around the garment 1500 near the bottom opening 100B area, and each bonded region 120 in the generally vertical column of bonded regions 120 particularly gets progressively smaller moving upward toward the top opening 100N.
The bonded regions 120 may be provided in any desired numbers, sizes, shapes, patterns, orientations, and the like and may be present a wide variety of different aesthetic appearances. As some additional examples, the bonded regions 120 may be round, square, rectangular, polygonal, oval, star shaped, cross shaped, or irregularly shaped in different specific examples of this technology.
Further, a single garment 1500 need not have all of the bonded regions 120 of the same number, size, shape, pattern, and/or orientation. The bonded regions 120 at interior locations within the bladder chamber 110 may be sized, shaped, and/or positioned to control a shape of the bladder chamber 110 (and thus a shape of the garment component 102) when it is in an inflated condition. A wide variety of bonded region 120 features are possible in various different specific examples of this technology.
FIGS. 15A-15D further show that one or more of the bonded regions 120 may include one or more through holes 122 defined through them. The through holes 122 may be provided in any number of the bonded regions 120 in different examples of this technology (e.g., in at least about 25% of the internal bonded regions 120, in at least 50% of the internal bonded regions 120, in at least about 60% of the internal bonded regions 120, etc.).
The through holes 122 particularly extend from the exposed surface of exterior laminated component 110A to the opposite exposed surface of the interior laminated component 110B. The through holes 122 may provide added ventilation or breathability to the garment 100 and garment component 102. Through holes 122, when present, may be provided in any desired numbers, sizes, shapes, patterns, orientations, and the like and may be present a wide variety of different aesthetic appearances.
As some additional examples, the through holes 122 substantially may be round, square, rectangular, polygonal, oval, star shaped, cross shaped, or irregularly shaped in different specific examples of this technology. Further, a single bonded region 120 and/or a single garment 100 need not have all of the through hole 122 of the same number, size, shape, pattern, and/or orientation. A wide variety of through hole 122 features are possible in various different specific examples of this technology.
FIG. 15B shows an example of a garment component 102 having an inflatable bladder chamber 110 engaged with other garment components, e.g., in any of the manners described above in conjunction with FIGS. 1A-1H and/or in any of the manners described in more detail below. In this illustrated example, a garment component 102 forming a front of the garment 100 is engaged with a hood or collar member 102C (e.g., at seam 108) and with a back garment component 102D (e.g., via seam 108A). The back garment component 102D also is engaged with the hood or collar member 102C (e.g., at seam 108).
FIGS. 15C and 15D show close-up views of opposite sides of an interior bonded region 120 of garment 100 of FIG. 15A. FIG. 15C shows the exterior side of this example (formed from exterior laminated component 110A) and FIG. 15D shows the interior side (formed from interior laminated component 110B).
As shown in FIG. 15C, at the exterior side of this example, the perimeter edge 120P of the bonded region 120 (i.e., the boundary between the bonded region 120 and an inflatable chamber portion 110D) particularly borders a recessed region, and the perimeter edge 120P may extend all or partially around the bonded region 120. Thus, at the outer surface, the bonded region 120 may be “debossed” (or recessed) with respect to a main surface 120SX area around that bonded region 120. But, as described above in conjunction with FIGS. 1C and 1D, at least one raised region 124X may be provided around the perimeter edge 120P.
As shown in FIG. 15D, at the interior side of this example, the perimeter edge 120P of the bonded region 120 forms a raised region 120S (e.g., a raised step that may extend all or partially around the bonded region 120). Thus, at the inner surface, the bonded region 120 may be “embossed” (or raised) with respect to a main surface 120SI area around that bonded region 120.
This raised region 120S, when present on the interior of the garment 100, particularly may help hold portions of the garment 100 off the wearer's body somewhat, e.g., when the inflatable bladder chamber 110 is in a deflated condition (e.g., for better breathability). The interior side may include a raised region 124I, as described above in conjunction with FIG. 1D.
As examples, the raised region 124X at the outside of the exterior perimeter edge 120P particularly may be formed by one or more of: (a) adhesive material (e.g., adhesive material 402 provided between the laminated components 110A, 110B, adhesive 116 material provided within one or both laminated components 110A, 110B, etc. flowing from beneath the press and gathering around the exterior side of the bonded region 120 when heat and pressure are applied; and/or (b) melted or softened material from one or both laminated components 110A, 110B flowing to and/or deforming at the raised region 124X when heat and/or pressure are applied.
The raised region 124I at the interior side of the perimeter edge 120P particularly may be formed by one or more of: (a) adhesive material (e.g., adhesive material provided between the laminated components 110A, 110B, adhesive 116 material provided within one or both laminated components 110A, 110B, etc. flowing from beneath the press and gathering around the interior side of the bonded region 120 when heat and pressure are applied; (b) melted or softened material from one or both laminated components 110A, 110B flowing to and/or deforming at the raised region 124I when heat and pressure are applied; and/or (c) pressing the laminated components 110A, 110B into a silicone press pad surface or other somewhat softened surface in the press when forming the bonded regions 120.
FIGS. 16A-16C illustrate features of another example garment 1600 structure in accordance with at least some aspects of this technology. FIG. 16A shows the garment 1600 in a substantially deflated condition and FIG. 16B shows the garment 1600 in a substantially inflated condition. Where the same reference numbers are used in FIGS. 16A-16C as used in the other figures described herein, the same or similar parts are being referenced (with any of the variations, options, or alternatives for that part), and much of the overlapping or repetitive description may be omitted. The examples of FIGS. 16A-16C may be formed from one or more garment components 102 with an inflatable bladder chamber 110 and multiple bladder chamber portions 110D of any of the types described above in conjunction with FIGS. 1A-15D.
The garment 1600 structure shown in FIGS. 16A and 16B particularly does not include a securing system 140. Rather, the garment 1600 is a pullover style and includes sleeve components 1640. This example garment 1600 includes at least the following garment components: (a) at least one main body component 1602B, (b) at least one upper component 1602U (e.g., extending around the neck region) that is/are attached to the main body component 1602B at perimeter seams 1610S, (c) a right sleeve component 1640R attached to the main body component 1602B at seam 1642R, and/or (d) a left sleeve component 1640L attached to the main body component 1602B at seam 1642L.
Each of the main body component(s) 1602B, the upper component(s) 1602U, the right sleeve component 1640R, and the left sleeve component 1640L of this example particularly includes an inflatable bladder portion 110D that is changeable between a delated condition (FIG. 16A) and an inflated condition (FIG. 16B). The inflatable bladder portions 110D in the various components 1602B, 1602U, 1640R, 1640L may be in fluid communication or interconnected with one another, e.g., to form a single overall inflatable bladder chamber 110 (e.g., in any of the manners described above and/or described in more detail below).
As shown in FIG. 16C, the sleeve components 1640L and 1640R particularly may include a garment component of the types described above for garment components 102, 802, 902, 1002 particularly substantially formed as an elongated rectangle or trapezoid shape (with fixed regions 120 forming a perimeter seam 1644P and internal bonded regions 1644A). The longer opposite edges 1646 of that elongated component may be fixed together (at perimeter seams 1644P along edges 1646) to particularly substantially form an elongated tubular or cylindrical structure (optionally with a tapered shape) with an open interior chamber 1600C, as shown in FIG. 16C. These opposite edges 1646 particularly may be fixed together via bonding (e.g., adhesive bonding or non-adhesive bonding), via one or more sewn seams, via one or more mechanical fasteners, and/or in other appropriate manners.
One open end 1648 of the sleeve components 1640 (e.g., the larger open end) particularly may be attached to one or more main body components 1602B at seam 1642R, 1642L. The other open end 1650 may remain open to allow the wearer's hand to extend outward.
If desired, the open end 1650 may be attached to another garment component, such as a sleeve cuff component, a storm cuff, etc. FIG. 16C further shows a fluid passageway 1652 that particularly may be used to allow fluid communication between bladder chamber portion 110D of sleeve component(s) 1640R, 1640L and bladder chamber portion(s) 110D provided in the main body component(s) 1602B.
As shown in FIGS. 16A and 16B, the garment components with inflatable bladder chamber portions 110D of this example garment 1600 (e.g., one or more of main body component(s) 1602B, upper component(s) 1602U, right sleeve component 1640R, and/or left sleeve component 1640L) generally have relatively small and spaced internal bonded regions 120, e.g., of the types shown in FIGS. 11D-11F.
These figures further illustrate that different interior bonded region 120 spacings and arrangements particularly may be used within a single garment component 1602B, 1602U, 1640R, 1640L to provide different inflatable chamber sizes and/or shapes within a single inflatable chamber portion 110D. For example, FIG. 16B illustrates that the sleeve components 1640R and 1640L include somewhat larger spacings between internal bonded regions 1644A at their tops and smaller spacings between internal bonded regions 1644A near their bottom open ends 1650. Similarly, FIG. 16B illustrates that the main body component 1602B includes somewhat larger spacings between internal bonded regions 1644A at its upper end and smaller spacings between internal bonded regions 1644A near the bottom opening 1602X. A wide variety of changes in bonded region 120 sizes and/or spacings within a given garment component and/or within a given garment structure are possible in different specific examples of this technology, such as changes in sizes, changes in spacings, changes in shapes, changes in relative orientation with respect to one another, changes in bonded region distribution and/or density features, changes in aesthetics, etc.
FIGS. 17A-17H provide various views of a jacket (as a garment 100) in accordance with some aspects of this technology, e.g., of the type described above in conjunction with FIGS. 1A-1H, but FIGS. 17A-17H are provided to describe and illustrate additional aspects and features of at least some examples of this technology. The garment 100 (as well as any of the other garments described herein) may be washable and reusable. FIG. 17A shows a front view of the garment 100; FIG. 17B shows a rear view; FIG. 17C shows a front view with the garment 100 in a deflated condition; FIG. 17D shows a front view with the garment 100 in an inflated condition; FIG. 17E shows a rear view with the garment 100 in a deflated condition; FIG. 17F shows a rear view with the garment 100 in an inflated condition; FIG. 17G shows a perspective view of the garment 100; and FIG. 17H shows an exploded view of the garment components. Where the same reference number is used in FIGS. 17A-17H as is used in the other figures included herein, the same or similar parts are being referenced (including any options or alternatives for those parts described herein), and much of the overlapping and/or duplicative description may be omitted.
Also, while FIGS. 17A-17H show garments 100 and garment components having specific aesthetic appearances, the garment 100 may have different aesthetic appearances while still performing the desired functions. As some examples, a garment 100 of the type shown in FIGS. 17A-17H may have internal bonded regions 120 of different sizes, different shapes (e.g., note FIGS. 11A-11H), different spacing distances (e.g., note FIGS. 11A-11H), etc. As additional examples: the internal bonded regions 120 may vary in sizes, shapes, spacing distances, and/or other arrangement or orientation features among the garment components (e.g., the internal bonded region 120 features in one garment component may differ from the internal bonded region 120 features of another garment component in a single garment 100 structure); and/or (b) the internal bonded regions 120 may vary in sizes, shapes, spacing distances, and/or other arrangement or orientation features within a single garment component (e.g., as discussed above in conjunction with FIG. 16B). Thus, the garment 100 of FIGS. 17A-17H may take on a wide variety of different aesthetic appearances from the specific example aesthetic appearance shown in FIGS. 17A-17H.
In one specific example of the garment 100 shown in FIGS. 17A-17H, at least the left front garment component 1702L, the right front garment component 1702R, the back garment component 1702B, the left sleeve component 1740L, and the right sleeve component 1740R will have a construction like garment components 102 shown in one of FIG. 4A or 5B, e.g., with: (a) a knit fabric 112 formed from a PET, polyester, or nylon material with a double jersey knit structure, (b) at least one thermoplastic polyurethane film 118 layer, and/or (c) an adhesive 116 layer particularly formed with either a full glue adhesive 116 (FIG. 4A) or spaced-apart adhesive 116 regions (e.g., as described above in conjunction with FIGS. 5A and 5B) engaging the film 118 with its respective fabric 112.
The film 118 in each laminated component 110A, 110B of this specific example may be less than about 100 micron thick (e.g., and in some specific examples, about 30-45 micron thick or about 50-60 micron thick). Alternatively, however, a two-layer film 118 (e.g., with a thermoplastic polyurethane layer 118A and a polyurethane layer 118B and/or with (at least) two thermoplastic polyurethane layers 118A and 118B of two different melt temperatures as described above) may be used in other specific examples of this technology. The two-layer film 118, when used, may have a total thickness of less than about 100 micron thick (e.g., and in some specific examples, having a total thickness of about 30-45 micron thick or about 50-60 micron thick), and each individual layer 118A, 118B of the two-layer film 118 may have a thickness between about 5 micron and about 90 micron, and in some specific examples, between about 8 micron and about 50 micron, between about 10 micron and about 40 micron, between about 15 micron and about 40 micron, or even between about 8 micron and about 30 micron.
Additionally or alternatively, in some specific examples, the knit fabric 112 at least at an outermost surface of one or more of the left front garment component 1702L, the right front garment component 1702R, the back garment component 1702B, the left sleeve component 1740L, and/or the right sleeve component 1740R may be at least partially covered (and in some examples, fully covered) with a woven fabric layer, e.g., like additional fabric layer 112X described above in conjunction with FIG. 4B.
At least some of the internal bonded regions 120 are formed as relatively small, spaced-apart bonded regions (e.g., substantially round in shape), e.g., of the types shown in FIGS. 11D-11H (e.g., with at least some of the internal bonded regions having a largest diagonal or diameter dimension of less than about 25 mm, or even less than about 20 mm, less than about 16 mm, or less than about 12 mm, and/or at least about 5 mm (and in some examples, at least about 6 mm or at least about 8 mm)). Additionally or alternatively, in some specific examples, at least some of the individual interior bonded regions 120 may have a continuous bonded area of at least about 19.6 mm2 (and in some examples, at least about 28 mm2 or even at least about 50 mm2). At least 25% of the interior bonded regions 120 of a garment component 102 and/or an overall garment 100 structure may have sizes within the above ranges (and in some examples, at least 50%, at least 75%, or even at least 90% of the interior bonded regions 120 of a garment component 1702L, 1702R, 1702B, 1740L, and/or 1740R and/or an overall garment 100 structure may have sizes within the above ranges.
The internal bonded regions 120 of this illustrated example garment 100 may be substantially evenly spaced throughout the garment 100 structure (optionally, having substantially constant sizes and spacings in all of the garment components 1702L, 1702R, 1702B, 1740L, and 1704R), with one internal bonded region 120 spaced from its immediately adjacent internal bonded regions 120 by about 35 mm to about 250 mm, by about 40 mm to about 200 mm, and/or by about 20 mm to about 70 mm.
Other bonded region 120 spacings may be used (and the spacing may be varied within a specific garment component 1702L, 1702R, 1702B, 1740L, 1704R and/or within an overall garment 100). As some more specific examples, bonded regions 120 may vary within a single garment 100 structure and/or even within a single garment portion (e.g., within one or more of garment components 102, 1702L, 1702R, 1702B, 1740R, 1740L, and/or 1740C) in one or more of: bonded region 120 sizes; bonded region 120 spacings; bonded region 120 “density” (e.g., the number of bonded regions 120 per unit area); bonded region 120 “distribution,” i.e., relative orientation of bonded regions 120 with respect to neighboring bonded regions 120 (e.g., generally linearly aligned v. aligned on a curve v. irregularly spaced; provided in staggered columns, etc.); etc.
The collar component 1702C of this illustrated example particularly does not include a bladder chamber portion 110D (although it could be formed with a bladder chamber portion 110D, if desired). If provided with a bladder chamber portion, the bladder chamber portion of the collar component 1702C may be in fluid communication with one or more of the bladder chamber portions 110D of one or more of the other garment components 1702L, 1702R, 1702B, 1740L, and/or 1740R. Additionally or alternatively: (i) the collar component 1702C may have the same or different internal bonded region 120 features from one or more of the other garment components 1702L, 1702R, 1702B, 1740L, and/or 1740R in the garment 100 and/or (b) the collar component 1702C may have any of the internal bonded region 120 characteristics described above for garment components 1702L, 1702R, 1702B, 1740L, and/or 1740R.
The sleeve components 1740L and 1740R particularly may substantially have a tubular construction, e.g., like that described above and shown in FIG. 16C.
Edges 1700Z on the left garment component 1702L and the right garment component 1702R (see FIG. 17H) particularly may constitute bonded regions 120 along a perimeter edge for engaging a securing system 140, like the zipper component shown in FIG. 17A (or other types of securing systems 140), including any of the securing systems and/or engagements described above in conjunction with FIGS. 1G and/or 1H.
The garment 100 of FIGS. 17A-17H particularly includes two pocket 104 structures-one on each of the left front garment component 1702L and the right front garment component 1702R in this illustrated example.
Additionally or alternatively, as further shown schematically in FIGS. 17A and 17B, this example garment 100 may include one or more of: (a) an inflation pump component 130 (e.g., in a pocket 104), (b) an air intake 132, e.g., for inflation pump component 130), (c) a pressure release component 134 (e.g., in a pocket 104), and/or (d) one or more relief valves 136 (e.g., in one or more of garment components 1702L, 1702R, 1702B, 1740R, and/or 1740L).
In some alternative structures, the thermoplastic polyurethane film 118 described above could be replaced by a single layer of polyurethane (and/or the facing polyurethane film 118 layers could form the bonded regions 120 using an adhesive, such as a hot melt adhesive 402).
Additionally or alternatively, the collar component 1702C could be replaced by a collar component including a hood (with or without a bladder chamber portion 110D within the hood).
The component edges labeled 1700P in FIG. 17H represent edges where garment 100 components 1702L, 1702R, 1702B, 1740L, 1740R, and 1702C engage one another to form one or more seams between the garment components. At least some of these seams may be formed at perimeter edges of the garment components formed by bonded regions 120 of a bladder chamber portion 110D provided in that garment component.
As some more specific examples, the garment 100 assembly of this example may include: (i) the top edge 1700P of right sleeve component 1740R engaged with the right sleeve edges 1700P of the right front garment component 1702R and the back garment component 1702B (see arrows “A” and “B” in FIG. 17H); (ii) the top edge 1700P of left sleeve component 1740L engaged with the left sleeve edges 1700P of the left front garment component 1702L and the back garment component 1702B (see arrows “C” and “D” in FIG. 17H); (iii) the lower right side edge 1700P of the back garment component 1702B engaged with the lower side edge 1700P of the right front garment component 1702R (see arrow “E” in FIG. 17H); (iv) the lower left side edge 1700P of the back garment component 1702B engaged with the lower side edge 1700P of the left front garment component 1702L (see arrow “F” in FIG. 17H); (v) the top right shoulder edge 1700P of the right front garment component 1702R engaged with the top right shoulder edge 1700P of the back garment component 1702B (see arrow “G” in FIG. 17H); (vi) the top left shoulder edge 1700P of the left front garment component 1702L engaged with the top left shoulder edge 1700P of the back garment component 1702B (see arrow “H” in FIG. 17H); and/or (vii) the collar garment component 1702C (its lower edge 1700P) engaged with each of the top edges 1700P of the right front garment component 1702R, the left front garment component 1702L, and the back garment component 1702B (see arrows “I,” “J,” “K,” and “L” in FIG. 17H).
The engagements between the garment components at edges 1700P can be made any desired manner, including by one or more of: sewn seams, adhesive bonding, mechanical fasteners, ultrasonic welding techniques, RF welding techniques (or other adhesive-free bonds), etc. Other example engagement seams and techniques are described in more detail below.
FIGS. 17C-17F illustrate differences between this example garment 100 in a deflated condition (FIGS. 17C and 17E) and an inflated condition (FIGS. 17D and 17F). As evident from these figures, in the inflated condition, the bladder chamber(s) 110 are filled with gas (e.g., air) under pressure to fill the bladder chamber portions 110D within garment components 1702L, 1702R, 1702B, 1740L, and 1740R.
The air in bladder chamber portions 110D of these garment components 1702L, 1702R, 1702B, 1740L, and 1740R provides a layer of insulation for the garment 100, reducing thermal conduction or transmission through the garment 100. In at least some examples of this technology, one or more of the garment components 1702L, 1702R, 1702B, 1740L, and 1740R, when inflated, will have a thickness dimension T (e.g., see FIG. 4A) of no more than about 50 mm (and in some examples, no more than about 40 mm, no more than about 30 mm, no more than about 25 mm, no more than about 20 mm, or even no more than about 16 mm).
The internal bonded regions 120 particularly may be spaced apart from one another with spacing distances sufficient to produce a desired garment thickness dimension T when the garment 100 is inflated (e.g., to provide a thickness within the ranges described above). Internal bonded region 120 shaping also may be used, at least in part, to control the inflated shape and thickness of the garment 100.
While not shown in the specific examples of FIGS. 17A-17H, if desired, one or more through hole openings may be provided, e.g., in one or more of the internal bonded regions 120, particularly if additional breathability or ventilation is necessary or desired. Such through hole openings, if desired, may be provided in a manner similar to the holes 122 described above in conjunction with FIGS. 15A-15D.
Additionally or alternatively, in some examples of this technology, the areas along the inside of the sleeve components 1740L and 1740R (e.g., the area along perimeter seam 1644P shown in FIG. 16C) and/or the areas along the sides of the garments 100 (e.g., the area along the seam joining the front right garment portion 1702R to the back garment portion 1702B and/or the area along the seam joining the front left garment portion 1702L to the back garment portion 1702B) may be left without inflatable chamber portions 110D for some increased width distance. Separate garment components (e.g., fabric components) may be provided in these areas to create the non-inflatable regions.
As some more specific examples, at least about 25 mm (or even at least about 40 mm or at least about 50 mm) around these seams may be free of inflatable bladder chamber portions 110D. The absence of inflatable chamber portions 110D beneath the sleeves 1740R/1740L and sides of the garment 100 structure may help the wearer's arms hang more naturally when the garment 100 is inflated.
FIGS. 17A-17H illustrate that the sleeve components 1740L and 1740R of this example may include a cuff component 1800 at the lower open end of each sleeve. The cuff component 1800 may be made of any desired materials and/or have any desired construction, including conventional materials and conventional constructions as are known and used in the garment (e.g., coat, jacket, etc.) art.
In this illustrated example, the cuff component 1800 particularly does not include an inflatable bladder chamber 110 and/or inflatable bladder portion 110D, although it could include such structures if desired (e.g., in the manner described above for garment components 102, 802, 902, 1002, etc.).
A cuff component 1800 particularly may be attached to sleeve component 1740L or 1740R in any desired manner, e.g., at a perimeter portion of a bonded region 120 forming a bladder chamber portion 110D within sleeve component 1740L or 1740R (e.g., like perimeter seam 1644P shown in FIG. 16C). This attachment—shown generally at element 1802 in FIG. 18—may be accomplished, e.g., via a sewn seam, via an adhesive bond, via a welded bond or other adhesive-free bond, via one or more mechanical fasteners, etc.
The cuff component 1800 particularly may include a size adjustment component 1804, e.g., as are conventionally known and used in the garment arts. FIG. 18 shows an example of a size adjustment component 1804 in the form of a tightening strap 1804S that can snuggly wrap a wearer's wrist and/or be secured on a securing component 1804B. In the illustrated example, the tightening strap 1804S is secured to a base member as the securing component 1804B by a hook-and-loop fastener system. Snaps, buttons, buckles, and/or other types of fastener systems may be used in other specific examples of this aspect of the present technology.
Additionally or alternatively, other types of size adjustment components 1804 could be used in other specific examples of this technology, such as one or more elastic bands around the wrist opening, one or more adjustable drawstring openings, etc. The size adjustment component 1804 or other type of tightening system around the wearer's wrist area can help prevent heat from escaping and/or cold air from entering the sleeves at the wrist area.
Additionally or alternatively, the cuff component 1800 may include a storm cuff type structure.
FIGS. 17A and 17B further illustrate a drawcord type securing element around or at the bottom opening 100B of this example garment 100. See the drawcord 1902 exposed loops 1902L in FIGS. 17A and 17B. FIGS. 19A and 19B show an example of one manner of engaging a drawcord type securing element 1900 in a garment component (e.g., one or more of the left front garment component 1702L, the right front garment component 1702R, and/or the back garment component 1702B in accordance with some aspects of this technology.
The bottom edge 1906 of garment component 1702L, 1702R, 1702B (or another garment component) particularly is rolled upward and stitched 1906S or bonded (or otherwise secured). This may occur at a bonded region 120 substantially forming a bottom perimeter seam of one or more of the left front garment component 1702L, the right front garment component 1702R, and/or the back garment component 1702B. This action produces a “tunnel” 1906T through which a drawcord 1902 can extend.
An opening 1906O that extends into the tunnel 1906T particularly allows the drawcord 1902 to emerge from the tunnel 1906T for user access. Example drawcord securing elements 1908 are shown in FIG. 19B. Other types of drawcord constructions may be used in other specific examples of this technology including drawcord assemblies formed as separate garment components attached to the bottom edge of garment components 1702L, 1702R, and/or 1702B.
Additionally or alternatively, other types of bottom securing elements and/or systems may be used in other specific examples of this technology. For example, the drawcord type securing element 1900 may be replaced by an elastic and/or stretchable waistband, belt, strapping system, or other type of securing system. A bottom opening 100B securing system, size adjustment component, and/or other type of tightening system around the wearer's waist area can help prevent heat from escaping and/or cold air from entering the garment 100 at the bottom opening 100B.
As described above, the example garment 100 of FIGS. 17A-17H includes several garment components having inflatable bladder chamber portions 110D—at least the left front garment component 1702L, the right front garment component 1702R, the back garment component 1702B, the left sleeve component 1740L, and the right sleeve component 1740R.
In some examples of this technology, the inflatable bladder portions 110D in two or more of these garment components 1702R, 1702L, 1702B, 1740R, and 1740L may be in fluid communication with one another. This may be accomplished in various ways in various different specific examples of this technology. As one example, fluid lines (e.g., plastic tubing) may be included in the garment 100 structure, and these fluid lines may connect to “ports,” e.g., like fluid inlet/outlets 814I/O shown in FIGS. 11A-11H and/or to the fluid passageways 1422 and 1424 shown in FIG. 14C.
The fluid lines particularly may connect to a common manifold, fluid line, and/or reservoir structure that places all of the desired inflatable bladder portions 110D in fluid communication with one another.
In use, the interconnected inflatable bladder portions 110D particularly may be inflated using a single pump component 130 and/or deflated using a single release component 134 (although two or more of these components could be provided, if desired, in some other specific examples of this technology).
Other ways of interconnecting separate garment components having inflatable bladder chamber portions 110D may be used in other specific examples of this technology. As one more specific example, two adjacent garment components having inflatable bladder portions 110D can include structure to enable gas to pass between the garment components through the seam joining the two garment components.
More specifically, the seam may be made from multiple layers of material forming the two adjacent garment components, and that seam may include (a) a first sealed region, (b) a second sealed region, and (c) a fluid passageway defined between layers of the multiple layer construction located between the first sealed seam region and the second sealed seam region. This fluid passageway places the inflatable bladder portions 110D in the two garments components in fluid communication with one another.
FIGS. 20A-20F illustrate examples of such seams 2000, 2026 and interconnection of garment components (e.g., garment components 2000A and 2000B having interconnected inflatable bladder portions 110D). Where the same reference numbers are used in FIGS. 20A-20F as used in the other figures described herein, the same or similar parts are being referenced (including any options or alternatives for those parts described herein), and much of the overlapping and duplicative description may be omitted. The methods of FIGS. 20A-20F may be used with any of the various laminates, bladders, and/or garment portions described above in conjunction with FIGS. 1A-19.
The seams 2000 and/or 2026 shown and described below in conjunction with FIGS. 20A-20F may correspond to seams at edges 1700P shown in FIG. 17H, e.g., seams between one or more of: (a) the right front garment component 1702R and the right sleeve component 1740R (see arrow A in FIG. 17H); (b) the right sleeve component 1740R and the back garment component 1702B (see arrow B in FIG. 17H); (c) the left front garment component 1702L and the left sleeve component 1740L (see arrow C in FIG. 17H); (d) the left sleeve component 1740R and the back garment component 1702B (see arrow D in FIG. 17H); (e) the sides of the right front garment component 1702R and the back garment component 1702B (see arrow E in FIG. 17H); (f) the sides of the left front garment component 1702L and the back garment component 1702B (see arrow F in FIG. 17H);); (g) the shoulder regions of the right front garment component 1702R and the back garment component 1702B (see arrow G in FIG. 17H); and/or (h) the shoulder regions of the left front garment component 1702L and the back garment component 1702B (see arrow H in FIG. 17H).
As noted above, the edges 1700P particularly may correspond to bonded regions 120 between an exterior laminated component 110A and an interior laminated component 110B (e.g., an adhesive or adhesive-free bond between the facing film 118 layers in the laminated components 110A, 110B).
In the example of FIGS. 20A-20C, seam 2000 is formed at or near perimeter edges of two garment components 2000A and 2000B to be joined. In this example method, the seams closing the individual bladder chamber portions 110D in the two garment components 2000A and 2000B and the seam joining these two garment components 2000A and 2000B to one another in a fluid communicating manner are formed simultaneously. Each of the laminated components 110A and 110B of garment components 2000A and 2000B shown in this illustrated example includes an outward facing fabric 112 layer (e.g., a knit fabric layer) and an inward facing film 118 layer (e.g., one or more thermoplastic polyurethane film 118 layers and/or one or more polyurethane film 118 layers).
The examples of FIGS. 20A-20C show formation of a composite scam 2000 that includes (a) the seams closing the individual bladder chamber portions 110D in the two garment components 2000A and 2000B (e.g., portions of their outer perimeter edge seams) and (b) the scam joining these two garment components 2000A and 2000B to one another. One or more fluid passageways 2014 may be provided through the composite seam 2000 to place the two bladder chamber portions 110D in fluid communication with one another.
The seam 2000 particularly is formed such that the edge of one garment component (garment component 2000B in the example of FIGS. 20A-20C) is contained between the exterior laminated component 110A and the interior laminated component 110B of the other garment component (the edge of garment component 2000A in this illustrated example).
More specifically, as shown in FIG. 20A (which is a cross-sectional view of the seam 2000 at a sealed region), the edge region 2002T of exterior laminated component 110A of garment component 2000B particularly at least partly is folded upward onto itself and an adhesive 2004T is applied (so that the facing layers of the fabric 112 will bond together at the edge region 2002T). Similarly, the edge region 2002B of interior laminated component 110B of garment component 2000B particularly at least partly is folded downward onto itself and an adhesive 2004B is applied (so that the facing layers of the fabric 112 will bond together at the edge region 2002B). At least portions of those folded edge regions 2002T and 2002B are positioned substantially facing one another and between the facing surfaces of the exterior laminated component 110A and the interior laminated component 110B of garment component 2000A, as shown in FIG. 20A.
In structures in which the exposed layer of the film 118 is a thermoplastic polyurethane material (or other material capable of bonding to itself in an adhesive-free manner), a sealed region of the seam 2000 is formed when the scam 2000 region particularly is exposed to heat and pressure or other bonding conditions when stacked in the manner shown in FIG. 20A. In this manner, a sealed seam 2000 is produced, e.g., as follows: (i) the film 118 of the exterior laminated component 110A of garment component 2000A will form an adhesive-free bond with the film 118 at the upper folded area of the garment component 2000B (at area A in FIG. 20A); (ii) the fabric 112 of the garment component 2000B will be fixed to the fabric 112 of the garment component 2000B in the upper folded region by adhesive 2004T (at area B in FIG. 20A); (iii) the film 118 of the interior laminated component 110B of garment component 2000A will form an adhesive-free bond with the film 118 at the lower folded area of the garment component 2000B (at area C in FIG. 20A); (iv) the fabric 112 of the garment component 2000B will be fixed to the fabric 112 of the garment component 2000B in the lower folded region by adhesive 2004B (at area D in FIG. 20A); and/or (v) the film 118 layer of exterior laminated component 110A of garment component 2000B will bond in an adhesive-free bond with the film 118 layer of the interior laminated component 110B of garment component 2000B at area E shown in FIG. 20A. In this manner, sealed portions 2010S of the scam 2000 are formed.
One or more fluid passageway portions 2010P extending through this example scam 2000 are illustrated in FIG. 20B (which is a cross-sectional view of the seam 2000 at a fluid passageway portion 2010P). Much of the seam 2000 structure in the fluid passageway portions 2010P of FIG. 20B is the same as that shown in FIG. 20A, e.g., with the folded edge regions 2002T, 2002B, the adhesives 2004T, 2004B, and regions A, B, C, and D.
In the fluid passageway portions 2010P, however, an adhesion blocker 2012 particularly is applied to at least one of the facing film 118 surfaces of the exterior laminated component 110A and interior laminated component 110B of garment component 2000B. Under the applied heat and pressure conditions and/or other bonding conditions (e.g., welding conditions), the adhesion blocker(s) 2012 particularly will prevent the facing film 118 layers of the exterior laminated component 110A and interior laminated component 110B of garment component 2000B from bonding together, thereby forming the fluid passageway 2014 between garment components 2000A and 2000B. As shown in FIG. 20B, the fluid passageway 2014 is located at the site of the adhesion blocker(s) 2012.
Also, as shown in FIGS. 20B and 20C, the fluid passageway(s) 2014 particularly are defined through the seam 2000 joining garment component 2000A to garment component 2000B, and/or these fluid passageways 2014 particularly are bordered on opposite sides by scaled regions 2010S of the seam 2000 (formed by bonded regions 120 and at areas where no adhesion blocker 2012 is provided).
Any desired type of adhesion blocker 2012 may be used in various specific examples of this technology. As some examples, adhesion blocker(s) 2012 may take the form of any of the adhesion blockers described herein, e.g., in conjunction with FIGS. 10 and 14A-14C, including, for example, adhesive tape and/or sticker type adhesion blockers. Adhesion blocker(s) 2012 may comprise fabric (e.g., like fabric 112) backed with adhesive (e.g., adhesive materials, including two-sided adhesives of the types commercially available from Bemis Associates, Inc.) that can be adhered to film(s) 118 at desired fluid passageway 2014 locations. Some advantages of the methods described above in conjunction with FIGS. 20A-20C include: the ability to form at least some seams 2000, bonded regions 120, and bladder chamber portions 110D in a single pressing step (e.g., with heat and pressure, with welding conditions, etc.); avoiding the need to incorporate separate fluid lines to connect bladder chamber portions 110D (and the hardware and connection steps associated therewith) into a garment structure; the ability to make multiple fluid passageways 2014 between garment components to help assure fluid communication is maintained; the ability to easily and selectively control and/or modify the fluid passageway 2014 locations; etc.
The examples of FIGS. 20A-20C show that at least some portions of a garment 100 may have at least some of its seams 2000 joining garment components 2000A and 2000B formed concurrent with formation of the seams closing off the perimeter edges of the bladder chamber portions 110D. Other ways of joining garment components 2000A and 2000B and their bladder chamber portions 110D together may be used in other examples of this technology. For example, complete individual garment components (e.g., two or more of garment components 1702R, 1702L, 1702B, 1702C, 1740R, and/or 1740L) may be formed separately and joined together by attaching their perimeter seams (formed by bonded regions 120) with one another (e.g., by one or more of adhesives, adhesive-free bonds, sewn seams, mechanical fasteners, etc.). Fluid passageways (e.g., through seams) and/or separate fluid lines may be provided to interconnect bladder chamber portions 110D of the various garment components, if such interconnection is desired.
FIG. 20D shows another example construction method that may be used in accordance with some aspects of this technology (e.g., in an arrangement of the type illustrated in FIG. 20C). In this example, the interior sides of two or more garment components are formed and joined together, separate from the exterior sides of those same two or more garment components. For example, as shown at the top of FIG. 20D, first: (a) an interior laminated component 110B (e.g., with fabric 112 layer and film 118 layer of any of the types described above) of garment component 2000A and (b) an interior laminated component 110B (e.g., with fabric 112 layer and film 118 layer of any of the types described above) of garment component 2000B are separately formed and joined together.
FIG. 20D schematically shows this as a welding step (e.g., ultrasonic welding, RF welding, etc.) by arrow 2020. This action particularly joins the perimeter edges of the interior laminated components 110B of garment components 2000A and 2000B together, as shown at the top right of FIG. 20D. Once joined at seam 2022S, the two garment components 2000A and 2000B can be unfolded to form a composite interior garment structure 2022I including portions of garment component 2000A and garment component 2000B. If desired, any excess material outside of the scam 2022S may be trimmed off the composite interior garment structure 2022I. The seam 2022S of this example composite interior garment structure 2022I is located at interfacing outer perimeter edges of the two garment components making up the composite interior garment structure 2022I.
In the same manner, a composite exterior garment structure 2022X may be formed separate from composite interior garment structure 2022I. Composite exterior garment structure 2022X (shown in the center of FIG. 20D) includes: (a) an exterior laminated component 110A (e.g., with fabric 112 layer and film 118 layer of any of the types described above) of garment component 2000A and (b) an exterior laminated component 110A (e.g., with fabric 112 layer and film 118 layer of any of the types described above) of garment component 2000B joined together at seam 2022S. The seam 2022S of this example is located at interfacing outer perimeter edges of the portions of the two garment components 2000A, 2000B making up the composite exterior garment structure 2022X. Seam tape 2024 (e.g., of the types commercially available, e.g., from Bemis Associates, Inc.) may be applied (e.g., adhesively) over surfaces of the seam 2022S on the composite interior garment structure 2022I and/or on the composite exterior garment structure 2022X.
In other examples, the seam tape 2024 particularly may be provided on the exterior surface of composite exterior garment structure 2022X and on the interior surface of the composite interior garment structure 2022I. Additionally or alternatively, seam tape 2024 may be applied to the interior surface and/or the exterior surface of either or both of the seams 2022S of either or both of composite exterior garment structure 2022X and/or component interior garment structure 2022I. Seam tape 2024, wherever present, may add some stiffness and/or help support and maintain seam integrity.
Then, the composite exterior garment structure 2022X and the composite interior garment structure 2022I particularly may be joined to one another at the seams 2022S, by applying heat and pressure and/or other securing conditions (e.g., welding conditions) to the seam region (see force arrows 2028). The heat and pressure and/or other conditions (and seam tape 2024, if present) will allow the facing film 118 layers to bond together and form a seam 2026 between the composite exterior garment structure 2022X and the composite interior garment structure 2022I.
If needed: (a) tooling particularly may be provided to limit the areas where the facing film 118 layers will bond to one another (e.g., for thermoplastic polyurethane films 118 that will bond together under heat and pressure and/or other securing conditions (e.g., welding conditions) without use of an adhesive) and/or (b) an adhesive particularly may be provided at selected locations between the facing film 118 layers (e.g., for polyurethane films 118 that require a separate adhesive to bond).
Additionally or alternatively, at least one adhesion blocker (e.g., adhesion blockers 2012 of any of the types described herein, including adhesive tape type adhesion blockers) may be provided at one or more locations along longitudinal length of the seam 2026. The adhesion blocker(s) will provide one or more fluid passageways (e.g., like passageways 2014 shown in FIG. 20C) between the fluid chamber portion 110D in garment component 2000A and the fluid chamber portion 110D in garment component 2000B. The fluid passageway 2014 structures will allow fluid to flow across (and through) the seam 2026 and place the first garment component 2000A in fluid communication with the second garment component 2000B.
Thus, seams 2026 of the types provided by the method of FIG. 20D may include sealed portions and fluid passageway portions through the seam 2026 (e.g., arranged like sealed portions 2010S and fluid passageway portions 2010P shown in FIG. 20C).
The method described above in conjunction with FIG. 20D may be used to connect the exterior laminated component 110A with the interior laminated component 110B of any number of garment components (e.g., any two or more of garment components 1702R, 1702L, 1702B, 1702C, 1740R, and/or 1740L of the types shown in FIGS. 17A-17H).
In some examples: (a) all interior garment laminated components 110B may be joined together to form an interior composite garment structure, (b) all exterior laminated garment components 110A may be joined together to form an exterior composite garment structure, (c) the interior composite garment structure may be placed inside and aligned with the exterior composite garment structure, and/or (d) the seams 2026 between the interior and exterior composite garment structures may be formed in one or more seam forming steps, e.g., in the manner described above in conjunction with FIG. 20D. If desired, the interior bonded regions 120 within the garment components may be formed at the same time that the scam 2026 is formed.
FIGS. 20E and 20F show another example seam structure and construction method that may be used in accordance with some aspects of this technology. FIG. 20E shows cross-sectional views at locations of a scam 2026 to be formed, and FIG. 20F shows a view of the seam 2026 in dot-dashed line at the interior surface and/or exterior surface of this example garment structure. In this example method, a sealed seam 2026 will be formed between two garment portions 2000A and 2000B, but a fluid passageway 2014 will be provided through that seam 2026. This method will connect the interior bladder chamber portion 110D of one garment portion 2000A with the interior bladder chamber portion 110D of another garment portion 2000B and place their bladder chamber portions 110D in fluid communication, e.g., in an arrangement of the type illustrated in FIG. 20C. The bladder chamber portions 110D are shown in broken lines in FIG. 20F. This example process simultaneously: (a) seals the outer perimeter edge of the bladder chamber portions 110D in two garment portions 2000A and 2000B, (b) joins interior and exterior components 110A and 110B of those two garment portions 2000A and 2000B together, and (c) places the interior bladder chamber portions 110D of those garment portions 2000A and 2000B in fluid communication across a scam 2026 joining those garment portions 2000A and 2000B. The method of FIGS. 20E and 20F can be used to interconnect any two garment portions of the types described above in a fluid communicating manner, e.g., any two or more of the garment portions 1702L, 1702R, 1702B, 1702C, 1740L, and/or 1740R along perimeter edges 1700P.
In this example method, as shown at the top of FIG. 20E, the interior laminated component 110B of garment potion 2000A is joined to the interior laminated component 110B of garment portion 2000B to thereby form a composite interior garment portion 2022I. This may be accomplished, for example, by a welding step shown by process arrow 2020 (e.g., an ultrasonic welding step, an RF welding step, etc.) or in another appropriate manner. As a more specific example, as shown in FIG. 20E, the two interior laminated components 110B may be placed in a stacked relationship (e.g., with their film 118 layers facing each other and their fabric 112 layers facing away from each other), and the welding step 2020 may be accomplished (e.g., with little or no heating). This welding step fixes the film 118 layers of the two interior laminated component 110B together at the location of the weld process 2020 (forming seam 2022S) without fixing the remainder of the film 118 layers together. The seam 2022S of this example is located at interfacing outer perimeter edges of the two garment components making up the composite interior garment structure 2022I. Any excess material (if any) outside of the seam 2022S may be trimmed off. The resulting joined interior laminated components 110B are referred to herein as a “composite interior garment portion” 2022I.
If desired, at this stage in the process: (i) interior laminated component 110B of garment portion 2000A may be partially attached to the exterior laminated component 110A of garment portion 2000A (e.g., at one or more interior bonded regions 120 for the garment portion 2000A) and/or (ii) interior laminated component 110B of garment portion 2000B may be partially attached to the exterior laminated component 110A of garment portion 2000B (e.g., at one or more interior bonded regions 120 for the garment portion 2000B). These “partial attachments” may be located away from the perimeter edges where the seam 2026 is to be formed.
In separate process steps, the exterior laminated component 110A of garment potion 2000A is joined to the exterior laminated component 110B of garment portion 2000B to thereby form a “composite exterior garment component” 2022X. This may be accomplished in the same manner as described above (e.g., via welding processes) for the composite interior laminated component 2022I. The seam 2022S of this example is located at interfacing outer perimeter edges of the two garment components making up the composite exterior garment structure 2022X.
Then, in some examples of this technology, as shown in the center of FIG. 20E, a seam tape 2024 may be applied over the seam(s) 2022S of at least one of the composite interior laminated component 2022I and/or the composite exterior laminated component 2022X. FIG. 20E shows the seam tape 2024 applied at the fabric 112 surfaces of both the composite interior laminated component 2022I and the composite exterior laminated component 2022X, and FIG. 20F shows the seam tape 2024 over the exterior surface of fabric layer 112. Additionally or alternatively, the seam tape 2024 may be applied at the film 118 surface(s) of either or both of the composite interior laminated component 2022I and/or the composite exterior laminated component 2022X. The seam tape 2024 may be formed from any suitable material, e.g., including materials commercially available (such as commercial products available from Bemis Associates Inc.). Seam tape 2024, when used, can help maintain a sealed connection in the final bladder and/or garment product.
The left center of FIG. 20E shows an area joining the outer perimeter edge of the garment portion 2000A with the outer perimeter edge of garment portion 2000B at a sealed seam region (which will form seam 2026), e.g., at plane 20EL-20EL shown in FIG. 20F. At some areas of the seam 2026, however, it may be desired to make a fluid passageway 2014 through the seam 2026 so that fluid can move between the bladder chamber portions 110D of garment portion 2000A and garment portion 2000B. As shown at the right center of FIG. 20E (a cross-sectional view taken at plane 20ER-20ER shown in FIG. 20F) and in FIG. 20F, at these fluid passageway 2014 areas, one or more adhesion blockers 2012 may be provided. The area depicted at the left center of FIG. 20E may be spaced longitudinally along the seam 2022S from the area depicted at the right center of FIG. 20E (e.g., in the manner shown in FIG. 20C). FIG. 20F illustrates the longitudinal direction and longitudinal length of the seams 2022 and the seam 2026 to be formed by the bracket labeled “LL.”
As some more specific examples: (i) an adhesion blocker 2012 may be applied to the films 118 across the seam 2022S between garment portion 2000A and garment portion 2000B of the interior composite laminated component 2022I, and/or (ii) an adhesion blocker 2012 may be applied to the films 118 across the seam 2022S between garment portion 2000A and garment portion 2000B of the exterior composite laminated component 2022X. The adhesion blocker(s) 2012 may be of any of the types described above.
The adhesion blockers 2012 in some examples may comprise a fabric component 2012F (see the shaded block in FIG. 20F) (e.g., like any of the fabrics 112 described above) with a two-sided adhesive backing 2012B (e.g., a polyurethane adhesive) applied that is adhered to the films 118 across the seam(s) 2022S. The two facing fabric component 2012F surfaces of the adhesion blockers 2012 within the desired fluid passageway 2014 area will prevent the films 118 of the interior composite laminated component 2022I and the exterior composite laminated component 2022X at the fluid passageway 2014 area(s) from fixing together under the pressing conditions that will follow. In some particular examples, when the adhesion blocker 2012 includes a fabric component 2012F layer with a two-sided adhesive backing 2012B, the two-sided adhesive backing 2012B may extend beyond the one or both edges of the attached fabric component 2012F layer in the longitudinal or length direction LL of the seam 2026 to be formed. See FIG. 20F. This feature, when present, may help provide additional bonding between films 118 using the adhesive backing 2012B and/or help prevent undesired leakage at the seam 2026 at areas adjacent the fluid passageway 2014.
Next in this process, the interior composite laminated component 2022I and the exterior composite laminated component 2022X will be joined together at the seams 2022S formed between the perimeter edges of garment portion 2000A and garment portion 2000B. In this specific example, pressing force, optionally together with heating, is applied along a longitudinal length of the seams 2022S. This step is shown in the central part of FIG. 20E by force arrows 2080 and pressing elements 2082 (e.g., tooling, press plates, etc.).
The pressing force 2080 fixes the films 118 of the interior composite laminated component 2022I with the films 118 of the exterior composite laminated component 2022X to form seam 2026 at locations along the seams 2022S where no adhesion blocker 2012 is present. This is shown at the bottom left of FIG. 20E. As shown in FIG. 20F, in some examples, the seam 2026 may be formed somewhat wider than the seams 2022S and/or somewhat wider than the seam tape 2024. Where the adhesion blocker 2012 is present, the films 118 of the interior composite laminated component 2022I do not bond with the films 118 of the exterior composite laminated component 2022X. This leaves a fluid passageway 2014 through the seam 2026 (between interfacing film 118 layers), as shown at the bottom right of FIG. 20E and in FIG. 20F.
Any desired way of fixing the films 118 of the interior composite laminated component 2022I with the films 118 of the exterior composite laminated component 2022X to form seam 2026 may be used. For example, heat and pressure may be used to create the bonded seam 2026. As other examples, welding techniques (e.g., ultrasonic welding, RF welding, etc.) and/or adhesives may be used to create bonded seam 2026.
If needed, tooling particularly may be used to limit the areas where pressing force 2080 is applied to the facing film 118 layers of the interior composite laminated component 2022I and the exterior composite laminated component 2022X.
Thus, seams 2026 of the types provided by the methods of FIGS. 20E and 20F may include sealed seam portions and one or more fluid passageway portions through the seam 2026 (e.g., arranged like sealed portions 2010S and fluid passageway portions 2010P shown in FIGS. 20C and 20F). The methods described above in conjunction with FIGS. 20E and 20F may be used to connect the exterior laminated component 110A with the interior laminated component 110B of any number of garment components (e.g., any two or more of garment components 1702R, 1702L, 1702B, 1702C, 1740R, and/or 1740L of the types shown in FIGS. 17A-17H).
In the examples of FIGS. 20D-20F, the seam(s) 2022S initially forming the composite interior laminated component 2022I and the composite exterior laminated component 2022X may be relatively narrow (e.g., less than about 3 mm wide, less than about 2 mm wide, or even less than about 1 mm wide).
The seam tape 2024, when present, may span the entire width of the seam(s) 2022S. In some examples, the seam tape 2024 may be less than about 20 mm wide, less than about 16 mm wide, or even less than about 12 mm wide (e.g., substantially centered on its respective seam 2022S).
The overall seam 2026 may span the entire width of the seam(s) 2022S and/or the entire width of the seam tape 2024, when present. In some examples, the seam 2026 may be less than about 30 mm wide, less than about 25 mm wide, or even less than about 20 mm wide (e.g., substantially centered on its respective seam 2022S and/or seam tape 2024 (if present)).
Additionally or alternatively, in the fluid passageway 2014 area(s), the adhesion blocker(s) 2012 may have a width that is wider than the seam 2022S width. In some examples, the adhesion blocker(s) 2012 may span from the bladder chamber portion 110D in garment portion 2000A to the bladder chamber portion 110D in garment portion 2000B. See FIGS. 20C and 20F.
Additionally or alternatively, at the fluid passageway 2014 area(s), the adhesion blocker(s) 2012 may extend in the longitudinal or length direction LL of the seam 2026: (i) for at least about 5 mm, and in some examples, at least about 7.5 mm or even at least about 10 mm and/or (ii) less than about 50 mm, and in some examples, less than about 40 mm or even less than about 35 mm. In this manner, in the longitudinal or length direction LL of the seam 2026, the fluid passageway 2014 may have a dimension of: (i) at least about 5 mm, and in some examples, at least about 7.5 mm or even at least about 10 mm and/or (ii) less than about 50 mm, and in some examples, less than about 40 mm or even less than about 35 mm. Some example fluid passageways 2014 may have a length along the direction of the seam 2026 of about 15 mm to 30 mm.
When multiple fluid passageways 2014 are present through a single seam 2026, the fluid passageways 2014 may have the same or different sizes, structures, and/or constructions.
In some specific examples, the seam 2000, 2026 will define a length direction extending along the seam from the seam 2000, 2026's one end to its opposite end. At least some bladders, garment portions, and/or garments (e.g., of the types described above in conjunction with FIGS. 17A-17H and/or 20A-20F) may include: (i) a first sealed seam portion 2010S having a first length dimension (L1) in the length direction, (ii) a second sealed seam portion 2010S having a second length dimension (L2) in the length direction, and (iii) a first fluid passageway portion 2010P having a third length dimension (L3) in the length direction. In at least some examples, a combined length of the first length dimension and the second length dimension may be at least two times the third length dimension (e.g., L1+L2≥2×L3). In some examples, the combined length of L1 and L2 may be at least 3 times, at least 4 times, or even at least 5 times the length of L3.
Additionally or alternatively, in at least some examples, in a single seam 2000, 2026, the combined lengths (e.g., LS) of all sealed seam portions 2010S in the seam 2000, 2026 will be greater than the combined lengths (e.g., LF) of all fluid passageway portions 2010P through that seam 2000, 2026. In some specific examples, LS will be at least 1.5 times LF, and in some examples, LS will be at least 2 times, at least 2.5 times, at least 3 times, or even at least 4 times LF.
Additionally or alternatively, edges of the seam 2026 may be spaced from its closest interior bonded region 120 within fluid chamber portions 110D by at least about 8 mm, and in some examples, at least about 10 mm, at least about 12 mm, or even at least about 15 mm.
The examples of FIGS. 20D-20F show formation of a composite seam 2026 that includes (a) the seams closing one edge of the individual bladder chamber portions 110D in two adjacent garment components 2000A and 2000B (e.g., portions of their outer perimeter edge seams) and (b) the seam joining these two garment components 2000A and 2000B to one another. One or more fluid passageways 2014 may be provided through the composite seam 2026 to place the two bladder chamber portions 110D in fluid communication with one another. In some examples, as shown in FIGS. 20D-20F, the composite seam 2026 may include the interface area at the outer perimeter edges of the two garment portions 2000A and 2000B (e.g., the adjacent edges where seams 2022S are formed).
The seams 2026 joining two garment portions at one location in an individual garment may have the same structures or constructions as the seams 2026 joining two garment portions at other locations in that same garment, and the different seams 2026 may be formed by the same method. Additionally or alternatively, in some examples, the seams 2026 joining two garment portions at one location in an individual garment may have a different structure or construction from one or more other seams 2026 joining two garment portions at one or more other locations in that same garment and/or two seams 2026 in a garment may be formed by different methods.
Seams with fluid passageways 2014 of the types described above in conjunction with FIGS. 20A-20F may be provided in any desired location(s) in a garment 100. One or more fluid passageways 2014 may be provided between any desired garment components as needed to assure the desired garments are in fluid communication with one another. The fluid passageways 2014 may be provided across seams at locations where inadvertent closure of the passageway(s) 2014 may be avoided (e.g., due to folds across the seam, due to motion of a wearer's arms, etc.).
In some example garments 100, one or more fluid passageways 2014 may be provided across seams between two adjacent garment portions desired to be in fluid communication with one another. As some more specific examples, as shown in the example garment of FIGS. 17A and 17B: (a) the seam between the front right garment component 1702R and the right sleeve component 1740R may include two fluid passageway portions 2014; (b) the shoulder seam between the front right garment component 1702R and the back garment component 1702B may include two fluid passageway portions 2014; (c) the seam between the front left garment component 1702L and the left sleeve component 1740L may include two fluid passageway portions 2014; (d) the shoulder seam between the front left garment component 1702L and the back garment component 1702B may include two fluid passageway portions 2014; (e) the seam between the back garment component 1702B and the right sleeve garment component 1740R may include two fluid passageway portions 2014; (f) the seam between the back garment component 1702B and the left sleeve garment component 1740L may include two fluid passageway portions 2014; (g) the side seam between the right front garment component 1702R and the back garment component 1702B may include at least two fluid passageway portions 2014 (e.g., from two to five passageway portions 2014); and/or (h) the side seam between the left front garment component 1702L and the back garment component 1702B may include at least two fluid passageway portions 2014 (e.g., from two to five passageway portions 2014).
Additionally or alternatively, if the collar component 1702C includes an inflatable bladder chamber 110D, one or more fluid passageways 2014 may be provided to extend between the seam(s) of the collar component 1702C and one or more of the front left garment portion 1702L, the front right garment portion 1702R, and/or the back garment component 1702B.
FIGS. 21A and 21B show additional features that may be included in garments 100 in accordance with some aspects of this technology. As described above (e.g., in conjunction with FIGS. 16A-16C and 17A-17H), some examples of this technology may include garment components formed into tubular structures (e.g., for garment sleeves), e.g., having an axial direction A shown in FIG. 16C (into and out of the page of FIGS. 21A and 21B).
Multiple garment components also can combine to form a tubular structure, such as garment components 1702L, 1702B, and 1702R and securing system 140 in FIGS. 17A-17H substantially forming a “tubular structure” that surrounds the wearer's body.
FIG. 21A illustrates cross-sectional views of a sleeve component (e.g., 1640L, 1640R, 1740L, 1740R) or other tubular component structure transverse to the axial direction, e.g., and near (e.g., within about 50 mm of) its top open end (where it is connected to another garment component, such as a front garment component and/or a back garment component).
FIG. 21A may illustrate features near a top open end 1648 of a garment component structure of the type shown in FIG. 16C. When changing between a deflated condition (left side of FIG. 21A) and an inflated condition (right side of FIG. 21A), such garment components may (a) decrease in open interior surface area (e.g., from A1 to A2) and/or (b) decrease in largest diagonal (e.g., diameter) dimension across the open interior surface area (e.g., from D1 to D2).
FIG. 21B illustrates a cross-sectional view of a sleeve component (e.g., 1640L, 1640R, 1740L, 1740R) or other substantially tubular component structure transverse to its axial direction, e.g., and near (e.g., within about 50 mm of) its bottom open end (e.g., where it may be connected to another garment component, such as a cuff component 1800, where the wearer's hand or arm exits, etc.).
FIG. 21B may illustrate features near a bottom open end 1650 of a garment component structure of the type shown in FIG. 16C. When changing between a deflated condition (left side of FIG. 21B) and an inflated condition (right side of FIG. 21B), such garment components may (a) decrease in interior surface area (e.g., from A3 to A4) and/or (b) decrease in largest diagonal (e.g., diameter) dimension (e.g., from D3 to D4). The decreased interior surface area A4 and/or diagonal dimension D4 features under the inflated condition can help keep a sleeve component 1640L, 1640R, 1740L, 1740R tighter around the wearer's wrist area, helping keep heat within the sleeve component 1640L, 1640R, 1740L, 1740R.
FIG. 21A may illustrate structures and properties near a top end 1648 of a garment component (e.g., one of sleeve components 1640L, 1640R, 1740L, 1740R), and FIG. 21B may illustrate structures and properties near a bottom end 1650 of that same garment component (e.g., one of sleeve components 1640L, 1640R, 1740L, 1740R). In at least some examples of this technology: (i) A1 may be greater than A3, (ii) A2 may be greater than A4, (iii) D1 may be greater than D3, and/or (iv) D2 may be greater than D4.
Additionally or alternatively, in at least some examples of this technology, the difference between A3 and A4 (i.e., ΔAB=A3-A4) (the change in the open internal area at the bottom end 1650) may be greater than the difference between A1 and A2 (i.e., ΔAT=A1-A2) (the change in the opening internal area at the top end 1648). In other words: ΔAB particularly may be greater than ΔAT. In at least some examples of this technology, ΔAB may be at least about 10% greater than ΔAT, and in some examples, at least about 15% greater, at least about 20% greater, or even at least about 25% greater.
Features of the “ΔA” values may be controlled and/or varied, e.g., by varying one or more of the amount of taper in the garment component (e.g., component 1640L, 1640R, 1740L, 1740R), if any; by varying the spacing of bonded regions 120; by varying the size of bonded regions 120; and the like. This greater ΔAB feature also may help assure that under the inflated condition, a sleeve component 1640L, 1640R, 1740L, 1740R holds tighter around the wearer's wrist area, helping keep heat within the sleeve component 1640L, 1640R, 1740L, 1740R.
As described above, garments 100 in accordance with examples of this technology particularly may have internal bonded regions 120 of many different sizes, shapes, spacings, and/or arrangements. Typically, internal bonded regions 120 may be selected: (a) to have a size, shape, and/or other properties suitable to provide adequate bonding strength for the expected conditions of use and/or (b) to provide desired inflation properties (e.g., thickness, aesthetics, etc.).
As also noted above, however, pressure may increase within an inflatable bladder portion(s) 110D at one or more local areas around the garment 100 or garment component 102, e.g., when external forces are applied to compress or flatten one or more inflatable chamber portions 110D and move air out of one or more inflatable bladder portions 110D. For example, when a wearer sits down or falls down, some inflatable chamber portions 110D may become compressed, and the gas from those chamber portions 110D may flow into other chamber portions 110D (e.g., via fluid passageways 2014). This can increase the pressure of the inflatable chamber portions 110D at some local areas. This issue can be further exacerbated, e.g., if some of the fluid passageways (e.g., 2014) between adjacent bladder chamber portions 110D become blocked. If that local pressure becomes excessively high and/or spikes, a scam of the garment 100 (e.g., seam 2000, 2026, and/or another seam formed by bonded region(s) 120) could burst, thereby damaging the inflatable bladder chamber 110. One or more relief valve(s) 136 of the types described above may be provided to help reduce the chances of damage in this scenario.
In addition or as an alternative to the relief valve(s) 136 structures discussed above, garments 100 and the individual garment components, e.g., 1702R, 1702L, 1702B, 1740R, and 1740L, may include one or more of the internal bonded regions 120 that function as a “sacrificial” bonded region. The sacrificial bonded region(s) may have structures generally the same as the other internal bonded regions 120 described above (e.g., formed by bonding film 118 of exterior laminated component 110A to film 118 of interior laminated component 110B), but the sacrificial bonded regions may be located, sized, shaped, and/or structured to more readily “fail” under an excessive force between the films 118 held by that bonded region 120.
When exposed to excessive force, the internal bonded regions 120 acting as sacrificial bonded regions will pull apart or delaminate between the film 118 layer on the exterior laminated component 110A and the film 118 layer on the interior laminated component 110B. In other words, the sacrificial bonded regions may be configured to become unbonded when a force pulling the films 118 apart is greater than a first threshold force. Considering that bonded regions that are not sacrificial may become unbonded under extreme conditions, such as if a force pulling the films 118 apart is greater than a second threshold force, the second threshold force may be greater than the first threshold force.
Breaking one of more of the sacrificial bonded regions under the excess pressure conditions will somewhat increase the volume of the bladder chamber portion 110D at that area, resulting in a decreased local pressure in that area. The decreased local pressure may be sufficient, in at least some instances, to prevent a larger seam of the bladder chamber portion 110D from bursting or being damaged.
The sacrificial bonding regions particularly may be made somewhat smaller in size, may use a different (weaker) adhesive material, and/or otherwise may be configured to fail under lower pressure conditions than other bonded regions 120 in that garment component.
Garments 100 in accordance with at least some aspects of this technology further may have features to support repair. For example, garments 100 having laminated components 110A, 110B with facing films 118 formed from thermoplastic polyurethane or other materials that form an adhesive-free bond are potentially repairable, even by an end user. For example, in the sacrificial internal bond situation described above or in the event of other internal bonded region 120 failure, the internal bonded regions 120 potentially could be re-created, e.g., by applying heat and pressure at the failed bond location.
Optionally, an appropriate pressing tool could be supplied to the end user to assist in this repair scenario. As another example, in the event of a failed seam formed by a bonded region 120 (e.g., seam 2000), the seam potentially could be repaired (even by an end user), e.g., by using a heated iron and a pressing force, by using a clamp tool, etc.
FIG. 22 illustrates some additional features that may be provided in garment 100 structures in accordance with at least some examples of this technology. FIG. 22 shows two garment components 102L, 102R similar to garment components 1702L and 1702R shown in FIGS. 17A-17H. These garment components 102L, 102R may have structures corresponding to any of the garment components described above in conjunction with FIGS. 1A-14C, including bonded regions 120 selectively located to form (i) an outer perimeter seam 150A and/or (ii) one or more internal fixed regions 150B (e.g., as spaced-apart bonded regions) within bladder chamber portions 110D.
In some examples of this technology, the bladder chamber portions 110D on the front left garment component 102L particularly may be in fluid communication with the bladder chamber portions 110D on the front right side garment component 102R, e.g., via fluid passageways 152 (or 2014) defined by the bonded regions 120 that connect with and extend around a back garment component or back portion of the overall garment 100 structure. This fluid communication is shown schematically in FIG. 22 by arrow 154. In at least some examples of this technology, the outer perimeter seam 150A may be maintained at least about 5 mm wide (and in some examples, at least about 6 mm wide or even at least about 8 mm wide), e.g., to assure adequate surface for bonding and bond strength (e.g., to prevent bursting under excess pressure). See dimension W in FIG. 22. The perimeter seam 150A need not have a uniform width W around its entire perimeter.
When changing such structures from the deflated condition to the inflated condition, the bladder chamber portions 110D become thicker (e.g., changing from substantially flat (e.g., approx. 2 mm or less) to dimension T shown in FIG. 4A). This change in thickness may tend to distort the edges of the garment components 102L, 102R, including distorting the edges 2100 where the portion(s) of the securing system 140 are fixed. This distortion can make it difficult to operate the securing system 140, particularly slider type securing systems that utilize an elongated track, such as zipper components. The distortion may make the track somewhat “wavy” and may cause the zipper slider to get hung up on the wave crests and valleys.
In accordance with at least some examples of this technology, a minimum buffer distance B may be maintained between: (a) the securing system 140 attachment location (e.g., see seams 2102 in FIG. 22 attaching the zipper track portions 156A and 156B to garment components 102L and 102R) and (b) a closest location of an internal fixed region 150B of the inflatable bladder chamber portion 110D. In some more specific examples, this minimum buffer distance B may be at least about 30 mm, and in some examples, at least about 40 mm, at least about 50 mm, or at least about 60 mm.
Additionally or alternatively, in accordance with at least some examples of this technology, a minimum buffer distance Z may be maintained between: (a) a closest location of an internal fixed region 150B of the inflatable bladder chamber portion 110D and (b) an edge of the perimeter seam 150A defining the interior edge of an inflatable chamber portion 110D. In some more specific examples, this minimum buffer distance Z may be at least about 30 mm, and in some examples, at least about 40 mm, at least about 50 mm, or at least about 60 mm.
Additionally or alternatively, in some examples of this technology, a minimum distance L may be maintained between: (a) the securing system 140 attachment location (e.g., see seams 2102 in FIG. 22 attaching the zipper track portions 156A to garment components 102L and 102R) and (b) an edge of the perimeter seam 150A defining the interior edge of an inflatable chamber portion 110D. In some more specific examples, this minimum distance L may be at least about 0.5 mm (e.g., for a sewn seam 2102)—and in some examples, at least 1 mm, at least 2 mm, or at least 3 mm—e.g., to help assure structural integrity of the perimeter seam 150A and a fluid tight connection.
FIG. 23 illustrates example steps for incorporating a pocket 104 into a garment component (e.g., 1702R in this illustrated example) in accordance with some aspects of this technology. In this process, a pocket component 104C particularly is constructed from a front pocket panel 2200F and a rear pocket panel 2200R.
These panels 2200F and 2200R particularly may be stitched together by a sewn seam 2202 (or otherwise attached), e.g., around at least three sides, with an unsecured space 2204 left open to access an interior chamber of the pocket component 104C defined between the front pocket panel 2200F and rear pocket panel 2200R. A front pocket entry element 2206F may be attached to the front pocket panel 2200F at the location of the unsecured space 2204 and/or a rear pocket entry element 2206R may be attached to the rear pocket panel 2200R at the location of the unsecured space 2204. These steps form this example pocket component 104C.
The garment component (e.g., 1702R in FIG. 23) particularly is provided with an internal bonded region 2220 (e.g., between film 118 layers) at the desired location for the pocket 104. As shown in FIG. 23, in this illustrated example, this bonded region 2220 is elongated and generally oriented in a bottom-to-top direction of the garment component 1702R structure.
At least one slot 2210 particularly is cut completely through the internal bonded region 2220. The pocket component 104C is partially inserted through the slot 2210 such that: (i) at least a portion of the front pocket entry element 2206F remains outside the garment component 1702R at the slot 2210 and/or at least a portion of the rear pocket entry element 2206R remains outside the garment component 1702R at the slot 2210 and/or (ii) the front pocket panel 2200F and the rear pocket panel 2200R extend along an interior surface of the garment component 1702R (with the front pocket panel located against the interior surface of garment component 1702R).
The front pocket entry element 2206F particularly may be engaged with the garment component 1702R at the internal bonded region 2220 (e.g., by one or more scams through the internal bonded region 2220) and/or the rear pocket entry element 2206R may be engaged with the garment component 1702R at the internal bonded region 2220 (e.g., by one or more seams through the internal bonded region 2220).
The front pocket panel 2200F and/or the rear pocket panel 2200R particularly may be engaged with the garment component 1702R, for example, by one or more of: (a) attachments (e.g., sewn seams and/or mechanical fasteners) provided at the internal bonded region 2220, (ii) attachments at one or more internal bonded regions 120 provided along the top edge of the pocket component 104C, (iii) attachments at one or more internal bonded regions 120 provided along the bottom edge of the pocket component 104C, and/or (iv) attachments along the bonded region 120 providing perimeter edge 1700Z of garment component 1702R.
The top and bottom edges of the pocket component 104C are shown in broken lines at the bottom right of FIG. 23 because the pocket component 104C is located beneath the garment component 1702R in the orientation shown in FIG. 23. The broken lines help show where the pocket component 104C may be located and locations of potential attachment to internal bonded regions 120 of garment component 1702R.
FIG. 24 illustrates a top view of an example bladder structure 2400 that may be included in garments 100 or garment components 102 in accordance with at least some examples of this technology (e.g., for a washable and reusable garment). The bladder 2400, garment 100, or garment component 102 may be made from any of the laminates and/or bladder structures described above in conjunction with FIGS. 1A-23, e.g., including from: (A) an interior laminate component 110B and (B) an exterior laminate component 110A. The laminate components 110A, 110B may have any of the structures described above, including, e.g.: a knit or other fabric 112 layer and a film 118 (e.g., having a film thickness of less than 120 micron), wherein the film 118 includes at least one fluid impervious layer chosen from a polyurethane layer and a thermoplastic polyurethane layer. In each laminate component 110A and 110B, the film 118 may be bonded to its respective fabric 112, e.g., using an adhesive 116 of the types described above.
The two laminate components 110A and 110B may be bonded together, e.g., in any of the various manners described above, e.g., in an adhesive or in an adhesive-free manner, to form a bladder structure 2400 having an inflatable bladder chamber 110. Bonds 120 between the film 118 layers of the laminated components 110A and 110B may form a perimeter seam (e.g., 150A) and internal bonded regions 120 (located within the inflatable bladder chamber 110). Thus, the structure of FIG. 24 may be included in a wide range of the specific examples and structures.
As shown in FIG. 24, the two laminated components 110A and 110B are bonded together (at their interfacing film 118 surfaces) to form internal bonded regions 120. In this illustrated example, the internal bonded regions 120 are located so as to form a plurality of spaced apart internal bonded regions 120.
More specifically, in the example shown in FIG. 24, the plurality of spaced apart internal bonded regions 120 are formed as (i) plural rows 2400R of internal bonded regions 120 and/or (ii) plural columns 2400C of internal bonded regions 120. When the inflatable bladder chamber 110 is placed in an inflated condition: (i) elongated rows of gas may be formed between adjacent rows 2400R of internal bonded regions 120 (see box 2402R in FIG. 24 as an example of a location for one gas row) and/or (ii) elongated columns of gas may be formed between adjacent columns 2400C of internal bonded regions 120 (see box 2402C in FIG. 24 as an example of a location for one gas column).
In some examples of this technology, at least two adjacent internal bonded regions 120 within a row 2400R of internal bonded regions 120 will have a bond-to-bond spacing distance R1. The bond-to-bond spacing distance (e.g., R1) is the closest distance separating two adjacent bonds 120 in the row 2400R. The bond-to-bond spacing distance may be constant or it may vary within a given row 2400R. When it varies, a row 2400R may have an average bond-to-bond spacing distance between adjacent internal bonded regions 2400R within that row 2400R (e.g., an average of all R1's).
Additionally, in some examples of this technology, an internal bonded region 120 of a first row 2400R may be spaced from a corresponding closest adjacent internal bonded region 120 of a second row 2400R located adjacent to the first row 2400R by a row-to-row spacing distance C1. This row-to-row spacing distance (e.g., C1) is the closest distance separating two adjacent bonds 120 in the column 2400C. The row-to-row spacing distance may be constant or it may vary along the row 2400R. When it varies, a row 2400R may have an average row-to-row spacing distance with corresponding adjacent internal bonded regions 120C of an adjacent row 2400R.
In at least some examples of this technology, for at least one bonded region 120, its bond-to-bond spacing distance R1 with an adjacent bonded region 120 within the row 2400R will be at least 10% less than the row-to-row spacing distance C1 between that same bonded region 120 and a closest adjacent bonded region 120 in an adjacent row 2400R. In some examples of this technology, the R1 spacing for a specific internal bonded region 120 will be at least 15% less, at least 20% less, at least 25% less, at least 40% less, or even at least 50% less than C1 for that specific internal bonded region.
In some examples of this technology, the plurality of spaced apart internal bonded regions 120 may be formed to include (a) plural rows 2400R of internal bonded regions 120 and (b) plural columns 2400C of internal bonded regions 120. When the inflatable bladder chamber 110 is placed in an inflated condition: (i) elongated rows of gas may be formed between adjacent rows 2400R of internal bonded regions 120 (e.g., see box 2402R) and (ii) elongated columns of gas may be formed between adjacent columns 2400C of internal bonded regions 120 (e.g., see box 2402C). Thus, the internal bonded regions 120 and the gas rows 2402R and gas columns may form a matrix type structure. Note also FIGS. 11D-11H and FIGS. 16A and 16B.
In such structures, adjacent internal bonded regions 120 within one or more rows 2400R of internal bonded regions 120 may have an average bond-to-bond spacing distance (e.g., the average of all “R1” distances within the row 2400R). Additionally, internal bonded regions 120 within a row 2400R may be spaced from closest adjacent internal bonded region(s) 120 in at least one adjacent row 2400R by an average row-to-row spacing distance (e.g., the average of all “C1” distance between two adjacent rows 2400R). In at least some examples, the average bond-to-bond spacing distance for a given row 2400R will be at least 10% less than the average row-to-row spacing distance for that row 2400R and at least one adjacent row 2400R (and in some examples, at least 15% less, at least 20% less, at least 25% less, at least 40% less, or even at least 50% less).
Laminated components 110A, 110B in accordance with at least some examples of this technology will provide a fluid impervious laminate structure for a washable and reusable garment. In some more specific examples, such laminated components 110A, 110B particularly will include a first knit fabric 112 including a plurality of loops formed by a first yarn, the fabric 112 having an inner face and an outer face.
This first yarn may comprise a first polymer material having a first melt temperature. A first film 118 having an inner surface and an outer surface and a thickness of less than about 120 micron is bonded to the inner face of the first knit fabric 112 to form the laminated component 110A, 110B.
The first film 118 of some examples particularly includes at least a thermoplastic polyurethane material having a second melt temperature, and this second melt temperature may be at least about 3° C. below the first melt temperature (and in some examples, at least about 5° C., at least about 10° C., at least about 15° C., or even at least about 20° C.). The fabric 112 and film 118 may have features of these components described above.
As noted above, some examples of this technology particularly use a knit structure for the fabric(s) 112 (e.g., on the exterior laminated component 110A and/or the interior laminated component 110B).
In some examples including the examples described above in conjunction with FIGS. 17A-17H, this knit structure may have a double jersey knit structure. “Double jersey” is also called “interlock jersey,” and this structure includes two sheets of jersey fabric attached along their piled sides. The resulting fabric particularly is smooth and flat on both sides, and because it has double the thickness of single jersey, typically it is more insulative and durable. Additionally, the double jersey knit structure can be advantageous because the knit structure can allow the adhesive 116 to penetrate somewhat deeper into the knit structure and thereby better hold the fabric 112 and film 118 together (e.g., to better prevent delamination and provide peel strength). When a double jersey knit structure particularly is used, in some examples, the yarn forming the knit structure may have a denier as low as about 10.
Garment 100 structures in accordance with aspects of this technology include an inflatable bladder chamber 110 that is switchable between a deflated condition and an inflated condition. Such garment 100 may have any of the various structures described above in conjunction with FIGS. 1A-23. The following describes some additional potential features and/or characteristics of garments 100 in accordance with some more specific examples of this technology.
The inflatable bladder chamber 110 is particularly structured to occupy a first volume in the deflated condition and a second volume in the inflated condition, wherein the second volume is greater than the first volume. The garment 100 particularly will have a first thermal resistance having a first RCT value in the deflated condition (RCT(D)) and a second thermal resistance having a second RCT value in the inflated condition (RCT(I)), and the second RCT value may be at least about two times the first RCT value (with the thermal resistance RCT values being measured according to either EN 31092 or EN ISO 5085-1 standard). In other words, RCT(I)≥2×RCT(D). In some examples, RCT(I)≥2.5×RCT(D), RCT(I)≥3×RCT(D), RCT(I)≥4×RCT(D), or RCT(I)≥5×RCT(D).
In some examples of this technology, the RCT(D) value particularly may be about 20° C.×m2/KW or higher. Additionally or alternatively, in some examples of this technology, the RCT(I) value may be about 240° C.×m2/KW or lower.
Garments 100 according to at least some examples of this technology may have the first RCT value (RCT(D)) and the second RCT value (RCT(I)) expressed in units of ° C.×m2/KW, and the second RCT value may be at least about 75 points greater than the first RCT value. In some examples, the second RCT value (RCT(I)) may be at least about 75 points, at least about 100 points, at least about 125 points, at least about 150 points, at least about 175 points, at least about 200 points, or even at least about 215 points greater than the first RCT value (RCT(D)) (each measured in units of ° C.×m2/KW). In other words, the difference between RCT(I) and RCT(D)—ΔRCT—may be at least about 75 points, at least about 100 points, at least about 125 points, at least about 150 points, at least about 175 points, at least about 200 points, or even at least about 215 points with RCT measured in units of ° C.×m2/KW.
As some more specific examples: (a) the garment component 102 structure of FIG. 11A may have an RCT(D) of about 34° C.×m2/KW and RCT(I) of about 124° C.×m2/KW for a ΔRCT of about 90; (b) the garment component 102 structure of FIG. 11B may have an RCT(D) of about 39° C.×m2/KW and RCT(I) of about 175° C.×m2/KW for a ΔRCT of about 136; (c) the garment component 102 structure of FIG. 11C may have an RCT(D) of about 25° C.×m2/KW and RCT(I) of about 168° C.×m2/KW for a ΔRCT of about 143; (d) the garment component 102 structure of FIG. 11D may have an RCT(D) of about 44° C.×m2/KW and RCT(I) of about 233° C.×m2/KW for a ΔRCT of about 189; (e) the garment component 102 structure of FIG. 11E may have an RCT(D) of about 43° C.×m2/KW and RCT(I) of about 218° C.×m2/KW for a ΔRCT of about 175; (f) the garment component 102 structure of FIG. 11F may have an RCT(D) of about 23° C.×m2/KW and RCT(I) of about 227° C.×m2/KW for a ΔRCT of about 204; (g) the garment component 102 structure of FIG. 11G may have an RCT(D) of about 39° C.×m2/KW and RCT(I) of about 154° C.×m2/KW for a ΔRCT of about 115; and/or (h) the garment component 102 structure of FIG. 11H may have an RCT(D) of about 40° C.×m2/KW and RCT(I) of about 202° C.×m2/KW for a ΔRCT of about 162.
As additional or alternative features, in the inflated condition, the inflatable bladder chamber 110 and/or a layer of the garment 100 including the inflatable bladder chamber 110 may have a thickness no greater than about 50 mm, and in some examples, no greater than about 35 mm, no greater than about 30 mm, no greater than about 25 mm, or even no greater than about 20 mm. The thickness of the garment 100 layer may be measured from the outermost surface of the fabric 112 of the exterior laminated component 110A to the innermost surface of the fabric 112 of the interior laminated component 110B, e.g., as shown in FIG. 4A.
Additionally or alternatively, in some specific garment 100 examples, the fabric 112 in a laminated component 110A and/or 110B may have: (a) a basis weight of at least about 15 grams per square meter (“gsm”) and less than about 150 grams per square meter; and/or (b) a linear mass density of at least about 10 denier and less than about 100 denier. As other potential ranges, the basis weight of the fabric 112 may be within a range of about 20 gsm to about 120 gsm, within a range of about 30 gsm to about 110 gsm, and/or within a range of about 35 to about 100 gsm.
Additionally or alternatively, as other potential ranges, the linear mass density of the fabric 112 may be within a range of about 12 denier to about 90 denier, within a range of about 15 denier to about 80 denier, and/or within a range of about 20 denier to about 70 denier. Still additionally or alternatively, the fabric 112 may monofilament or multi-filament polyester.
As described above, garments 100 in accordance with aspects of this technology are convertible between a deflated condition and an inflated condition. As also described above, garments 100 in accordance with aspects of this technology may have substantially different thermal resistivity (RCT) values in the inflated condition versus the deflated condition. Therefore, in at least some examples of this technology, a wearer can change the insulative properties over the course of a single use. For example, a wearer might have the garment 100 in an inflated condition when waiting for an athletic activity or workout to start, change to a deflated condition (e.g., using release system 134) before starting or during the athletic activity or workout (e.g., as the wearer becomes active), and then return to an inflated condition (e.g., using pump component 130) after the athletic activity or workout concludes.
Additionally or alternatively, in some examples of this technology, a wearer can control the amount of change in the RCT value, e.g., depending on the pressure and/or thickness to which the bladder chamber 110 is inflated.
The laminate components—exterior laminate component 110A and/or interior laminate component 110B—also may have “basis weight” properties, e.g., measured in grams per square meter. In some examples of this technology, the laminate components 110A and 110B of the types described above in conjunction with FIGS. 17A-17H (e.g., with a knit fabric 112 and thermoplastic polyurethane film 118 bonded by adhesive 116 (either full adhesive 116 or intermittent adhesive 116)) may have a basis weight in the range of about 90 gsm to about 210 gsm, and in some examples, from about 100 gsm to about 200 gsm, from about 110 gsm to about 190 gsm, or from about 120 gsm to about 180 gsm. Additionally or alternatively, in some examples, the combined garment component 102 structures of the types described above in conjunction with FIGS. 17A-17H—with exterior laminated component 110A bonded to interlaminated component 110B—may have a basis weight within the range of about 200 gsm to about 400 gsm, and in some examples, from about 220 gsm to about 380 gsm, from about 230 gsm to about 370 gsm, and/or from about 240 gsm to about 360 gsm.
Bladder portions, bladders, garment components (e.g., 102), and garments (e.g., 100) of the types described above are formed from an exterior component (e.g., exterior laminated component 110A) and an interior component (e.g., interior laminated component 110B) with one or more bladder chambers defined between the exterior component and the interior component. The exterior component (e.g., exterior laminated component 110A) and the interior component (e.g., interior laminated component 110B) defining an individual bladder chamber portion (e.g., 110D) or an individual bladder chamber (e.g., 110) may be the same or different from one another (e.g., have the same or different constructions and/or properties). When different, the exterior component (e.g., exterior laminated component 110A) may differ from the interior component (e.g., interior laminated component 110B) within an individual bladder chamber portion (e.g., 110D) or an individual bladder chamber (e.g., 110), for example, by one or more of: fabric 112 materials; fabric 112 structure (e.g., one or more of: single layer v. multi-layer construction; coated with DWR or other components v. not coated; knit v. woven v. non-woven; etc.); fabric 112 thickness; fabric 112 basis weight; fabric 112 denier; film 118 materials; film 118 structure (e.g., single layer v. multi-layer, different multi-layer constructions, etc.); film 118 thickness; film 118 basis weight; adhesive material 116 between fabric 112 and film 118; adhesive 116 patterns (e.g., dot glue v. full glue, different dot glue patterns, etc.); peel strength; one or more other physical properties of the fabrics 112, the films 118, the adhesives 116, and/or the overall composite laminated component in the exterior laminated component 110A v. the interior laminated component 110B.
Additionally or alternatively, in at least some examples of this technology, a single garment 100 may include multiple garment portions that are engaged together (optionally in fluid communication with one another). When multiple (e.g., two or more) garment portions including bladders or bladder portions are present in a single garment, the garment portions may have the same or different constructions. When different, one garment portion may differ from one or more other garment portion(s) in a single garment, for example, by one or more of: in any of the different ways described above as to how the exterior laminated component 110A may differ from the interior laminated 110B; an interior laminated component 110B of one garment portion may differ from an interior laminated component 110B of one or more other garment portions in the garment in any of the different ways described above as to how the exterior garment portion 110A may differ from the interior garment portion 110B; an exterior laminated component 110A of one garment portion may differ from an exterior laminated component 110A of one or more other garment portions in the garment in any of the different ways described above as to how the exterior garment portion 110A may differ from the interior garment portion 110B; two or more garment portions of a single garment may have different interior bonded region 120 features; two or more garment portions of a single garment may have different ways of attaching the exterior laminated component 110A with the interior laminated component (e.g., one via welding, one via adhesives 402); different ways of attaching garment portions to other garment portions may be used in a single garment structure; different ways of placing garment bladder chamber portions in fluid communication with one another may be used in a single garment structure; etc.
In some example garments 100 in accordance with aspects of this technology, including garments of the types shown in FIGS. 1A-1H and 17A-17H, a garment 100 and/or an individual garment component (e.g., one or more of garment components 102, 1702L, 1702R, 1702B, 1740R, 1740L, and/or 1740C) may include: (A) a first zone having a first interior bonded region 120 distribution and/or density and (B) a second zone having a second interior bonded 120 distribution and/or density that differs from the first interior bonded region 120 distribution and/or density. As some more specific examples, the first zone may have a first spacing between adjacent bonded regions 120 and the second zone may have a second spacing between adjacent bonded regions 120, wherein the second spacing is greater than the first spacing. These spacings may be measured as center-to-center bonded region 120 spacings and/or nearest edge-to-nearest edge bonded region 120 spacings.
In example garments 100 of the types shown in FIGS. 1A-1H and 17A-17H, at least some of bonded region 120 spacings in one or more of the front left garment component 1702L, the front right garment component 1702R, and/or the back garment component 1702B may be greater than at least some of bonded region 120 spacings in one or more of the left sleeve garment component 1740L and/or the right sleeve garment component 1740R. Smaller bonded region 120 spacings may be used to control the thickness of the bladder chambers 110D within the garment components when inflated, e.g., to prevent excessive garment thickness at various areas of the garment (e.g., at the sleeves, at the sides of the garment 100, etc. For example, smaller bonded region 120 spacings in the sleeve components 1740L and 1740R may be provided (as compared to the spacings in at least some portions of the front left garment component 1702L, the front right garment component 1702R, and/or the back garment component 1702B) so that the circumference of the sleeves does not become too large and/or so that movement of the arms is not impeded.
While FIGS. 1A-24 illustrate garment components and garments having various different features, such as bladder chamber sizes, shapes, and specific configurations, many variations in features are possible without departing from this technology. The specifically illustrated garments, garment components, their bladders and bladder chamber portions, and/or other features could be varied widely in size, shape, configuration, and/or aesthetic appearance while still providing the desired functions and/or properties described above.
Additionally or alternatively, aspects of this technology may be used in products other than garments. For example, laminates and bladders of the types described herein may be used in protective equipment (e.g., knee pads, elbow pads, shoulder pads, other padding, and the like) and/or in bags (such as backpacks, equipment bags, etc.).
The present invention is disclosed above and in the accompanying drawings with reference to a variety of example structures. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims.
For the avoidance of doubt, the present application includes at least the subject matter described in the following numbered Clauses. The Clauses below are included in five separate Clause Sets, i.e., Clause Set A, Clause Set B, Clause Set C, Clause Set D, and Clause Set E. Features described in these Clause Sets may be used together in some aspects of this technology. For example: (a) any one or more of the laminate features described in Clause Set A may be used in the bladder structures described in Clause Set B and/or in the garment structures described in Clause Sets C, D, and/or E; (b) any one or more of the bladder features described in Clause Set B may be used in the garment structures described in Clause Sets C, D, and/or E and/or the bladders of Clause Set B may use any of the laminate features described in Clause Set A; (c) the garments described in Clause Set C may have any of the garment features described in Clause Sets D and/or E, may use any of the bladders or bladder features described in Clause Set B, and/or may use any of the laminate structures or laminate features described in Clause Set A; (d) the garments described in Clause Set D may have any of the garment features described in Clause Set C, may use any of the bladders or bladder features described in Clause Set B, and/or may use any of the laminate structures or laminate features described in Clause Set A; and/or (e) the garments described in Clause Set E may have any of the garment features described in Clause Sets C and/or D, may use any of the bladders or bladder features described in Clause Set B, and/or may use any of the laminate structures or laminate features described in Clause Set A.
1. A bladder structure for a washable and reusable garment, the bladder structure comprising:
an interior component formed from a first laminate structure, the first laminate structure comprising: (i) a first knit fabric having a double jersey knit structure, and (ii) a first film having an outer surface, an inner surface, and a thickness of less than 120 micron, wherein the first film includes at least one fluid impervious layer chosen from a polyurethane layer and a thermoplastic polyurethane layer, wherein the outer surface of the first film is bonded to the first knit fabric; and
an exterior component formed from a second laminate structure, the second laminate structure comprising: (i) a second knit fabric having a double jersey knit structure, and (ii) a second film having an outer surface, an inner surface, and a thickness of less than 120 micron, wherein the second film includes at least one fluid impervious layer chosen from a polyurethane layer and a thermoplastic polyurethane layer, wherein the outer surface of the second film is bonded to the second knit fabric,
wherein the inner surface of the first film is bonded to the inner surface of the second film at an outer perimeter seam, the outer perimeter seam at least partially defining an inflatable bladder chamber between the inner surface of the first film and the inner surface of the second film, wherein the inner surface of the first film is joined to the inner surface of the second film at a plurality of spaced apart internal bonded regions, and
wherein the bladder structure includes:
a first zone including a first portion of the plurality of spaced apart internal bonded regions arranged in a first distribution, and
a second zone including a second portion of the plurality of spaced apart internal bonded regions arranged in a second distribution, wherein the second distribution differs from the first distribution.
2. The bladder structure according to claim 1, wherein when the bladder chamber is inflated to a maximum thickness: (i) the first zone has a first average thickness extending from an outer face of the interior component to an outer face of the exterior component, (ii) the second zone has a second average thickness extending from the outer face of the interior component to the outer face of the exterior component, and (iii) the first average thickness differs from the second average thickness.
3. The bladder structure according to claim 1, wherein in the first distribution, two adjacent spaced apart internal bonded regions have a first spacing distance, wherein in the second distribution, two adjacent spaced apart internal bonded regions have a second spacing distance, and wherein the first spacing distance differs from the second spacing distance.
4. The bladder structure according to claim 1, wherein in the first distribution, an average spacing between adjacent spaced apart internal bonded regions comprises a first average spacing distance, wherein in the second distribution, an average spacing between two adjacent spaced apart internal bonded regions have a second average spacing distance, and wherein the first average spacing distance differs from the second average spacing distance.
5. The bladder structure according to claim 1, wherein at least 90% of the plurality of spaced apart internal bonded regions define a bonded region size of at least 50 mm2.
6. The bladder structure according to claim 5, wherein at least 90% of the plurality of spaced apart internal bonded regions define a bonded region size of less than 700 mm2.
7. The bladder structure according to claim 1, wherein each of the first knit fabric and the second knit fabric has a basis weight of at least 20 grams per square meter and less than 120 grams per square meter.
8. The bladder structure according to claim 1, wherein each of the first knit fabric and the second knit fabric is formed from yarn having a linear mass density of at least 10 denier and less than 100 denier.
9. The bladder structure according to claim 1, wherein the double jersey knit structures forming each of the first knit fabric and the second knit fabric are formed with drawn textured yarn.
10. The bladder structure according to claim 1, wherein at least 90% of the plurality of spaced apart internal bonded regions have a curved perimeter shape and define a bonded region size of at least 50 mm2 and less than 700 mm2, wherein each of the first knit fabric and the second knit fabric has a basis weight of at least 20 grams per square meter and less than 120 grams per square meter, wherein each of the first knit fabric and the second knit fabric is formed from yarn having a linear mass density of at least 10 denier and less than 100 denier, and wherein the double jersey knit structures forming each of the first knit fabric and the second knit fabric are formed with drawn textured yarn.
11. The bladder structure according to claim 1, wherein the thickness of each of the first film and the second film is at least 40 micron and less than 100 micron, and wherein each of the first film and the second film is formed from a thermoplastic polyurethane material.
12. The bladder structure according to claim 1, wherein the first film comprises a first layer and a second layer joined together, wherein the first layer is formed from a thermoplastic polyurethane material that forms the inner surface of the first film, wherein the second layer is bonded to the first knit fabric and is formed from a polyurethane material or a thermoplastic polyurethane material, and wherein the first layer is bonded with the second layer on an opposite side of the second layer from the first knit fabric.
13. The bladder structure according to claim 12, wherein the first layer is between 20 micron and 50 micron thick, and wherein the second layer is between 20 micron and 50 micron thick.
14. The bladder structure according to claim 12, wherein the second film comprises a third layer and a fourth layer joined together, wherein the third layer is formed from a thermoplastic polyurethane material that forms the inner surface of the second film, wherein the fourth layer is bonded to the second knit fabric and is formed from a polyurethane material or a thermoplastic polyurethane material, and wherein the third layer is bonded with the fourth layer on an opposite side of the fourth layer from the second knit fabric.
15. The bladder structure according to claim 1, wherein the second film comprises a first layer and a second layer joined together, wherein the first layer is formed from a thermoplastic polyurethane material that forms the inner surface of the second film, wherein the second layer is bonded to the second knit fabric and is formed from a polyurethane material or a thermoplastic polyurethane material, and wherein the first layer is bonded with the second layer on an opposite side of the second layer from the second knit fabric.
16. A bladder structure for a washable and reusable garment, the bladder structure comprising:
an interior component formed from a first laminate structure, the first laminate structure comprising: (i) a first knit fabric, and (ii) a first film having an outer surface, an inner surface, and a thickness of less than 120 micron, wherein the first film includes at least one fluid impervious layer chosen from a polyurethane layer and a thermoplastic polyurethane layer, wherein the outer surface of the first film is bonded to the first knit fabric; and
an exterior component formed from a second laminate structure, the second laminate structure comprising: (i) a second knit fabric, and (ii) a second film having an outer surface, an inner surface, and a thickness of less than 120 micron, wherein the second film includes at least one fluid impervious layer chosen from a polyurethane layer and a thermoplastic polyurethane layer, wherein the outer surface of the second film is bonded to the second knit fabric,
wherein the inner surface of the first film is bonded to the inner surface of the second film at an outer perimeter seam, the outer perimeter seam at least partially defining an inflatable bladder chamber between the inner surface of the first film and the inner surface of the second film, wherein the inner surface of the first film is joined to the inner surface of the second film at a plurality of spaced apart internal bonded regions.
17. The bladder structure according to claim 16, wherein the plurality of spaced apart internal bonded regions includes plural rows of internal bonded regions, and wherein when the inflatable bladder chamber is placed in an inflated condition, elongated rows of gas are formed between adjacent rows of internal bonded regions.
18. The bladder structure according to claim 17, wherein two adjacent internal bonded regions within a first row of internal bonded regions have a first bond-to-bond spacing distance, and wherein one of the two adjacent internal bonded regions of the first row is spaced from a corresponding closest adjacent internal bonded regions of a second row located adjacent to the first row by a first row-to-row spacing distance.
19. The bladder structure according to claim 18, wherein the first bond-to-bond spacing distance is at least 25% less than the first row-to-row spacing distance.
20. The bladder structure according to claim 16, wherein the plurality of spaced apart internal bonded regions includes plural rows of internal bonded regions and plural columns of internal bonded regions, and wherein when the inflatable bladder chamber is placed in an inflated condition, elongated rows of gas are formed between adjacent rows of internal bonded regions and elongated columns of gas are formed between adjacent columns of internal bonded regions.