WO2004098328A1 - Foam material and garments made therefrom - Google Patents

Foam material and garments made therefrom Download PDF

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Publication number
WO2004098328A1
WO2004098328A1 PCT/GB2003/002022 GB0302022W WO2004098328A1 WO 2004098328 A1 WO2004098328 A1 WO 2004098328A1 GB 0302022 W GB0302022 W GB 0302022W WO 2004098328 A1 WO2004098328 A1 WO 2004098328A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam material
slits
foam
cuts
sheet
Prior art date
Application number
PCT/GB2003/002022
Other languages
French (fr)
Inventor
John Carroll
Original Assignee
Sundridge Tackle Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sundridge Tackle Limited filed Critical Sundridge Tackle Limited
Priority to DE60331961T priority Critical patent/DE60331961D1/de
Priority to AU2003227923A priority patent/AU2003227923A1/en
Priority to CA2525257A priority patent/CA2525257C/en
Priority to AT03725388T priority patent/ATE462318T1/en
Priority to US10/574,457 priority patent/US20070062638A1/en
Priority to EP03725388A priority patent/EP1622474B1/en
Priority to PCT/GB2003/002022 priority patent/WO2004098328A1/en
Publication of WO2004098328A1 publication Critical patent/WO2004098328A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/012—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches for aquatic activities, e.g. with buoyancy aids
    • A41D13/0125—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches for aquatic activities, e.g. with buoyancy aids with buoyancy aids
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06—Thermally protective, e.g. insulating
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06—Thermally protective, e.g. insulating
    • A41D31/065—Thermally protective, e.g. insulating using layered materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]

Definitions

  • the present invention concerns a closed cell foam material especially intended for use in flotation suits or other garments or buoyancy aids and to such including the material.
  • Flotation suits or garments are generally produced having a waterproof outer shell material or fabric which is normally coated on its normally inner side with a breathable polyurethane film or other layer which allows air and/or water vapour to pass through but not water, thus forming a waterproof breathable outer shell or fabric layer.
  • a waterproof breathable outer shell or fabric layer which allows air and/or water vapour to pass through but not water, thus forming a waterproof breathable outer shell or fabric layer.
  • Floatation suits or other garments or buoyancy aids are made buoyant by having a layer of buoyant plastics material foam stitched as part of the garment inwardly of the outer shell material or fabric.
  • the plastics foam has closed cells, such as air and/or vapour filled bubbles, which provide buoyancy should the user fall into the water.
  • the foam also acts as thermal insulation.
  • buoyant foam sheet A problem with existing buoyant foam sheet was that it is not breathable i.e. air and/or water vapour cannot pass through it. The wearer of such a garment can, therefore, become uncomfortable through perspiration being unable to be dispersed to the outside of the garment.
  • the foam material when subject to compression tests in which the foam material is compressed for a period and then released, the foam material does not return sufficiently closely to its original thickness to allow it to pass the CE testing or other.
  • the removal of foam material in the formation of holes provides a space into which the foam may spread into during compression and then does not later return on release of the compression.
  • slits or cuts and/or needle-punched holes are provided in the foam which does not involve the removal of foam material or involves only minimal removal of material as a result of, e.g. cutting or puncturing, the required characteristics of the foam are maintained within allowable ranges thus enabling the material to be used as a buoyancy aid meeting regulation requirements.
  • the size and/or spacing of the slits or needle-punched holes has or have to be selected so as to make the resultant foam material comply with strength requirements of, for example, CE testing.
  • a flexible or pliable closed cell foam material in sheet form for forming at least part of a garment characterised in that the foam material has one or more slits or cuts and/or needle-punched holes therein extending through the sheet from one surface to the other.
  • the closed cell foam material is formed of a synthetic material such as a polymeric foam such as polyurethane or neoprene or any suitable material.
  • the closed cells may contain bubbles of vapour or air.
  • the slits or cuts and/or needle-punched holes are selected to be of a spacing and/or selected to be each of a shape and/or size and/or length as to minimise or not adversely affect the strength and/or shrinkage rate of the foam sheet such as relevant in the subjection to thermal stability testing and/or compression testing for meeting quality requirements for buoyancy aids.
  • the side surfaces defining the slits and/or holes are normally in abutment and/or close proximity when the sheet is flat or unflexed and are such as to advantageously separate or press less against each other when the sheet is flexed to allow air and/or water vapour to pass therethrough.
  • the slits or cuts preferably each comprise at least two intersecting linear slits or so-called "cross-cuts".
  • the slits may be in the form of straight line cuts or a cross, for example, an "X” or “+”, or in the form of a "Y” or “V” or any other form which will allow the passage of water - vapour on flexing.
  • the length and/or configuration and/or spacing of the slits or cuts or holes are selected to achieve the required rate passage of water vapour or breathability as required.
  • Each slit or cut is preferably but not essentially about 3 mm long and/or the foam material is normally in the range of 2 mm to 6 mm thick depending on the buoyancy required.
  • the sheet foam material is regular or plain or normally planar (i.e. without any dome-like configurations, projections or extensions where the apertures are).
  • a fabric combination comprising a foam or other material as defined above and in the dependent claims in combination with an outer fabric sheet or layer e.g. nylon fabric or polyester or other, which is waterproof or waterproof and water-vapour permeable e.g. by having a hydrophilic or micro-porous or other suitable coating on the inside.
  • a garment whenever including a fabric combination as mentioned above or as claimed in the claims, wherein the foam material and outer fabric sheet are stitched or otherwise bonded together in peripheral regions leaving the foam and fabric sheet merely juxtaposed in other regions.
  • an innermost permeable lining layer will be provided inwardly of the foam material sheet or layer and between the latter and the outer layer a non-woven or other "slip" layer provided to ensure the foam material moves freely relative to the outer layer.
  • the foam material layer will normally be provided over most of the area thereof - similarly for the upper part of a boiler suit.
  • a thinner sheet of form or less of such be provided or reduced in the lower regions.
  • a method of making a closed cell foam material "breathable” i.e. such as to enable air and/or water vapour to pass therethrough, whilst at the same time as not reducing the strength and/or the resilient characteristics as tested for in thermal stability and/or compression testing for buoyancy and device regulations, comprises forming slits or cuts and/or needle-punched holes in the foam material such that no foam material is removed or only consequential minimal amounts are removed in the process and the surfaces defining the slit and/or hole are normally in abutment or in close proximity when flat, and selecting the size and/or spacing of the slits and/or punched holes such as not to impair strength and/or resilient characteristics.
  • Fig. 1 is a plan view of a part of a flat sheet of closed cell foam material according to the invention
  • Fig. 2 is an enlarged partially cut-away fragmentary perspective detail of a cross-cut of the sheet of Fig. 1 but slightly flexed;
  • Fig. 3 is a section through three cross cuts of Fig 1 ;
  • Fig. 4 is an inverted plan of part of the flat sheet of Fig. 1 ;
  • Fig. 5 is a schematic plan of an alternative embodiment having needle- punched holes
  • Fig. 6 is a schematic plan of an alternative embodiment having straight line cuts.
  • Fig. 7 is a schematic cross section through the layers of a garment including the foam material of Fig. 1 according to the invention.
  • a flat flexible closed cell foam material sheet 1 which may, for example, be of polyethylene.
  • the sheet is in the region of 3 mm thick.
  • a plurality of parallel rows of cross-cut slits 2 or cruciform cuts 2 formed by intersecting linear slits of approximately 3 mm length are provided in the sheet 1 extending therethrough from are surface to the opposite surface.
  • the slits 2 are also aligned with slits in adjacent rows.
  • the slits 2 may be formed by using a razor cutter or knife cutter or like sharp thin cutting device or other method such that foam material is not removed or only a minimal amount is removed from the sheet 1 in the process.
  • the slits 2 are such that when the sheet 1 is laid flat the slits are closed or substantially closed but when the sheet 1 is flexed, the slits 2 open to allow water vapour to pass.
  • Fig. 5 is a schematic plan illustrating a part of a flexible closed cell foam material sheet 1 a wherein a plurality of aligned rows of "needle- punched" holes 2a are provided pierced through the foam sheet 1 a.
  • Fig. 6 shows simply straight line elongate slits 2b in such foam material .
  • the side surfaces of the foamed plastics material defining the slits and/or holes 2, 2a and 2b are normally in abutment and/or close proximity ("substantially closed") when the sheet is flat or unflexed and are such as to advantageously separate or press less against each other ("open") when the sheet is flexed to allow air and/or water vapour to pass therethrough.
  • the slits or cuts will preferably comprise elongate slits or at least two intersecting linear slits or so-called "cross-cuts" although many suitable shapes are possible.
  • Fig. 7 is a schematic cross section through part of a garment 3 including the foam material sheet 1 according to the invention and includes an inner lining fabric layer 4, a outer waterproof and water vapour permeable fabric layer 5 and a non-woven, "slip" layer 6 between the foam layer, and outer layer 5 provided to enable layers 1 and 5 to readily move relative to each other.
  • the outer layer 5 has a hydrophilic polymer coating or micro- porous or other coating 7 on its normally inner surface to provide the mentioned vapour permeability to the outer layer 5.
  • the layers 4, 1 , 6 and 5 are stitched together in peripheral/seam regions (not shown).
  • a flexible buoyant foamed plastics material having vapour or air filled bubbles or closed cells and having cuts or slits or piercings through the foam which do not involve removal of foam material or of only minimal amounts and which cuts or piercings in the unflexed condition of the foam are closed or substantially closed but which open on flexing of the foam such as allow water vapour to pass through the foam.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Oceanography (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

A flexible or pliable closed cell foam material (1) in sheet form for forming at least part of a garment, characterized in that the foam material (1) has one or more slits or cuts and/or needle-punched holes (2) therein extending through the sheet from one surface to the other, in which the slits or cuts and/or needle-punched holes (2) are selected to be of a spacing and/or selected to be each of a shape and/or size and/or length as to minimize or not adversely affect the strength and/or shrinkage rate of the foam sheet such as regards the subjection to thermal stability testing and/or compression testing for buoyancy aids, and in which the side surfaces defining the slits and/or holes are normally in abutment and/or close proximity when the sheet is flat or unflexed and separate or press less against each other when flexed to allow air and/or water vapour to pass therethrough.

Description

FOAM MATERIAL AND GARMENTS MADE THEREFROM
The present invention concerns a closed cell foam material especially intended for use in flotation suits or other garments or buoyancy aids and to such including the material.
Flotation suits or garments are generally produced having a waterproof outer shell material or fabric which is normally coated on its normally inner side with a breathable polyurethane film or other layer which allows air and/or water vapour to pass through but not water, thus forming a waterproof breathable outer shell or fabric layer. Thus, any water vapour resulting from perspiration of the user can be dispersed through the outer shell to the outside so as to keep the user dry and comfortable.
Floatation suits or other garments or buoyancy aids are made buoyant by having a layer of buoyant plastics material foam stitched as part of the garment inwardly of the outer shell material or fabric. The plastics foam has closed cells, such as air and/or vapour filled bubbles, which provide buoyancy should the user fall into the water. The foam also acts as thermal insulation.
A problem with existing buoyant foam sheet was that it is not breathable i.e. air and/or water vapour cannot pass through it. The wearer of such a garment can, therefore, become uncomfortable through perspiration being unable to be dispersed to the outside of the garment.
Initially we proposed an improved flotation or buoyant foam material in which in order to permit water vapour to pass through the foam apertures in the foam wherein significant amount of material was removed from the foam sheet to leave normally open holes through the foam so as to allow water vapour to pass through. We have now discovered that the use of such holes is not satisfactory because the resultant foam is weakened and/or does not meet, for example, CE safety requirements for buoyancy aids. We have now discovered that forming through normally open holes in the foam when flat involving removal of a significant amount of material to produce a hole of a shape corresponding to the removed material reduces the thermal stability in that when subject to low temperatures e.g. 30°C for a period and then returned to normal temperature, the volume or buoyancy characteristics do not return to such as they were originally. Also, when subject to compression tests in which the foam material is compressed for a period and then released, the foam material does not return sufficiently closely to its original thickness to allow it to pass the CE testing or other. In this respect, it is believed the removal of foam material in the formation of holes provides a space into which the foam may spread into during compression and then does not later return on release of the compression.
We have unexpectedly discovered that when slits or cuts and/or needle-punched holes are provided in the foam which does not involve the removal of foam material or involves only minimal removal of material as a result of, e.g. cutting or puncturing, the required characteristics of the foam are maintained within allowable ranges thus enabling the material to be used as a buoyancy aid meeting regulation requirements. The size and/or spacing of the slits or needle-punched holes has or have to be selected so as to make the resultant foam material comply with strength requirements of, for example, CE testing.
According to the present invention there is provided a flexible or pliable closed cell foam material in sheet form for forming at least part of a garment, characterised in that the foam material has one or more slits or cuts and/or needle-punched holes therein extending through the sheet from one surface to the other.
Preferably the closed cell foam material is formed of a synthetic material such as a polymeric foam such as polyurethane or neoprene or any suitable material. The closed cells may contain bubbles of vapour or air. Preferably the slits or cuts and/or needle-punched holes are selected to be of a spacing and/or selected to be each of a shape and/or size and/or length as to minimise or not adversely affect the strength and/or shrinkage rate of the foam sheet such as relevant in the subjection to thermal stability testing and/or compression testing for meeting quality requirements for buoyancy aids.
The side surfaces defining the slits and/or holes are normally in abutment and/or close proximity when the sheet is flat or unflexed and are such as to advantageously separate or press less against each other when the sheet is flexed to allow air and/or water vapour to pass therethrough. The slits or cuts preferably each comprise at least two intersecting linear slits or so-called "cross-cuts".
The slits may be in the form of straight line cuts or a cross, for example, an "X" or "+", or in the form of a "Y" or "V" or any other form which will allow the passage of water - vapour on flexing.
The length and/or configuration and/or spacing of the slits or cuts or holes are selected to achieve the required rate passage of water vapour or breathability as required.
Each slit or cut is preferably but not essentially about 3 mm long and/or the foam material is normally in the range of 2 mm to 6 mm thick depending on the buoyancy required.
The sheet foam material is regular or plain or normally planar (i.e. without any dome-like configurations, projections or extensions where the apertures are). Also according to the invention there is provided a fabric combination comprising a foam or other material as defined above and in the dependent claims in combination with an outer fabric sheet or layer e.g. nylon fabric or polyester or other, which is waterproof or waterproof and water-vapour permeable e.g. by having a hydrophilic or micro-porous or other suitable coating on the inside.
Further according to the present invention, there is provided a garment whenever including a fabric combination as mentioned above or as claimed in the claims, wherein the foam material and outer fabric sheet are stitched or otherwise bonded together in peripheral regions leaving the foam and fabric sheet merely juxtaposed in other regions. Preferably an innermost permeable lining layer will be provided inwardly of the foam material sheet or layer and between the latter and the outer layer a non-woven or other "slip" layer provided to ensure the foam material moves freely relative to the outer layer.
For a jacket, the foam material layer will normally be provided over most of the area thereof - similarly for the upper part of a boiler suit. For leggings and the legs of a boiler suit, a thinner sheet of form or less of such be provided or reduced in the lower regions.
Also according to the present invention there is provided a method of making a closed cell foam material "breathable" i.e. such as to enable air and/or water vapour to pass therethrough, whilst at the same time as not reducing the strength and/or the resilient characteristics as tested for in thermal stability and/or compression testing for buoyancy and device regulations, comprises forming slits or cuts and/or needle-punched holes in the foam material such that no foam material is removed or only consequential minimal amounts are removed in the process and the surfaces defining the slit and/or hole are normally in abutment or in close proximity when flat, and selecting the size and/or spacing of the slits and/or punched holes such as not to impair strength and/or resilient characteristics. The invention will be described further, by way of example, with reference to the accompanying drawings, in which:-
Fig. 1 is a plan view of a part of a flat sheet of closed cell foam material according to the invention;
Fig. 2 is an enlarged partially cut-away fragmentary perspective detail of a cross-cut of the sheet of Fig. 1 but slightly flexed;
Fig. 3 is a section through three cross cuts of Fig 1 ;
Fig. 4 is an inverted plan of part of the flat sheet of Fig. 1 ;
Fig. 5 is a schematic plan of an alternative embodiment having needle- punched holes;
Fig. 6 is a schematic plan of an alternative embodiment having straight line cuts; and
Fig. 7 is a schematic cross section through the layers of a garment including the foam material of Fig. 1 according to the invention.
In Figs. 1 to 4 a flat flexible closed cell foam material sheet 1 is illustrated which may, for example, be of polyethylene. The sheet is in the region of 3 mm thick.
A plurality of parallel rows of cross-cut slits 2 or cruciform cuts 2 formed by intersecting linear slits of approximately 3 mm length are provided in the sheet 1 extending therethrough from are surface to the opposite surface. The slits 2 are also aligned with slits in adjacent rows.
The slits 2 may be formed by using a razor cutter or knife cutter or like sharp thin cutting device or other method such that foam material is not removed or only a minimal amount is removed from the sheet 1 in the process. The slits 2 are such that when the sheet 1 is laid flat the slits are closed or substantially closed but when the sheet 1 is flexed, the slits 2 open to allow water vapour to pass. Fig. 5 is a schematic plan illustrating a part of a flexible closed cell foam material sheet 1 a wherein a plurality of aligned rows of "needle- punched" holes 2a are provided pierced through the foam sheet 1 a. Fig. 6 shows simply straight line elongate slits 2b in such foam material .
The side surfaces of the foamed plastics material defining the slits and/or holes 2, 2a and 2b are normally in abutment and/or close proximity ("substantially closed") when the sheet is flat or unflexed and are such as to advantageously separate or press less against each other ("open") when the sheet is flexed to allow air and/or water vapour to pass therethrough. The slits or cuts will preferably comprise elongate slits or at least two intersecting linear slits or so-called "cross-cuts" although many suitable shapes are possible.
Fig. 7 is a schematic cross section through part of a garment 3 including the foam material sheet 1 according to the invention and includes an inner lining fabric layer 4, a outer waterproof and water vapour permeable fabric layer 5 and a non-woven, "slip" layer 6 between the foam layer, and outer layer 5 provided to enable layers 1 and 5 to readily move relative to each other. The outer layer 5 has a hydrophilic polymer coating or micro- porous or other coating 7 on its normally inner surface to provide the mentioned vapour permeability to the outer layer 5. The layers 4, 1 , 6 and 5 are stitched together in peripheral/seam regions (not shown).
Also according to the present invention there is provided a flexible buoyant foamed plastics material having vapour or air filled bubbles or closed cells and having cuts or slits or piercings through the foam which do not involve removal of foam material or of only minimal amounts and which cuts or piercings in the unflexed condition of the foam are closed or substantially closed but which open on flexing of the foam such as allow water vapour to pass through the foam.

Claims

1. A flexible or pliable closed cell foam material in sheet form for forming at least part of a garment, characterised in that the foam material has one or more slits or cuts and/or needle-punched holes therein extending through the sheet from one surface to the other.
2. A foam material as claimed in claim 1 , in which the foam material is buoyant in water.
3. A foam material as claimed in claim 1 or 2, in which the slits or cuts and/or needle-punched holes are selected to be of a spacing and/or selected to be each of a shape and/or size and/or length as to minimise or not adversely affect the strength and/or shrinkage rate of the foam sheet such as regards the subjection to thermal stability testing and/or compression testing for buoyancy aids.
4. A foam material as claimed in any of claims 1 to 3, in which the side surfaces defining the slits and/or holes are normally in abutment and/or close proximity when the sheet is flat or unflexed and separate or press less against each other when flexed to allow air and/or water vapour to pass therethrough.
5. A foam material as claimed in any of claims 1 to 4, in which the slits or cuts each comprise at least two intersecting linear slits or so-called "crosscuts".
6. A foam material as claimed in any of claims 1 to 5, in which the slits are in the form of slits or a cross, for example, an "X" or "+", or in the form of a "Y" or "V" or any other form which will allow the passage of water - vapour on flexing.
7. A foam material as claimed in any of claims 1 to 6, in which the closed cells or bubbles contain vapour or air.
8. A foam material as claimed in any of claims 1 to 7, in which the length and/or configuration and/or spacing of the slits or cuts are selected to achieve the required passage of water vapour or breathability as required.
9. A foam material as claimed in any of claims 1 to 8, in which each slit or cut is about 3 mm long and/or the foam material is in the region of approximately 2 mm to 6 mm thick depending on the buoyancy required.
10. A foam material as claimed in claim 9, in which the slits or cuts and/or holes are spaced at different intervals as required.
11. A foam material as claimed in any of claims 1 to 10, in which the sheet is regular or plain or normally planar (i.e. without any dome-like configurations, projections or extensions in the regions where the apertures are).
12. A fabric combination comprising a foam or other material as claimed in any of claims 1 to 11 , in combination with an outer fabric sheet or layer.
13. A fabric combination as claimed in claim 11 , in which the outer fabric sheet or layer is waterproof or waterproof and water-vapour permeable.
14. A garment whenever including a fabric combination as claimed in claim 12 or 13, wherein the foam material and outer fabric sheet are stitched or otherwise bonded together in peripheral regions leaving the foam and fabric sheet merely juxtaposed in other regions.
15. A method of making a closed cell foam material "breathable" or such as to enable air and/or water vapour to pass therethrough whilst at the same time as not reducing the strength and/or the resilient characteristics as tested for in thermal stability and/or compression testing for buoyancy aid device regulations, comprises forming slits or cuts and/or needle-punched holes in the foam material such that no foam material is removed or only minimal foam material is removed in the process and the surfaces defining the slit and/or hole are normally in abutment or in close proximity, and selecting the size and/or spacing of the slits and/or punched holes as not to impair strength and/or resilient characteristics.
16. A flexible buoyant foamed plastics material having vapour or air filled bubbles or closed cells and having cuts or slits or piercings through the foam which do not involve removal of foam material or of only minimal amounts and which cuts or piercings in the unflexed condition of the foam are closed or substantially closed but which open on flexing of the foam such as to allow water vapour to pass through the foam.
7. A foam material as claimed in claim 16, in which the cuts or slits are elongate slits or "X" - shaped cuts or so called cross-cuts or slits.
PCT/GB2003/002022 2003-05-12 2003-05-12 Foam material and garments made therefrom WO2004098328A1 (en)

Priority Applications (7)

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DE60331961T DE60331961D1 (en) 2003-05-12 2003-05-12
AU2003227923A AU2003227923A1 (en) 2003-05-12 2003-05-12 Foam material and garments made therefrom
CA2525257A CA2525257C (en) 2003-05-12 2003-05-12 Foam material and garments made therefrom
AT03725388T ATE462318T1 (en) 2003-05-12 2003-05-12 GARMENT WITH A FOAM LAYER
US10/574,457 US20070062638A1 (en) 2003-05-12 2003-05-12 Foam material and garments made therefrom
EP03725388A EP1622474B1 (en) 2003-05-12 2003-05-12 Garment including foam material
PCT/GB2003/002022 WO2004098328A1 (en) 2003-05-12 2003-05-12 Foam material and garments made therefrom

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PCT/GB2003/002022 WO2004098328A1 (en) 2003-05-12 2003-05-12 Foam material and garments made therefrom

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WO2004098328A1 true WO2004098328A1 (en) 2004-11-18

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US (1) US20070062638A1 (en)
EP (1) EP1622474B1 (en)
AT (1) ATE462318T1 (en)
AU (1) AU2003227923A1 (en)
CA (1) CA2525257C (en)
DE (1) DE60331961D1 (en)
WO (1) WO2004098328A1 (en)

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CA2525257C (en) 2010-08-03
US20070062638A1 (en) 2007-03-22
DE60331961D1 (en) 2010-05-12
ATE462318T1 (en) 2010-04-15
AU2003227923A1 (en) 2004-11-26
EP1622474A1 (en) 2006-02-08
EP1622474B1 (en) 2010-03-31
CA2525257A1 (en) 2004-11-18

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