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  Garment with molded pockets for containment of fly fishing accessories and method of manufacturing sameUSPTO Application #: 20060143774Title: Garment with molded pockets for containment of fly fishing accessories and method of manufacturing same Abstract: An article of clothing with three-dimensional, molded pockets. Preferably, the molded pockets are constructed of a fabric/foam laminate that has been heat/compression molded. In a preferred embodiment, the molded pockets find utility in the containment of fly boxes and other accessories used in fly fishing. A method of manufacturing a garment with three-dimensional, molded pockets. (end of abstract)
Agent: Antoinette M. Tease, P.l.l.c. - Billings, MT, US Inventors: Kenneth C. Walsh, Richard Siberell USPTO Applicaton #: 20060143774 - Class: 002094000 (USPTO) Related Patent Categories: Apparel, Body Garments, Coats, Hunters' And Special-article Carrying The Patent Description & Claims data below is from USPTO Patent Application 20060143774. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to clothing, and more specifically, to a garment that has molded pockets for the containment of fly fishing accessories. [0003] 2. Description of the Related Art [0004] A typical fly fishing vest contains pockets that are made out of cut and sewn fabric pieces. These standard pockets are not as easy to access or as aesthetically interesting as the molded pockets of the present invention, nor do they provide the impact protection afforded by the present invention. Although some innovations relating to fishing vests have been patented, no one has yet applied the technology relating to molded pockets to provide a fishing vest with storage compartments that are more user-friendly, attractive, and impact-resistant than traditional pockets. Some examples of innovations in fishing vests are described below. [0005] The background art is characterized by U.S. Pat. Nos. 4,852,293; 4,901,899; 5,063,614; 5,247,707; 5,465,425; 5,632,113; 6,119,269; and 6,536,156 and by U.S. Patent Application No. 2003/0173390; the disclosures of which patents and patent application are incorporated by reference as if fully set forth herein. [0006] In U.S. Pat. No. 4,852,293 (Levine et al., 1989), the inventors patented a fishing accessory container. This invention is limited in that the container takes the form of a bag that contains removable transparent plastic inserts. [0007] In U.S. Pat. No. 4,901,899 (Barrett, 1990), the inventor patented a foldable equipment carrier. This invention is limited in that it takes the form of a plurality of carrier packs that comprise a plurality of collapsible "puff" pouches. [0008] In U.S. Pat. No. 5,063,614 (McSheffery, 1991), the inventor patented a reversible fishing garment, preferably in the form of a vest, with exterior flaps that open outward from the wearer's body. The exterior flaps include detachable, clear plastic pockets. The purpose of this invention is to give the wearer flexibility in terms of the number of pockets worn on the vest and also to provide clear visibility into the pocket contents. This invention is limited in that exterior flaps and detachable pockets are required to provide sufficient storage capacity. [0009] U.S. Pat. No. 5,247,707 (Parker et al., 1993) describes a utility vest that can be used in connection with fly fishing or other outdoor activities. The main feature of this vest is a large pocket on the back of the garment that folds out into a backpack for carrying coats, sweaters and similar items that do not fit within the smaller pockets of the vest. This invention is limited in that it requires that a pair of straps run through the shoulder areas of the vest and terminate in belt loops for stabilizing the backpack. [0010] U.S. Pat. No. 5,465,425 (Crispin, 1995) discloses a fishing garment with removable pockets. The pockets have fastening means on both the front and back sides of the pocket, so that the pockets can be stacked on top of each other and so that the wearer can reposition the pockets as desired. The garment itself is shorter than a typical fishing vest so that it can be worn in deep water without getting the garment wet. This invention is limited in that its pockets must have fastening means on both the front and back sides of the pockets. [0011] U.S. Pat. No. 5,632,113 (Raymond et al., 1997) discloses a fishing bait and tackle organizer. This invention is limited in that it takes the form of a casing member having binder rings that hold a plurality of self-sealing storage bags. [0012] U.S. Pat. No. 6,119,269 (Imler et al., 2000) provides a fishing vest with a removable storage container system. The vest includes two large pockets, each of which is sized to hold a large container or slip. Each slip has a hinged cover and a number of adjustable sections within it. The vest also includes a rod holder loop near the bottom of the vest. This invention also includes a hand carrying case for storage of multiple slips. The invention is limited in that the large pockets are of a conventional design. [0013] U.S. Pat. No. 6,536,156 (Peterson, 2003) discloses a fishing lure organizer. This invention is limited in that it takes the form of a container having compartments. [0014] In U.S. Patent Application No. 2003/0173390 (Smith), the inventor described a harness-like fishing gear holder vest upon which various pouches are mounted for storing fishing supplies and caught fish. The harness comprises two shoulder straps and three pouches attached to the front of each strap. The straps are attached to a waist belt, which has two additional pouches attached to the sides. A chest strap holds the two shoulder straps together. The harness also provides two rod-holding rings, a detachable line cutter, and a snap hook for securing a fish net or stringer. The purpose of this invention is to provide a mechanism for holding fishing accessories that is easily adjusted to the size of the wearer and that can be substantially submersed in water. This invention is limited in that the pouches are of conventional design. [0015] Molding of laminates to form containers is known in the art. For example, cases for sunglasses and compact discs (CDs) are formed in this way. The applicant was the first to discover that molded pockets can be incorporated into garments in accordance with the invention disclosed herein. [0016] It is an object of preferred embodiments of the present invention to provide a mechanism for storing fly fishing accessories on a fishing vest or other garment worn by a person while fly fishing; however, the manner in which the present invention accomplishes this objective is vastly different from the prior art. It is a further object of preferred embodiments of the present invention to provide storage compartments that are easily accessible to the user and that add to the aesthetic appeal of the garment. It is a further object of preferred embodiments of the present invention to provide storage compartments with added impact protection. Finally, it is an object of the preferred embodiments of the present invention to accomplish all of the foregoing objects without restricting the range of motion of the wearer. None of the inventions described above accomplishes all of these objectives. BRIEF SUMMARY OF THE INVENTION [0017] The present invention involves the incorporation of three-dimensional, molded pockets into a garment. Preferably, the molded pockets are constructed of a fabric/foam laminate that has been heat/compression molded. In a preferred embodiment, the molded pockets find utility in the containment of fly boxes and other accessories used in fly fishing. [0018] In a preferred embodiment, the fishing vest of the present invention comprises molded vest pockets that are constructed of a compression-molded, foam/fabric, three-part laminate. The three-part laminate preferably comprises a stretch woven nylon outer fabric surface or outer layer, bonded to a thin layer of closed cell foam, and an inside layer comprising a light-weight knit nylon fabric layer bonded to the back/inside of the closed foam layer. The laminate is formed using techniques known in the art, such as flame lamination or adhesives, and then the molded pockets are formed by heating the laminated package until pliable (and until a uniform temperature is reached throughout) and placing the laminated package between male and female mold parts, which are pressed together and held in place until the laminated package has cooled to room/ambient temperature. The resulting formed/molded part is removed from the mold, its edges trimmed as necessary, and is then incorporated into the final assembly of the vest pocket. A zipper or other closure mechanism (such as a snap, button, Velcro or magnet closure) and/or other fabric elements are attached before the vest pocket is connected/sewn to the vest body. [0019] In other preferred embodiments, various materials are used to construct the laminate to achieve different effects, or a different function or appearance. In alternative embodiments, two materials, or a single material, that accomplish(es) the functions of all three, are/is used. All of the preferred embodiments, however, involve a molded shape for the pocket(s). The fabrics selected to construct the laminate provide the desired surfaces, both inside and out, to achieve structural as well as aesthetic objectives. [0020] In another preferred embodiment, the invention is a method of manufacturing molded pockets and a method of manufacturing a garment (preferably a fly fishing vest) having molded pockets. In an initial step, the materials are assembled for lamination. In the next step, the package is heated or otherwise treated to form a laminate. In the next step, the laminate is heated and positioned in a mold that is used for forming the molded pocket element of the vest, and sufficient pressure is applied to the mold to cause the laminate to take the shape of the mold. In the next step, the pockets are assembled (e.g., by trimming off excess material and adding closure mechanisms and/or other fabric elements) and attached to the vest body, producing a vest having molded pockets. [0021] In another preferred embodiment, the invention is a fishing vest comprising: a back panel; two front panels joined to the front panel by sewing or other method of attachment; and one or more pockets joined to the back panel or to one or more of the front panels; wherein each pocket is formed of a plurality of materials that comprise a package that is processed to produce a laminate that is molded to form a component of a molded pocket that is capable of accommodating a fly box, said plurality of materials comprising an outer fabric layer, a middle foam layer and an inner fabric layer, said outer layer comprising a stretchable, woven, nylon fabric, said middle foam layer comprising a closed cell foam, and said inner fabric layer comprising light-weight knit nylon fabric. [0022] In another preferred embodiment, the invention is a method of manufacturing a fishing vest having a body, said method comprising: placing three layers of material adjacent to one another, said three layers comprising an outer layer, a middle layer and an inner layer, said outer layer comprising a stretchable, woven, nylon fabric, said middle layer comprising a closed cell foam, and said inner layer comprising light-weight knit nylon fabric; forming a laminate out of the three layers of material; heating the laminated materials until the middle foam layer is pliable and has a consistent temperature throughout; placing the laminate between a male mold part and a female mold part, with the outer layer in direct contact with the female mold part and the inner layer in direct contact with the male mold part; pressing the mold parts together and holding them in place until the laminate has cooled substantially to room temperature, forming the molded pocket; removing the molded pocket from the mold; trimming the edges of the molded pocket and adding a closure mechanism and/or other fabric elements to produce an assembled molded pocket; and attaching the assembled molded pocket onto the body of the fishing vest. 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