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  Quilted cold-weather garment with a substantially uncompressed interior foam layerUSPTO Application #: 20070245448Title: Quilted cold-weather garment with a substantially uncompressed interior foam layer Abstract: Disclosed is an improved cold weather garment construction. The construction uses two fabric layers positioned about an intermediate foam layer. To improve range of motion and reduces bulkiness, the three layers are quilted together and the foam is provided in varying thicknesses to match anticipated weather conditions. Additionally, the intermediate foam layer can have a skinned layer adjacent to the exterior layer and a convoluted surface opposite the interior layer. (end of abstract) Agent: Mark Young, P.A. - Jacksonville, FL, US Inventor: Robert Bury USPTO Applicaton #: 20070245448 - Class: 002108000 (USPTO) Related Patent Categories: Apparel, Body Garments, Vests, Jacket Type The Patent Description & Claims data below is from USPTO Patent Application 20070245448. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATION [0001] This application is continuation in part and claims the benefit of priority of U.S. nonprovisional application Ser. No. 11/074,303, filed Mar. 4, 2005, the entire contents of which are incorporated herein by this reference. FIELD OF THE INVENTION [0002] This invention relates to a cold weather garment. More particularly, the present invention relates to a multi-layer, quilted garment with a substantially uncompressed interior foam layer. BACKGROUND [0003] Through the years, various improvements have been made in the area of cold weather garments. All cold weather garments to date have sought to provide adequate insulation against cold temperatures, wind and water, while at the same time allowing for sufficient moisture vapor transmission from the wearer's body. Garments achieving these goals, however, tend to be unattractive and bulky. [0004] One well-known cold weather garment system was developed by the outdoorsmen J. G. Phillips, Jr. and Sr. and is known as the Phillips System. The Phillips System, which has been in use for over two decades, provides an opened cell foam layer in between interior and exterior fabric layers. The exterior fabric, or shell, is typically a nylon fabric, and the interior layer is typically a woven or knit lining. The edges of the garment are stitched together. The resulting construction is a unitary garment that is effective in cold weather. The drawbacks of the Phillips System, however, are that it has poor wind resistance and is bulky. Over the years there have been a number of improvements to the Phillips System. [0005] U.S. Pat. No. 4,690,847 to Lassiter discloses one such improvement. Lassiter '847 improves upon the Phillips System by convoluting the face of the intermediate foam layer. The convoluted face is positioned adjacent the inner fabric layer. The convoluted foam increases flexibility, reduces material and weight and enhances moisture transfer by increasing surface area. This System, however, still suffers from the aforementioned problem of bulkiness and, as a result, it often lacks sufficient dexterity to perform routine movements. [0006] Another improvement to the Phillips System is disclosed in U.S. Pat. No. 4,734,306 to Lassiter. Specifically, Lassiter '306 employs a skinned foam layer between the interior and exterior fabric layers. The "skinning" is achieved by forming a thin layer upon a flat surface of the foam. The opposite face of the foam can either be convoluted as taught in Lassiter '847 or flat. The use of a skinned foam improves handling during manufacturing, enhances wind resistance, while at the same time maintaining sufficient moisture vapor transmission rates. However, although skinned foam facilitates handling during manufacturing, it does not remedy the bulkiness inherent to the Phillips System. [0007] Yet another improvement to the Phillips System is demonstrated by U.S. Pat. No. 4,739,522 to Lassiter. Lassiter '522 provides a Phillips-type garment with increased buoyancy by interspersing a series of polystyrene pellets within an opened polyurethane foam to thereby form an intermediate foam layer with both opened and closed cells. The resulting garment allows its wearer to keep warm and remain afloat while immersed in cold water. The interior foam can also have a convoluted face as taught by Lassiter '847. Again, this improvement does not address the aforementioned problem of bulkiness. [0008] U.S. Pat. No. 4,807,303 to Mann improves upon the Phillips System by providing an exterior layer with low air permeability and high moisture vapor transmission. This increases wind resistance without sacrificing breathability. Mann teaches a garment comprised of three components, an outer layer of nylon fabric; an approximately one inch thick layer of soft and flexible polyurethane open cell foam; and an interior woven or knit lining fabric. The exterior layer can be a woven fabric that is constructed from a fine denier, multi-filament, synthetic yarn woven into a high density construction with controlled air porosity and moisture vapor transport properties. The interior foam layer can be convoluted as described in Lassiter '847. Again, although Mann '303 addresses weather resistance, it is not concerned with the mobility of the resulting garment. Mann does not teach or suggest a plurality of lines of stitching securing together the exterior, interior and intermediate layers in a quilt, wherein the plurality of lines intersect one another to form a box stitch pattern upon the garment. [0009] U.S. Pat. No. 5,408,700 to Reuben teaches an inner lining having a down-fill or down-fill composition disposed within a pouch forming the inner lining, wherein the composition is substantially evenly distributed throughout the pouch and retained therein in a compressed form. Significantly, the loft of the down-fill composition is reduced by at least twice the normal loft thereof to produce an insulating lining of reduced thickness. By substantially compressing the down-fill material, a thin lining is formed at the expense of the thermal insulating value, which is substantially compromised. Reuben does not teach or suggest a substantially uncompressed intermediate layer of opened-celled polyurethane foam. [0010] Thus, although each of the above referenced inventions achieves its individual objective, they all suffer from a common problem. Namely, neither the original Phillips System, nor any of its subsequent variations or other known prior art, address a wearer's dexterity and range of movement while wearing the garment and, concomitantly, preserve superior insulating properties of an interior foam layer. In all previous constructions, a thick intermediate foam layer is provided throughout the garment that needlessly encumbers its wearer and/or the intermediate layer is substantially compressed in quilting. Therefore, there exists a need in the art to provide a more streamlined garment that nonetheless affords sufficient weather resistance and moisture vapor transmission. The invention is directed to overcoming one or more of the problems and solving one or more of the needs as set forth above. SUMMARY OF THE INVENTION [0011] It is therefore one of the objectives of this invention to create a cold weather garment affords its wearer increased dexterity and a wider range of movement, while not sacrificing cold weather resistance. [0012] It is also an object of this invention to provide a multilayered garment wherein the multiple layers are quilted together to reduce bulkiness. [0013] Still another object of this invention is to provide a multilayered garment in a number of different thicknesses such that users can select a specific garment based upon anticipated weather conditions. [0014] These and other objectives are achieved by providing a cold weather garment with an interior layer, an exterior layer, and an intermediate layer of a polyurethane foam there between. The garment additionally includes a plurality of lines of stitching that secure together the interior, exterior, and intermediate layers into a quilt pattern. [0015] The objectives of the present invention are also achieved by providing a cold weather garment formed of an exterior layer of a waterproof and/or windproof breathable fabric and an interior layer of a mesh fabric. A layer of an open-celled polyurethane foam is positioned in between the interior and exterior layers. The intermediate layer has a first flat face disposed adjacent to the exterior layer and a skin formed upon the flat face to enhance ease of construction and improve wind resistance. The intermediate layer also includes a convoluted surface with peaks and valleys that is disposed adjacent to the interior layer. The convoluted surface reduces material and weight and improves moisture vapor transfer. A plurality of lines of stitching are provided to secure together the exterior, interior and intermediate layers as a quilt. The plurality of lines also intersect one another to form a box stitch. [0016] The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS [0017] The foregoing and other aspects, objects, features and advantages of the invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where: [0018] FIG. 1 is a front view of a quilted cold-weather garment constructed in accordance with the principles of the present invention; [0019] FIG. 2 is a cross-sectional view of the quilted garment taken along line 2-2 of FIG. 1; Continue reading... Full patent description for Quilted cold-weather garment with a substantially uncompressed interior foam layer Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Quilted cold-weather garment with a substantially uncompressed interior foam layer patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. 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