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.

1 . A cold-weather garment comprising: an exterior layer of a waterproof and windproof breathable fabric; an interior layer of a mesh fabric; a substantially uncompressed intermediate layer of an opened-celled polyurethane foam positioned between the exterior and interior layers, the intermediate layer having a first flat face disposed adjacent the exterior layer, the flat face having a skin so as to enhance ease of construction and improve wind resistance, the intermediate layer also having a second convoluted face including peaks and valleys disposed adjacent the interior layer, the convoluted face reducing weight and providing added surface area for moisture transfer; 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, the quilting improving the dexterity of the garment's wearer, and improving insulation and water vapor transmission of the garment.  
   
   
       2 . A cold-weather garment comprising: an exterior layer, an interior layer, and a substantially uncompressed intermediate layer of a polyurethane foam; a plurality of lines of stitching securing together the interior, exterior and intermediate layers into a quilt pattern formed from a series of individual cells throughout the garment, the quilt pattern improving the dexterity of the garment's wearer, and improving insulation and water vapor transmission of the garment.  
   
   
       3 . The garment as described in  claim 2  wherein the exterior layer is formed from polytetrafluoroethylene fabric.  
   
   
       4 . The garment as described in  claim 2  wherein the interior layer is formed from a mesh fabric.  
   
   
       5 . The garment as described in  claim 2  wherein one face of the foam layer is convoluted.  
   
   
       6 . The garment as described in  claim 2  wherein the face of the foam layer is skinned.  
   
   
       7 . The garment as described in  claim 2  wherein the foam is an opened cell polyurethane foam.  
   
   
       8 . The cold weather garment as described in  claim 2  wherein the foam is either ⅛, ¼, ½ or ¾ inches thick and wherein the thickness is selected on the basis of anticipated weather conditions.  
   
   
       9 . A cold-weather garment comprising a substantially uncompressed intermediate foam layer formed between interior and exterior fabric layers, the foam being an opened cell synthetic foam; a number of lines of stitching securing together the interior, exterior and intermediate layers, the lines of stitching intersecting one another at multiple locations upon the garment, the intersecting lines of stitching forming a box stitch, the uncompressed foam layer improving insulation and water vapor transmission of the garment.  
   
   
       10 . The cold weather garment as described in  claim 9  wherein the foam is ⅛, ¼, ½ or ¾ inches thick and wherein the thickness is selected on the basis of anticipated weather conditions.