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.

1 . A fishing vest comprising: 
 a back panel;    two front panels joined to the back panel; 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 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.    
   
   
       2 . 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;    processing the layers to form a laminate;    heating the laminate until it is pliable and the temperature is consistent throughout the laminate;    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.    
   
   
       3 . A method of manufacturing a fishing vest having a body, said method comprising: 
 fabricating the body of the fishing vest, said body having an outside surface;    molding a laminate to produce a molded pocket, said laminate 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;    trimming the edges of the molded pocket to produce an assembled molded pocket; and    attaching the assembled molded pocket onto the outside surface of the body of the fishing vest.    
   
   
       4 . A fishing vest comprising: 
 a body having a back panel and two front panels; and    one or more molded pockets.    
   
   
       5 . The fishing vest of  claim 4 , wherein each of the one or more molded pockets is comprised of three layers of material.  
   
   
       6 . The fishing vest of  claim 5 , wherein the three layers of material are comprised of an outer layer, a middle layer, and an inner layer.  
   
   
       7 . The fishing vest of  claim 6 , wherein the outer layer is comprised of a stretch woven nylon fabric, the middle layer is comprised of closed cell foam, and the inner layer is comprised of a light-weight knit nylon fabric.  
   
   
       8 . A method of manufacturing each of the molded pockets of the vest of  claim 6 , comprising the steps of: 
 fabricating the body of the fishing vest of  claim 6 , said body having the front panels and the back panel, each panel having an outside surface;    molding a laminate to produce a molded pocket, 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;    trimming the edges of the molded pocket to produce an assembled molded pocket; and    attaching the assembled molded pocket onto the outside surface of one of the panels of the fishing vest of  claim 6 .    
   
   
       9 . The method of manufacturing of  claim 8 , further comprising the step of attaching a closure mechanism and/or other fabric elements to each assembled molded pocket before it is sewn to the outside surface of one of the panels of the vest.  
   
   
       10 . The fishing vest of  claim 4 , wherein each of the one or more molded pockets is comprised of two layers of material.  
   
   
       11 . The fishing vest of  claim 5  or  10 , wherein one of the layers of material is selected from the group consisting of: a woven or knitted fabric, a fabric that is stretchable by virtue of its yarn type, and a fabric that is constructed via a weaving or knitting process with one or more elastomeric yarns.  
   
   
       12 . The fishing vest of  claim 5  or  10 , wherein one of the layers of material is selected from the group consisting of: a closed cell foam, an open-cell foam, a non-woven polyester, a lofted or non-lofted interfacing, a needle punch, a mesh scrim, and a heavy thermoplastic film.  
   
   
       13 . A method of manufacturing the vest of  claim 10 , comprising the steps of: 
 fabricating the two front panels and the back panel of the fishing vest of  claim 10;     molding a laminate to produce each of the one or more molded pockets; and    attaching each of the one or more molded pockets onto one of the panels of the fishing vest of  claim 10 .    
   
   
       14 . The method of manufacturing of  claim 13 , further comprising the step of attaching closure mechanisms and/or other fabric elements to each of the one or more molded pockets before it is sewn onto one of the panels of the fishing vest.  
   
   
       15 . The fishing vest of  claim 4 , wherein each of the one or more molded pockets is comprised of one layer of material.  
   
   
       16 . The fishing vest of  claim 15 , wherein the layer of material is selected from the group consisting of: a closed cell foam, an open-cell foam, a non-woven polyester, a lofted or non-lofted interfacing, a needle punch, a mesh scrim, a heavy thermoplastic film, and a woven or knitted fabric.  
   
   
       17 . A method of manufacturing each of the molded pockets of the vest of  claim 15 , comprising the steps of: 
 fabricating the body of the fishing vest of  claim 15 , said body having the two front panels and the back panel;    molding a laminate to produce each of the one or more molded pockets; and    attaching each of the one or more molded pocket onto one of the panels of the vest of  claim 15 .    
   
   
       18 . The method of manufacturing of  claim 17 , further comprising the step of attaching closure mechanisms and/or other fabric elements to each of the one or more molded pockets before it is sewn to one of the panels of the vest of  claim 15 .  
   
   
       19 . An article of clothing comprising 
 a body having at least one panel; and    one or more molded pockets.    
   
   
       20 . The article of clothing of  claim 19 , wherein each of the one or more molded pockets is comprised of three layers of material.  
   
   
       21 . The article of clothing of  claim 20 , wherein the three layers of material comprise: an outer layer, a middle layer, and an inner layer.  
   
   
       22 . The article of clothing of  claim 21 , wherein the first layer is comprised of a stretchable woven nylon fabric, the second layer is comprised of closed cell foam, and the third layer is comprised of a light-weight knit nylon fabric.  
   
   
       23 . A method of manufacturing the article of clothing of  claim 21 , comprising the steps of: 
 fabricating the body of the article of clothing of  claim 21 , said article of clothing having the at least one panel;    molding a laminate to produce each of the one or more molded pockets; and    attaching each of the one or more molded pockets onto one of the panels of the article of clothing of  claim 21 .    
   
   
       24 . The method of manufacturing of  claim 23 , further comprising the step of attaching closure mechanisms and/or other fabric elements to each of the one or more molded pockets before it is sewn to one of the panels of the article of clothing of  claim 21 .  
   
   
       25 . The article of clothing of  claim 19 , wherein each of the one or more molded pockets is comprised of two layers of material.  
   
   
       26 . The article of clothing of claims  20  or  25 , wherein one of the layers of material is selected from the group consisting of: a woven or knitted fabric, a fabric that is stretchable by virtue of its yarn type, and a fabric that is constructed via a weaving or knitting process with one or more elastomeric yarns.  
   
   
       27 . The article of clothing of claims  20  or  25 , wherein one of the layers of material is selected from the group consisting of: a closed cell foam, an open-cell foam, a non-woven polyester, a lofted or non-lofted interfacing, a needle punch, a mesh scrim, and a heavy thermoplastic film.  
   
   
       28 . A method of manufacturing the article of clothing of  claim 25 , comprising the steps of: 
 fabricating the body of the article of clothing of  claim 25 , said article of clothing having the at least one panel;    molding the layers of material to produce each of the one or more molded pockets; and    attaching each of the one or more molded pockets onto one of the panels of the article of clothing of  claim 25 .    
   
   
       29 . The method of manufacturing of  claim 28 , further comprising the step of attaching closure mechanisms and/or other fabric elements to each of the one or more molded pockets before it is sewn to the panels of the article of clothing.  
   
   
       30 . The article of clothing of  claim 19 , wherein each of the one or more molded pockets is comprised of one layer of material.  
   
   
       31 . The article of clothing of  claim 30 , wherein the layer of material is selected from the group consisting of: a closed cell foam, an open-cell foam, a non-woven polyester, a lofted or non-lofted interfacing, a needle punch, a mesh scrim, a heavy thermoplastic film, and a woven or knitted fabric.  
   
   
       32 . A method of manufacturing the article of clothing of  claim 30 , comprising the steps of: 
 fabricating the article of clothing of  claim 30 , said article of clothing having the at least one panel;    molding the one layer of material to produce each of the one or more molded pockets; and    attaching each of the one or more molded pockets onto one of the panels of the article of clothing of  claim 30 .    
   
   
       33 . The method of manufacturing of  claim 32 , further comprising the step of attaching closure mechanisms and/or other fabric elements to each of the one or more molded pockets before it is sewn to the at least one panel of the article of clothing.