Polychloroprene-free wetsuit and material

Abstract

A polychloroprene-free wetsuit and material is described consisting of a class of copolymers or a physical mix of polymers consisting of materials with both thermoplastic and elastomeric properties to produce thermoplastic resin pellets. The non-toxic thermoplastic resin pellets are mixed with additives and a blowing agent to produce thermoplastic elastomer closed-cell foam for use in wetsuits. Depending on the wetsuit application, the density of the thermoplastic elastomer foam may vary. In many wetsuit applications low densities such as less than 0.25 grams/cubic centimeters are desirable.

1 . A wetsuit comprising:
 one or more sheets of closed-cell foam formed to cover one or more body parts of a wearer, the closed-cell foam being derived from polymerized thermoplastic resin pellets mixed with at least one foaming agent, the closed-cell foam being formed to a density of less than 0.25 grams per cubic centimeter, each of the one or more sheets of closed-cell having a thickness between about 2 millimeters and about 5 millimeters and enabling movement of the one or more body parts of the wearer when covered by the one or more sheets of closed-cell foam.   
     
     
         2 . The wetsuit in accordance with  claim 1 , further comprising an outer fabric attached to and covering at least a portion of an outer surface of at least one of the one or more sheets of closed-cell foam. 
     
     
         3 . The wetsuit in accordance with  claim 2 , wherein the outer fabric includes woven nylon. 
     
     
         4 . The wetsuit in accordance with  claim 2 , wherein the outer fabric includes aramid fiber. 
     
     
         5 . The wetsuit in accordance with  claim 2 , wherein the outer fabric includes spandex. 
     
     
         6 . The wetsuit in accordance with  claim 2 , wherein the outer fabric includes woven polypropylene. 
     
     
         7 . The wetsuit in accordance with  claim 1 , further comprising an inner liner attached to and covering at least a portion of an inner surface of at least one of the one or more sheets of closed-cell foam. 
     
     
         8 . The wetsuit in accordance with  claim 7 , wherein the inner liner includes spun nylon. 
     
     
         9 . The wetsuit in accordance with  claim 7 , wherein the inner liner includes polypropylene fleece. 
     
     
         10 . A material comprising closed-cell foam derived from polymerized thermoplastic resin pellets mixed with at least one foaming agent, the closed-cell foam being formed to a density of less than 0.25 grams per cubic centimeter, each of the one or more sheets of closed-cell having a thickness between about 2 millimeters and about 5 millimeters. 
     
     
         11 . The material in accordance with  claim 10 , further comprising an outer fabric attached to and covering at least a portion of an outer surface of the closed-cell foam. 
     
     
         12 . The material in accordance with  claim 11 , wherein the outer fabric includes woven nylon. 
     
     
         13 . The material in accordance with  claim 11 , wherein the outer fabric includes aramid fiber. 
     
     
         14 . The material in accordance with  claim 11  wherein the outer fabric includes spandex. 
     
     
         15 . The material in accordance with  claim 11 , wherein the outer fabric includes woven polypropylene. 
     
     
         16 . The material in accordance with  claim 10 , further comprising an inner liner attached to and covering at least a portion of an inner surface of the closed-cell foam. 
     
     
         17 . The material in accordance with  claim 16 , wherein the inner liner includes fleece polypropylene. 
     
     
         18 . The material in accordance with  claim 16 , wherein the inner liner includes spun nylon. 
     
     
         19 . A method for manufacturing a wetsuit, the method comprising:
 providing one or more sheets of closed-cell foam formed to cover one or more body parts of a wearer, the closed-cell foam being derived from polymerized thermoplastic resin pellets mixed with at least one foaming agent, the closed-cell foam being formed to a density of less than 0.25 grams per cubic centimeter, each of the one or more sheets of closed-cell having a thickness between about 2 millimeters and about 5 millimeters and enabling movement of the one or more body parts of the wearer when covered by the one or more sheets of closed-cell foam; and   assembling the one or more sheets of closed-cell foam into a pattern defining at least a portion of the wetsuit.   
     
     
         20 . The method in accordance with  claim 19 , wherein providing the one or more sheets of the closed-cell foam includes cutting the closed-cell foam into the one or more sheets to cover the one or more body parts of the wearer.