Breathable waterproof garment

Abstract

A method of manufacturing a breathable waterproof garment, the method comprising: forming a first garment layer ( 30 ) in a stretched configuration over an oversized three-dimensional garment former ( 20 ) having a profile extending substantially in three dimensions and corresponding to an oversized three-dimensional profile of the garment when worn; covering the first garment layer with an intermediate garment layer ( 40 ) resistant to penetration by liquid water but permeable to water vapour; covering the intermediate garment layer ( 40 ) with a second garment layer ( 50 ); and while the first and second garment layers ( 30, 50 ) are simultaneously stretched over the three-dimensional garment former ( 20 ) adhering the intermediate garment layer ( 40 ) to both the first and second garment layers ( 30, 40 ) at a plurality of discrete securement locations.

1 . A method of manufacturing a breathable waterproof garment, the method comprising:
 forming a first garment layer in a stretched configuration over an oversized three-dimensional garment former having a profile extending substantially in three dimensions and corresponding to an oversized three-dimensional profile of the garment when worn;   covering the first garment layer with an intermediate garment layer resistant to penetration by liquid water but permeable to water vapour;   covering the intermediate garment layer with a second garment layer; and   while the first and second garment layers are simultaneously stretched over the three-dimensional garment former adhering the intermediate garment layer to both the first and second garment layers at a plurality of discrete securement locations.   
     
     
         2 . A method according to  claim 1 , wherein the step of adhering the intermediate garment layer to both the first and second garment layers occurs substantially simultaneously. 
     
     
         3 . A method according to  claim 1 , wherein the step of adhering the intermediate garment layer to both the first and second garment layers comprises applying heat. 
     
     
         4 . A method according to  claim 3 , wherein heat is applied internally via a heating element provided inside the three-dimensional garment former. 
     
     
         5 . A method according to  claim 3 , wherein heat is applied externally via an external heating element. 
     
     
         6 . A method according to  claim 1 , wherein the step of adhering the intermediate garment layer to both the first and second garment layers comprises applying pressure. 
     
     
         7 . A method according to  claim 6 , wherein pressure is applied by pressure application apparatus comprising a first part defining a first mould chamber and a second part defining a second mould chamber, the first and second mould chambers together defining an internal profile substantially corresponding to an external profile of the oversized three-dimensional garment former, whereby when the first and second parts are brought together the pressure device and three-dimensional garment former act together to apply pressure to the first, second and intermediate garment layers. 
     
     
         8 . A method according to  claim 1 , the step of applying pressure comprises creating a pressure differential between fluid exposed to an outer surface of the second garment layer and fluid exposed to an inner surface of the first garment layer 
     
     
         9 . A method according to  claim 8 , wherein pressure is applied by exposing an outer surface of the second garment layer with a pressurised fluid. 
     
     
         10 . A method according to  claim 9 , wherein the pressurised fluid is applied to the outer surface of the second garment layer in a pressurised chamber. 
     
     
         11 . A method according to  claim 10 , wherein the pressurised fluid is applied to the outer surface of the second garment layer at a temperature exceeding an activation temperature of the adhesive. 
     
     
         12 . A method according to  claim 1 , wherein the oversized three-dimensional garment former is alterable between an expanded configuration and a contracted configuration, and the method further comprises placing at least one of the first, intermediate and second garment layers over the oversized three-dimensional garment former whilst the oversized three-dimensional garment former is in the contracted configuration. 
     
     
         13 . A method according to  claim 1 , wherein:
 the oversized three-dimensional garment former is alterable between an expanded configuration and a contracted configuration; and   pressure is applied by providing pressure application apparatus comprising a body defining: a chamber having an internal profile substantially corresponding to an external profile of the oversized three-dimensional garment former; and an opening for inserting the oversized three-dimensional garment former into the chamber when the oversized three-dimensional garment former is in the contracted configuration;   whereby pressure is applied to opposed sides of the intermediate garment structure by moving the oversized three-dimensional garment former into the expanded configuration after being positioned inside the chamber in a predetermined orientation relative to the chamber.   
     
     
         14 . A method according to  claim 13 , wherein the oversized three-dimensional garment former comprises at least one inflatable part. 
     
     
         15 . A method according to  claim 14 , wherein pressurised fluid is applied to the at least one inflatable part when the oversized three-dimensional garment former is positioned inside the chamber to move the oversized three-dimensional garment into the expanded configuration. 
     
     
         16 . A method according to  claim 15 , wherein pressurised gas is applied to the at least one inflatable part at a temperature exceeding an activation temperature of the adhesive. 
     
     
         17 . A method according to  claim 14 , wherein the oversized three-dimensional garment former is inserted into the chamber with the at least one inflatable part in a partially inflated configuration. 
     
     
         18 . A method according to  claim 1 , wherein the garment includes a pair of apertures for receiving a wearer's arms or legs. 
     
     
         19 . A method according to  claim 12 , wherein the garment comprises a pair of tubular sleeves or a pair of tubular leg parts. 
     
     
         20 . A method according to  claim 1 , wherein the garment comprises a glove. 
     
     
         21 . A method according to  claim 1 , wherein the first garment layer forms an inner layer of the garment and the second garment layer forms an outer layer of the garment. 
     
     
         22 . A method according to  claim 1 , wherein at least one of the first and second garment layers is a knitted garment layer. 
     
     
         23 . A method of manufacturing a breathable waterproof garment, the method comprising:
 providing an intermediate garment structure comprising a first garment layer and an inflatable oversized intermediate garment layer resistant to penetration by liquid water but permeable to water vapour provided over the first garment layer;   inflating the intermediate garment structure to stretch the first layer into a predetermined stretched configuration; and   while the first garment layer is in the predetermined stretched configuration adhering the intermediate garment layer to the first garment layer at a plurality of discrete securement locations.   
     
     
         24 . A method according to  claim 23 , wherein:
 the intermediate garment layer is provided over the first garment layer and the intermediate garment structure further comprises a second garment layer provided over the intermediate garment layer, wherein the step of inflating the intermediate garment structure stretches each of the first and second garment layers into the predetermined stretched configuration; and   the method further comprises while the first and second garment layers are simultaneously in the pre-determined stretched configuration adhering the intermediate garment layer to both the first and second garment layers at a plurality of discrete securement locations by applying pressure to an outer surface of the second garment layer whilst the intermediate garment structure is inflated.   
     
     
         25 . A method according to  claim 24 , wherein the step of adhering the intermediate garment layer to both the first and second garment layers occurs substantially simultaneously. 
     
     
         26 . A method according to  claim 24 , wherein the step of adhering the intermediate garment layer to both the first and second garment layers comprises applying heat. 
     
     
         27 . A method according to  claim 26 , wherein heat is applied externally via an external heating element. 
     
     
         28 . A method according to  claim 24 , wherein the pressure is applied to the outer surface of the second garment layer by providing pressure application apparatus comprising a body defining:
 a chamber having an internal profile substantially corresponding to an oversized three-dimensional external profile of the garment when worn; and   an opening for inserting the intermediate garment structure into the chamber;   whereby pressure is applied to opposed sides of the intermediate garment structure by inflating the intermediate garment structure after being positioned inside the chamber in a predetermined orientation relative to the chamber.   
     
     
         29 . A method according to  claim 23 , wherein the intermediate garment structure is formed on an oversized garment former. 
     
     
         30 . A method according to  claim 23 , wherein the garment includes a pair of apertures for receiving a wearer's arms or legs. 
     
     
         31 . A method according to  claim 30 , wherein the garment comprises a pair of tubular sleeves or a pair of tubular leg parts. 
     
     
         32 . A method according to  claim 23 , wherein the garment comprises a glove. 
     
     
         33 . A method according to  claim 23 , wherein the first garment layer forms an inner layer of the garment and the second garment layer forms an outer layer of the garment. 
     
     
         34 . A method according to  claim 23 , wherein at least one of the first and second garment layers is a knitted garment layer 
     
     
         35 . A breathable waterproof garment having a profile extending substantially in three dimensions when stretched over a planar former, the garment comprising:
 an inner garment layer;   an outer garment layer; and   an intermediate garment layer provided in a folded configuration between the inner and outer garment layers, the intermediate garment layer being resistant to penetration by liquid water but permeable to water vapour;   wherein the intermediate garment layer is attached to both the inner garment layer and the outer garment layer by regions of adhesive provided at a plurality of discrete securement locations.   
     
     
         36 . A breathable waterproof garment according to  claim 35 , wherein at least one of the inner and outer garment layers is a knitted garment layer. 
     
     
         37 . A breathable waterproof garment according to  claims 35 , wherein the inner and outer garment layers and the intermediate garment layer all have a profile corresponding to a predetermined profile of the garment. 
     
     
         38 . A breathable waterproof garment according to  claim 35 , wherein at least one of the inner and outer garment layers each consist of a single seamless part. 
     
     
         39 . A method of manufacturing a breathable waterproof garment including a pair of apertures for receiving a wearer's arms or legs, the method comprising:
 providing a first garment layer in a stretched configuration over an oversized garment former having a profile defining a pair of oversized arm or leg parts;
 while the first garment layer is in the stretched configuration adhering the first garment layer to a first surface of an intermediate garment layer resistant to penetration by liquid water but permeable to water vapour at a plurality of discrete securement locations; and 
   adhering a second garment layer to a second surface of the intermediate garment layer opposed to the first surface at a plurality of discrete securement locations while the second garment layer is in a stretched configuration.   
     
     
         40 . A method according to  claim 39 , wherein the garment comprises a pair of tubular sleeves. 
     
     
         41 . A method according to  claim 39 , wherein the garment comprises a pair of tubular leg parts. 
     
     
         42 . A method according to  claim 39 , wherein the first garment layer forms an inner layer of the garment and the second garment layer forms an outer layer of the garment. 
     
     
         43 . A method according to  claim 39 , wherein at least one of the first and second garment layers is a knitted garment layer 
     
     
         44 . A method according to  claim 39 , wherein the step of adhering the second garment layer to the intermediate garment layer is carried subsequently to the step of adhering the first garment layer to the intermediate garment layer. 
     
     
         45 . A method according to  claim 44 , wherein the step of adhering the second garment layer to the intermediate garment layer is carried out while the second garment layer is stretched over the intermediate garment layer. 
     
     
         46 . A method according to  claim 45 , wherein the step of adhering the second garment layer to the intermediate garment layer is carried out while the first and intermediate garment layers are on the oversized garment former. 
     
     
         47 . A method according to  claim 39 , wherein the step of adhering the intermediate garment layer to the first garment layer and adhering the second garment layer to the intermediate garment layer are carried out simultaneously whilst the first and second garment layers and the intermediate garment layer are stretched over the oversized garment former. 
     
     
         48 . A method according to  claim 39 , wherein the oversized garment former is alterable between an expanded configuration and a contracted configuration, and the method further comprises placing at least one of the first, intermediate and second garment layers over the oversized garment former whilst the oversized garment former is in the contracted configuration. 
     
     
         49 . A breathable waterproof garment including a pair of apertures for receiving a wearer's arms or legs, the garment comprising:
 an inner garment layer;   an outer garment layer; and   an intermediate garment layer provided in a folded configuration between the inner and outer garment layers, the intermediate garment layer being resistant to penetration by liquid water but permeable to water vapour; wherein the intermediate garment layer is attached to both the inner garment layer and the outer garment layer by regions of adhesive provided at a plurality of discrete securement locations.   
     
     
         50 . A breathable waterproof garment according to  claim 49 , wherein at least one of the inner and outer garment layers is a knitted garment layer. 
     
     
         51 . A breathable waterproof, garment according to  claim 49 , wherein the inner and outer garment layers and the intermediate garment layer all have a profile corresponding to a predetermined profile of the garment. 
     
     
         52 . A breathable waterproof garment according to  claim 49 , wherein at least one of the inner and outer garment layers each consist of a single seamless part.