Waterproof, breathable garments are typically formed of laminates incorporating a waterproof, water-vapor permeable functional material that is arranged as a layer in a textile laminate within a garment. As used herein, the term “garment” is intended to include articles for covering the upper and/or lower torso of a wearer, such as seamless gloves, hats, shirts, jackets, vests, pants, leggings, leg coverings, arm coverings, garment inserts from these materials, and the like. Materials which are both waterproof and water vapor permeable are commonly referred to as “functional” materials. The functional layer may be made of an expanded polytetrafluoroethylene (ePTFE) material available from W. L. Gore and Associates, Inc., Elkton, Md., under the tradename GORE-TEX®. The expanded PTFE is characterized as having a density less than 2.0 g/cm3. Other functional materials, such as polyurethanes, have also been developed and are known in the art.
U.S. Pat. No. 8,256,030 describes waterproof, breathable non-textile seamed articles which exhibit high levels of durability and allow wearers a high level of flexibility and article strength. Two non-textile materials, such as ePTFE, are joined around the desired periphery by a suitable sealing means to form a seam. US Pub. No. 2011/0179549 also shows a seamed glove.
It can be challenging to sew together the garment component panels, incorporating the laminate of textile(s) and functional layer(s), to form a waterproof and water vapor permeable garment, as the functional layer becomes permeable to water when it is pierced during the sewing process. It is therefore necessary that the laminate panels are assembled and joined by a waterproof joining process whereby the seams are sealed with a superimposed adhesive or sealing tape that is applied to the seam by a bonding or welding process.
Challenges that often results when forming such waterproof, breathable garments include limitations on garments design to allow for effective seam taping during manufacture, issues with the seam sealing depending on the types of laminates being joined, stiffness of seams, unattractive appearance, and the like. A further problem is that sealing the seamed portions of the garment to make the garment waterproof may compromise the breathability and flexibility of the garment and contribute to poor fit or comfort.
Thus, there remains a need in the art for waterproof and breathable garments that are easy to manufacture and comfortable to wear.