Protective Coverall having Antistatic Resilient Cuffs of Protective Fabric

Abstract

A protective coverall comprising a protective fabric having an outer face and an inner face, the inner face having an antistatic treatment, the protective coverall having a plurality of sleeves each ending in a resilient cuff, with each resilient cuff made from the protective fabric and a plurality of continuous circumferential elastic threads, each resilient cuff comprising a fold of the protective fabric, with the outer face of the protective fabric being folded upon itself to form first and second fold layers, with the plurality of continuous circumferential elastic threads in contact with and being held between fold layers and the inner face of the protective fabric forming both the cuff interior and exterior surface.

Claims

1. A protective coverall comprising a protective fabric, the protective fabric comprising an outer face and an inner face, wherein the inner face has an antistatic treatment, the protective coverall having a plurality of sleeves, each sleeve ending in a resilient cuff, wherein the inner face of the protective fabric forms an interior surface of the coverall and each of the sleeves, and the outer face of the protective fabric forms an exterior surface of the coverall and each of the sleeves, each resilient cuff further having a cuff interior surface configured for facing the person, and a cuff exterior surface, each resilient cuff comprising a fold of the protective fabric, with the outer face of the protective fabric being folded upon itself to form first and second fold layers, with the distal end of each resilient cuff being the fold, each resilient cuff further comprising a plurality of continuous circumferential elastic threads held between the first and second fold layers, in contact with the outer face of the protective fabric, and the inner face of the protective fabric forming both the cuff interior surface and the cuff exterior surface.

2. The protective coverall of claim 1, wherein the sleeves include arm sleeves and leg sleeves.

3. The protective coverall of claim 1, wherein the resilient cuff has a proximate end at the sleeve and a distal end, and wherein the resilient cuff has a length, from the distal end to the proximate end, of 1 to 5 inches.

4. The protective coverall of claim 1, wherein the plurality of continuous circumferential elastic threads is present in the resilient cuff as a parallel array of spaced-apart elastic threads.

5. The protective coverall of claim 4, wherein the resilient cuff contains a parallel array of 4 to 15 circumferential threads spaced apart a distance of 0.125 to 1.0 inches.

6. The protective coverall of claim 4, wherein the resilient cuff comprises, from the distal end to the proximate end, a fold area, a parallel array of spaced-apart elastic threads area, and a seam allowance area.

7. The protective coverall of claim 1, wherein the plurality of continuous circumferential elastic threads is held between the first and second fold layers by adhesive or by ultrasonic welds.

8. The protective coverall of claim 7, wherein the plurality of continuous circumferential elastic threads is present in a parallel array and the threads are held between the first and second fold layers by weld lines that are transverse to the parallel array, the weld lines being made by lines of adhesive or ultrasonic weld lines.

9. The protective coverall of claim 1, wherein the protective coverall further comprises a hood sleeve configured for receiving the head of a person when the person wears the protective coverall, with said hood sleeve ending in the resilient cuff.

10. The protective coverall of claim 1, wherein the protective coverall further comprises an accessory sleeve for receiving an accessory worn by the a person when the person wears the protective coverall, with said accessory sleeve ending in the resilient cuff.

11. The protective coverall of claim 1, further comprising a waistband comprising a parallel waist array of a plurality of spaced-apart elastic threads, wherein the spaced-apart elastic threads are oriented circumferential to the waist, and wherein the parallel waist array contains 4 to 15 circumferential threads spaced apart a distance of 0.125 to 1.0 inches, and wherein the waistband comprises has a width, the width being 1 to 5 inches and comprising a first seam allowance area, a parallel waist array of spaced-apart elastic threads area, and a second seam allowance area, and wherein the parallel waist array of spaced-apart elastic threads area comprises the parallel waist array of continuous circumferential elastic threads held between two layers of protective fabric by weld lines that are transverse to the parallel waist array, the weld lines being made by lines of adhesive or ultrasonic weld lines.

12. A protective coverall comprising a protective fabric, the protective fabric comprising an outer face and an inner face, wherein the inner face has an antistatic treatment, the protective coverall having a body portion configured for covering at least a portion of a torso of a person when the protective coverall is worn by the person; the body portion having at least one torso opening configured for donning the protective coverall and a neck opening configured for receiving a head and neck of the person, the body portion further having a plurality of openings; the plurality of openings including a first opening ending in a first arm sleeve configured for receiving a portion of a right arm of the person when the person wears the protective coverall, and a second opening ending in a second arm sleeve configured for receiving a portion of a left arm of the person when the person wears the protective coverall, each of the first and second arm sleeves further having an opening configured for receiving a wrist and hand of the person, with each arm sleeve having a proximate end at the body portion and a distal end at the opening configured for receiving a wrist and hand, the plurality of openings further including a third opening ending in a first leg sleeve configured for receiving a portion of a right leg of the person when the person wears the protective coverall, and a fourth opening ending in a second leg sleeve configured for receiving a portion of a left leg of the person when the person wears the protective coverall, each of the first and second leg sleeves further having an opening configured for receiving an ankle and foot of the person, with each leg sleeve having a proximate end at the body portion and a distal end at the opening configured for receiving an ankle and foot, wherein the body portion, each of the arm sleeves, and each of the leg sleeves have an interior surface configured for facing the person when the person wears the protective coverall, and an exterior surface; and the inner face of the protective fabric forms said interior surface of the body portion, each of the arm sleeves, and each of the leg sleeves, and the outer face of the protective fabric forms the exterior surface of the body portion, each of the arm sleeves, and each of the leg sleeves, wherein the distal end of each arm sleeve and each leg sleeve comprises a resilient cuff made from the protective fabric and a plurality of continuous circumferential elastic threads, said resilient cuff having a proximate end and a distal end, with the proximate end of each cuff attached to the distal end of each respective arm sleeve and leg sleeve, each resilient cuff further having a cuff interior surface configured for facing the person, and a cuff exterior surface, each resilient cuff comprising a fold of the protective fabric, with the outer face of the protective fabric being folded upon itself to form first and second fold layers, with the distal end of each resilient cuff being the fold, each resilient cuff further comprising a plurality of continuous circumferential elastic threads held between the first and second fold layers, in contact with the outer face of the protective fabric, and the inner face of the protective fabric forming both the cuff interior surface and the cuff exterior surface.

13. The protective coverall of claim 12, wherein the resilient cuff has a length, from the distal end to the proximate end, of 1 to 5 inches.

14. The protective coverall of claim 12, wherein the plurality of continuous circumferential elastic threads is present in the resilient cuff as a parallel array spaced-apart elastic threads.

15. The protective coverall of claim 14, wherein the resilient cuff contains a parallel array of 4 to 15 circumferential threads spaced apart a distance of 0.125 to 1.0 inches.

16. The protective coverall of claim 14, wherein the resilient cuff comprises, from the distal end to the proximate end, a fold area, a parallel array of spaced-apart elastic threads area, and a seam allowance area.

17. The protective coverall of claim 12, wherein the plurality of continuous circumferential elastic threads is held between the first and second fold layers by adhesive or by ultrasonic welds.

18. The protective coverall of claim 17, wherein the plurality of continuous circumferential elastic threads are in a parallel array and the threads are held between the first and second fold layers by lines of adhesive or ultrasonic weld lines transverse to the parallel array.

19. The protective coverall of claim 12, wherein the body portion further comprises a hood opening ending in a hood sleeve configured for receiving the head of a person when the person wears the protective coverall, the hood sleeve further having an opening configured for access to a person's face, with the hood sleeve having a proximate end at the body portion and a distal end at the opening configured for access to a person's face, wherein the distal end of the hood sleeve also comprises said resilient cuff.

20. The protective coverall of claim 12, wherein the body portion further comprises an opening ending in an accessory sleeve for receiving an accessory worn by the a person when the person wears the protective coverall, the accessory sleeve further having an opening configured for some portion of the accessory sleeve, with the accessory sleeve having a proximate end at the body portion and a distal end at the opening configured for access to the accessory, wherein the distal end of the accessory sleeve also comprises said resilient cuff.

21. The protective coverall of claim 12, further comprising a waistband comprising a parallel waist array of a plurality of spaced-apart elastic threads, wherein the spaced-apart elastic threads are oriented circumferential to the waist, and wherein the parallel waist array contains 4 to 15 circumferential threads spaced apart a distance of 0.125 to 1.0 inches, and wherein the waistband comprises has a width, the width being 1 to 5 inches and comprising a first seam allowance area, a parallel waist array of spaced-apart elastic threads area, and a second seam allowance area, and wherein the parallel waist array of spaced-apart elastic threads area comprises the parallel waist array of continuous circumferential elastic threads held between two layers of protective fabric by weld lines that are transverse to the parallel waist array, the weld lines being made by lines of adhesive or ultrasonic weld lines.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIGS. 1a & 1b are front and back illustrations, respectively, of a protective coverall having a plurality of sleeves, each sleeve ending in a resilient cuff; this embodiment further includes a resilient waistband encircling the waist.

[0021] FIG. 2 is an illustration of a perspective view of the resilient cuff fabric comprising a fold of the protective fabric, with the outer face of the protective fabric being folded upon itself to form first and second fold layers, with a plurality of continuous circumferential elastic threads being held between the fold layers, and the inner face of the protective fabric forming both the cuff interior surface and the cuff exterior surface. This is a view of the extended cuff fabric, as if the cuff fabric with elastic threads were stretched or extended under tension.

[0022] FIG. 3 is an illustration of a top view of the resilient cuff fabric showing the protective fabric being folded upon itself with a plurality of continuous circumferential elastic threads being held between the fold layers, the continuous circumferential elastic threads present in a parallel array and held by transverse weld lines that are transverse to the parallel array of elastic threads. This is a view of the extended cuff fabric, as if the cuff fabric with elastic threads were stretched or extended under tension.

[0023] FIGS. 4a & 4b are illustrations of idealized cross sections of the extended resilient cuff fabric, with FIG. 4a illustrating the unbonded areas in the resilient cuff between weld lines and FIG. 4b illustrating the bonded areas caused by those transverse weld lines.

[0024] FIG. 5 illustrates, in an idealized manner, the principle of providing a resilient cuff that extends the conductive path from the inside of the coverall sleeve to the outside of the cuff. The resilient cuff comprising a fold of the protective fabric is shown with the conductive inner face of the protective fabric forming both the cuff interior surface and the cuff exterior surface, and this conductive inner face further being in direct contact with the conductive inner face of the sleeve fabric.

[0025] FIG. 6 is a detail illustration of one type of sewn seam between the resilient cuff and the sleeve, which can be used to attach the inner face of the cuff interior surface in direct contact with the inner face of the sleeve fabric.

[0026] FIGS. 7a & 7b are front and back illustrations, respectively, of a protective coverall further comprising an accessory sleeve for receiving an accessory worn by a person wearing the coverall, with the sleeve further comprising the resilient cuff. FIG. 7c illustrates the accessory in this embodiment, which is a waist-mounted powered air purifying respirator (PAPR).

[0027] FIGS. 8a & 8b are back and side illustrations, respectively, of a hood sleeve comprising two resilient cuffs, one resilient cuff for receiving a respirator accessory on the front of the head or face, and one resilient cuff for receiving a powered air purifying respirator (PAPR) mounted on the head or back of the neck of the coverall wearer.

[0028] FIGS. 9a & 9b are front and back illustrations, respectively, of a protective coverall having a plurality of sleeves, each sleeve ending in a resilient cuff; this embodiment further includes a resilient waistband across the back of the coverall from hip-to-hip.

DETAILED DESCRIPTION OF THE INVENTION

[0029] This invention relates to a protective coverall, preferably an electrostatic dissipative (ESD) protective coverall, having a resilient ESD cuff, the cuff made resilient by entrapping a plurality of continuous elastic threads or strands in the circumference of the cuff between two plies of the protective fabric of the coverall, the threads or strands being separated from each other a specific distance in the cuff. The elastic threads or strands are held in place between the two plies of coverall material preferably by welds made by ultrasonic bonding or by the use of an adhesive. The protective fabric of the coverall preferably has an antistatic treated inner face and an outer face, and the inner face of the protective fabric forms the interior surface of the coverall and each of the sleeves, and the outer face of the protective fabric forms the exterior surface of the coverall and each of the sleeves.

[0030] The term resilient as used herein has the common meaning of a material that will spring back or recoil to its original shape after extended or stretched. A resilient cuff is one that can be extended or stretched and will endeavor to spring back to its original relaxed state.

[0031] The resilient cuff of the protective coverall further has a cuff interior surface configured for facing the person, and a cuff exterior surface. The resilient cuff further comprises a fold of the protective fabric, which provides two plies of coverall material which hold the plurality of spaced-apart continuous elastic threads or strands therebetween. The protective fabric is folded such that the outer face of the protective fabric is folded upon itself, which forms first and second fold layers, and the outer face of the protective fabric in contact with the plurality of spaced-apart continuous circumferential elastic threads or strands. The inner face of the protective fabric therefore forms both the cuff interior surface and the cuff exterior surface. The fold becomes the distal end of each resilient cuff, with the proximate end of the resilient cuff being attached to its associated sleeve. The antistatic cuff interior surface can therefore be attached to the antistatic inner surface of the sleeve and extend the antistatic performance of the interior surface of the coverall through the sleeve to the entire outer surface of the cuff.

[0032] The use of a plurality of spaced-apart continuous circumferential elastic threads creates a cuff using less material than in conventional knit cuffs and avoid the use of a wide fabric strip of elastic material, thereby generating less waste when disposing of the coverall.

[0033] Typically, ESD protective coveralls are typically worn with ESD components, for example ESD gloves and ESD boots. The inventive resilient cuff is again superior in providing continuous ESD contact between such ESD components, as the area for ESD contact is now increased and provides a better route for continuous electrostatic charge transfer from the coverall to the component (e.g., boot, glove, etc.), by improving continuity of ESD transfer from to the antistatic treated interior surface of coverall to the component's dissipating surface (typically the soles or under the soles of the wearer's ESD footwear).

[0034] The multiple parallel elastic threads or strands in the resilient cuff also create multiple parallel challenges to ingress of particles and liquids, as each elastic thread or strand in the cuff provides a separate contact between the resilient cuff and the wearer. The inventive cuff also provides for a more comfortable fit, as the elastic force retracting or closing the cuff to the person is spread over a wider area versus a single narrow strip of a woven elastic material. It is believed the increased area of contact provides a resilient cuff that is less likely to slide, roll, or move than conventional cuffs.

[0035] Additionally, the use of a resilient cuff made primarily from the coverall protective fabric instead of a second material, as is typical, is believed to simplify the recycling process; the use of only a few elastic threads or strands reduces the added mass of elastic as compared to strips of woven elastic fabric as is typically used.

[0036] The use of the coverall fabric ensures the resilient cuff provides the same chemical or biological protection as the coverall itself, which may not be the possible if a second elastic fabric is used for the cuff.

[0037] This invention relates to a protective coverall comprising a protective fabric, the protective fabric comprising an outer face and an inner face, wherein the inner face has an antistatic treatment. The protective coverall has a plurality of sleeves, each sleeve ending in a resilient cuff, wherein the inner face of the protective fabric forms the interior surface of the coverall and each of the sleeves, configured for facing the person; and the outer face of the protective fabric forms the exterior surface of the coverall and each of the sleeves, which faces the environment. Each resilient cuff further has a cuff interior surface configured for facing the person, and a cuff exterior surface. Each resilient cuff further comprises a fold of the protective fabric, with the outer face of the protective fabric being folded upon itself to form first and second fold layers, with the distal end of each resilient cuff being the fold. A plurality of continuous circumferential elastic threads or strands is held between the first and second fold layers, in contact with the outer face of the protective fabric, and the inner face of the protective fabric forms both the cuff interior surface and the cuff exterior surface. Elastic thread or elastic strand are used interchangeably herein and mean an individual continuous elastic filament, an elastic yarn, or a coalesced grouping of continuous elastic filaments.

[0038] FIGS. 1a & 1b are front and back illustrations, respectively, of a protective coverall having a plurality of sleeves, each sleeve ending in a resilient cuff. This embodiment further includes a resilient waistband encircling the waist. The coverall 10 has two arm sleeves 11 having resilient cuffs 12 and two pants sleeves 14 having resilient cuffs 15, and is also provided with a hood, which is considered herein to be a hood sleeve 16 as this is simply an additional sleeve for the head of the wearer. The hood sleeve is configured for receiving the head of a person when the person wears the protective coverall, with said hood sleeve ending in a resilient cuff 17, which can be sized to fit a respirator worn by the person. This version of the coverall also has a resilient waistband 18 encircling the waist. The coverall is further provided with a visible flap 19 of protective apparel fabric covering a vertical fastener (not shown) on the front of the coverall.

[0039] FIG. 2 is an illustration of a perspective view of the resilient cuff fabric 20 construction. This is a view of the extended cuff fabric, as if the cuff fabric with elastic threads was stretched or extended under tension. The cuff has fold 21 of the protective fabric, with the lighter-colored outer face of the protective fabric being folded upon itself to form first 22 and second 23 fold layers, with a plurality of continuous circumferential elastic threads 24 being held between the fold layers, with the darker-colored inner face of the protective fabric forming both the cuff interior surface and the cuff exterior surface. The darker color is used herein for inner face of the protective fabric to illustrate that it is the side that has antistatic treatment; this is not to imply any particular required color or shade. In typical use, the fold 21 forms the distal end 26 of the resilient cuff (the actual terminating edge of the cuff), while the free ends of the first and second fold layers provide the proximate end 25 of the resilient cuff; those first and second fold layer ends are then sewn or otherwise attached preferably to a sleeve of the coverall. Also shown are a plurality of transverse weld lines 27 that are transverse to the parallel array of elastic threads. In some embodiments, the resilient cuff has a proximate end at the sleeve and a distal end, and wherein the resilient cuff has a length, from the distal end to the proximate end, of 1 to 5 inches.

[0040] FIG. 3 is an illustration of a top view of the resilient cuff fabric 20 showing the protective fabric being folded upon itself to form the distal end 26 of the resilient cuff and the proximate end 25 of the resilient cuff with its the free ends 31 of the first and second fold layers. This again is a view of the extended cuff fabric, as if the cuff fabric with elastic threads was stretched or extended under tension. The plurality of continuous circumferential elastic threads 24 are held between the fold layers, the continuous circumferential elastic threads present in a parallel array 32 and held by transverse weld lines 27 that are weld points or lines that are generally parallel to each other, and also generally orthogonal to the parallel array of spaced-apart elastic threads. As used herein, spaced-apart means the individual threads or strands are preferably not elastically connected to one another; in other words, a woven strip of elastic is not considered to comprise an array of spaced-apart threads as there are weft or fill yarns elastically connecting any array of warp yarns. The weld points need not be strictly orthogonal but should simply traverse across the array of elastic threads in some manner. For example, the weld points or lines can be curved as shown in FIG. 3, with the general nature of the curve being across the parallel array of elastic threads.

[0041] The resilient cuff is made by joining the array ends of the resilient cuff fabric together to form a circular structure that will encircle a limb of the body, such as a wrist or ankle, etc., or some other structure such as an accessory. In this fashion the parallel array can expand and form a cylinder-like circumferential resilient seal to the limb of the body or other structure, with the parallel array of elastic threads being present in the cylindrical wall of the resilient cuff. Each individual thread, therefore, provides a new circular contact with the encircled limb or accessory, providing multiple barriers of ingress.

[0042] In some embodiments, the plurality of continuous circumferential elastic threads is present in the resilient cuff as a parallel array spaced-apart elastic threads; and in some preferred embodiments the resilient cuff contains a parallel array of 4 to 15 circumferential threads spaced apart from each other a distance of 0.125 to 1.0 inches. Further, as shown in FIGS. 3 & 4a/4b, in one embodiment the resilient cuff comprises, from the distal end to the proximate end, a fold area 35, a parallel array of spaced-apart elastic threads area 36, and a seam allowance area 37. The seam allowance area can be used to attach the cuff to the coverall or the sleeve. The presence of the fold in the fold area assures the electrical conductivity (the ESD performance) of the cuff continues from the interior cuff surface to the exterior cuff surface.

[0043] In some embodiments, the plurality of continuous circumferential elastic threads is held between the first and second fold layers by adhesive or by ultrasonic welds. Preferably, the plurality of continuous circumferential elastic threads is present in a parallel array and the threads are held between the first and second fold layers by weld lines that are transverse to the parallel array, such described herein for FIG. 3, the weld lines being made by lines of adhesive or ultrasonic weld lines. In some embodiments, the weld lines are essentially continuous. For example, when ultrasonic welding is used, the plurality of continuous circumferential elastic threads present in a parallel array can be welded to both layers of protective fabric, and also the two layers of protective fabric can be welded together between each of the continuous circumferential elastic thread. In some embodiments, however, particularly when adhesive is used, the weld lines of adhesive do not have to be continuous; the adhesive only needs to be present at each continuous circumferential elastic thread in the parallel array to hold each thread in place. The two layers of protective fabric are not necessarily required to be fully welded to each other between each of the continuous circumferential elastic threads.

[0044] FIGS. 4a & 4b are illustrations of idealized cross sections of the extended resilient cuff fabric 20, showing the parallel array of the plurality of continuous circumferential elastic threads 24. FIG. 4a illustrates the unbonded areas in the resilient cuff between weld lines and FIG. 4b illustrates the bonded areas caused by those transverse weld lines. An extreme compression of the elastic threads is shown in FIG. 4b simply for illustration that the fold layers and elastic threads are bonded together. Some compression would be normal if the welding was done by an ultrasonic anvil, which would compress the fold layers and the elastic threads during bonding; if an adhesive is used for the weld lines, then any compression would be less.

[0045] FIG. 5 illustrates, in an idealized manner, the principle of providing a resilient cuff that extends the conductive path from the inside of a coverall sleeve 50 to the outside of the cuff 51. The resilient cuff 51 comprises a fold 52 of the protective fabric is shown, in this instance fold layers 53 are separated to show the darker conductive inner face 54 of the protective fabric forming both the interior cuff surface 56 and the exterior cuff surface 57, and the darker conductive inner face of the cuff further being in direct contact with the darker conductive inner face 55 of the sleeve fabric. The connection point or seam 58 between the inside of the coverall sleeve 50 to the outside of the cuff 51 shown circled is detailed in FIG. 6.

[0046] FIG. 6 is a detail illustration of one type of sewn seam 60 between the resilient cuff fabric 61 and the sleeve fabric 62, which can be used to attach the inner face 63 of resilient cuff fabric 61 in direct contact with the inner face 64 of the sleeve fabric 62.

[0047] FIGS. 7a & 7b are front and back illustrations, respectively, of a protective coverall 70 wherein the back side of the coverall further comprises an accessory sleeve comprising a resilient cuff 71 for receiving an accessory 72 worn by a person wearing the coverall. In this figure, the accessory 72 is a waist-mounted powered air purifying respirator (PAPR) with exterior connection port 73.

[0048] FIGS. 8a & 8b are back and side illustrations, respectively, of a hood sleeve 81 of a coverall, wherein the hood sleeve comprises two resilient cuffs, a first resilient cuff 82 for receiving a full-face respirator accessory 83 worn on the front of the head or the face; and in this embodiment the hood sleeve 81 further comprises a second resilient cuff 84 for at the back of the hood sleeve for receiving an accessory worn by the a person when the person wears the protective coverall, with said accessory sleeve ending in the resilient cuff. In the version of the coverall shown in FIG. 8b, the accessory sleeve is used receiving an accessory 85 for supporting the respirator worn by a person wearing the coverall. In this specific figure, the respirator is a powered air purifying respirator (PAPR), with air filter accessory 85 of that PAPR mounted on the back of the neck of the coverall wearer. Both a fixed component (mounted to a helmet or headset) and a hose passthrough, amongst other options, are possible. The component 85 shown in FIG. 8b is a head mounted filter, and the PAPR motor is inside the hood with air flow channels wrapping around the head. This interface could be customized, or additional sleeves having resilient cuffs added as necessary to support the function of a particular accessory.

[0049] FIGS. 1a & 1b and FIGS. 9a & 9b are front and back illustrations, respectively, of embodiments of a protective coverall having a plurality of sleeves, each sleeve ending in a resilient cuff, and a resilient waistband. FIGS. 1a & 1b illustrate a resilient waistband 18 encircling the waist. As shown, the coverall has a front vertical enclosure, which is preferably a zippered enclosure with a covering flap protecting the zipper stringers, a zipper stringer being the combination of the teeth and tape (or cloth) that forms each side of the zipper. In this embodiment, preferably the elastic waistband starts at one side of the front enclosure, generally starting at one zipper stringer, and continues around the circumference of the waist area of the coverall, ending at the opposing zipper stringer. FIGS. 9a & 9b illustrate a resilient waistband only across the back of the coverall from hip-to-hip. In this embodiment, the elastic waistband starts at one side of the coverall, in the hip area, and continues across the back of the coverall in the waist area of the coverall, ending in the hip area of the other side of the coverall.

[0050] The resilient waistband can be made the same way as the resilient cuff; that is, comprising a fold of the protective fabric, with the outer face of the protective fabric being folded upon itself to form first and second fold layers, and the plurality of continuous circumferential elastic threads being held between the first and second fold layers, the continuous circumferential elastic threads only in contact with the outer face of the protective fabric, and the inner face of the protective fabric forming both the waistband interior surface and the waistband exterior surface. The waistband made with the fold of protective fabric can then be attached or sewn in the coverall in a manner such as done with the cuff, such that the waistband exterior surface faces the environment, and the waistband interior surface faces the person, meaning the antistatic-treated inner face of the second interior layer of protective fabric faces the person. Since the fold is present in this embodiment, the fold functions as a second seam allowance area. The waistband is attached or seamed to the coverall to provide ESD or antistatic continuity across the waistband in a similar manner to that described for attaching the resilient cuff to the coverall sleeve; that is, the waistband is attached to the coverall fabric of the upper and lower portions of the body portion on either side of the waistband, such that the antistatic-treated inner face of those coverall fabrics is in contact with the inner face of the waistband interior surface.

[0051] In a preferred embodiment for a waistband, however, the exterior surface of the waistband is the outer face of the protective fabric for aesthetic reasons to match the look of the coverall. Therefore, no fold of protective fabric is used to make the waistband. The plurality of continuous circumferential elastic threads can be held in place as before between two layers of protective fabric, wherein each layer of the protective fabric comprises an outer face and an inner face, with the inner face having an antistatic treatment; wherein the waistband has a first exterior layer of protective fabric and a second interior layer of protective fabric. In this waistband, the continuous circumferential elastic threads are only in contact with the inner face of the first exterior layer of protective fabric and the outer face of the second interior layer of protective fabric. The waistband is sewn into the coverall such that the outer face of the first exterior layer of protective fabric faces the environment, and the inner face of the second interior layer of protective fabric of the waistband faces the person, meaning the antistatic-treated inner face of the second interior layer of protective fabric faces the person. This provides an exterior face of the waistband that is the same as the exterior surface of the coverall, and an interior face of the waistband that is the same as the interior surface of the coverall.

[0052] The waistband is attached or seamed in the coverall to provide ESD or antistatic continuity across the waistband in a similar manner as described for attaching the resilient cuff to the coverall sleeve; that is, the waistband is attached to the coverall fabric on either side of the waistband such that the antistatic-treated inner faces of those coverall fabrics are in contact with the inner face of the second interior layer of protective fabric of the waistband.

[0053] In some embodiments, the protective coverall comprises a waistband comprising a parallel waist array of a plurality of spaced-apart elastic threads, wherein the spaced-apart elastic threads are oriented circumferential to the waist, and wherein the parallel waist array contains 4 to 15 circumferential threads spaced apart a distance of 0.125 to 1.0 inches. The waistband can have a width of 1 to 5 inches, that width comprising a first seam allowance area, a parallel waist array of spaced-apart elastic threads area, and a second seam allowance area. Preferably, the parallel waist array of spaced-apart elastic threads area comprises the parallel waist array of continuous circumferential elastic threads held between two layers of protective fabric by weld lines that are transverse to the parallel waist array, the weld lines being made by lines of adhesive or ultrasonic weld lines, as previously described for the resilient cuff.

[0054] In another embodiment, the protective coverall comprises a protective fabric, the protective fabric comprising an outer face and an inner face, wherein the inner face has an antistatic treatment, and the protective coverall has a body portion configured for covering at least a portion of a torso of a person when the protective coverall is worn by the person. The body portion has at least one torso opening configured for donning the protective coverall and a neck opening configured for receiving a head and neck of the person. The body portion further has a plurality of openings; the plurality of openings including a first opening ending in a first arm sleeve configured for receiving a portion of a right arm of the person when the person wears the protective coverall, and a second opening ending in a second arm sleeve configured for receiving a portion of a left arm of the person when the person wears the protective coverall, with each of the first and second arm sleeves further having an opening configured for receiving a wrist and hand of the person. Each arm sleeve has a proximate end at the body portion and a distal end at the opening configured for receiving a wrist and hand. The plurality of openings further includes a third opening ending in a first leg sleeve configured for receiving a portion of a right leg of the person when the person wears the protective coverall, and a fourth opening ending in a second leg sleeve configured for receiving a portion of a left leg of the person when the person wears the protective coverall. Each of the first and second leg sleeves further has an opening configured for receiving an ankle and foot of the person, with each leg sleeve having a proximate end at the body portion and a distal end at the opening configured for receiving an ankle and foot. The body portion, each of the arm sleeves, and each of the leg sleeves have an interior surface configured for facing the person when the person wears the protective coverall, and an exterior surface. The inner face of the protective fabric forms said interior surface of the body portion, each of the arm sleeves, and each of the leg sleeves, and the outer face of the protective fabric forms the exterior surface of the body portion, each of the arm sleeves, and each of the leg sleeves. The distal end of each arm sleeve and each leg sleeve comprises a resilient cuff made from the protective fabric and a plurality of continuous circumferential elastic threads, said resilient cuff having a proximate end and a distal end, with the proximate end of each cuff attached to the distal end of each respective arm sleeve and leg sleeve. Each resilient cuff further has a cuff interior surface configured for facing the person, and a cuff exterior surface. Each resilient cuff comprises a fold of the protective fabric, with the outer face of the protective fabric being folded upon itself to form first and second fold layers, with the distal end of each resilient cuff being the fold. The plurality of continuous circumferential elastic threads is held between the first and second fold layers, in contact with the outer face of the protective fabric, and the inner face of the protective fabric forms both the cuff interior surface and the cuff exterior surface.

[0055] The resilient cuff of the protective coverall can have a length, from the distal end to the proximate end, of 1 to 5 inches. Additionally, the plurality of continuous circumferential elastic threads can be present in the resilient cuff of the protective coverall as a parallel array spaced-apart elastic threads. Specifically, the resilient cuff can contain a parallel array of 4 to 15 circumferential threads spaced apart a distance of 0.125 to 1.0 inches.

[0056] Preferably, the resilient cuff of the protective coverall comprises, from the distal end to the proximate end, a fold area, a parallel array of spaced-apart elastic threads area, and a seam allowance area. The seam allowance area can be used to attach the cuff to the coverall or the sleeve. The presence of the fold in the fold area assures the electrical conductivity (the ESD performance) of the cuff continues from the cuff interior surface to the cuff exterior surface.

[0057] In the resilient cuff, the plurality of continuous circumferential elastic threads can be held in place between the first and second fold layers by adhesive or by ultrasonic welds. In particular, the plurality of continuous circumferential elastic threads can be positioned in a parallel array with the threads held in place between the first and second fold layers by lines of adhesive or ultrasonic weld lines that are generally transverse to the parallel array.

[0058] The body portion of the protective coverall can further comprise a hood opening ending in a hood sleeve configured for receiving the head of a person when the person wears the protective coverall, the hood sleeve further having an opening configured for access to a person's face, with the hood sleeve having a proximate end at the body portion and a distal end at the opening configured for access to a person's face, wherein the distal end of the hood sleeve also comprises said resilient cuff.

[0059] The body portion of the protective coverall can also comprise an opening ending in an accessory sleeve for receiving an accessory worn by the a person when the person wears the protective coverall, the accessory sleeve further having an opening configured for some portion of the accessory, with the accessory sleeve having a proximate end at the body portion and a distal end at the opening configured for access to the accessory, wherein the distal end of the accessory sleeve also comprises said resilient cuff.

[0060] The protective coverall can further comprise a waistband as previously described, specifically a waistband comprising a parallel waist array of a plurality of spaced-apart elastic threads, wherein the spaced-apart elastic threads are oriented circumferential to the waist. The parallel waist array can contain 4 to 15 circumferential elastic threads spaced apart a distance of 0.125 to 1.0 inches.

[0061] The waistband can further have a width of 1 to 5 inches and can comprise a first seam allowance area, a parallel waist array of spaced-apart elastic threads area, and a second seam allowance area. Preferably, the parallel waist array of spaced-apart elastic threads area comprises the parallel waist array of continuous circumferential elastic threads held between two layers of protective fabric by weld lines that are transverse to the parallel waist array, the weld lines being made by lines of adhesive or ultrasonic weld lines.

[0062] The resilient cuff can preferably be made by adhering or heat welding the plurality of continuous circumferential elastic threads to the two layers of protective fabric or the two fold layers of protective fabric while the elastic threads are held under tension. While this can be accomplished using adhesives, preferred methods include the application of heat or energy to tack bond the threads to the protective fabric, and a preferred method is the use of ultrasonic bonding. This can be achieved using an apparatus such as disclosed in U.S. Pat. Nos. 10,889,066 or 11,254,066 to Begrow, et al. or other ultrasonic bonding machines available in the art.

[0063] The continuous elastic threads can be filaments of an elastomeric material, the elastomeric material preferably having the ability to return to its original length rapidly after repeated stretching, even to at least twice its original length. Preferred elastic threads include polyurethane based yarns such as spandex or elastane; however, any fiber generally having stretch and recovery can be used. Suitable well-known elastomeric yarns also include the products sold under the tradenames Creora, Dorlastan, Lycra, and other brand names.

[0064] The preferred continuous elastic thread is spandex elastomeric filament(s). As used herein, spandex (or elastane, used interchangeably herein) has its usual definition, that is, a manufactured fiber in which the fiber-forming substance is a long chain synthetic polymer composed of at least 85% by weight of a segmented polyurethane. Among the segmented polyurethanes of the spandex type are those described in, for example, U.S. Pat. Nos. 2,929,801; 2,929,802; 2,929,803; 2,929,804; 2,953,839; 2,957,852; 2,962,470; 2,999,839; and 3,009,901.

[0065] In some processes for making spandex elastomeric filaments, coalescing jets are used to consolidate the spandex filaments immediately after extrusion. It is also well known that dry-spun spandex filaments are tacky immediately after extrusion. The combination of bringing a group of such tacky filaments together and using a coalescing jet will produce a coalesced multifilament yarn, which is then typically coated with a silicone or other finish before winding to prevent sticking on the package. Such a coalesced grouping of filaments, which is actually a number of tiny individual filaments adhering to one another along their length, is superior in many respects to a single filament of spandex of the same linear density.

[0066] Each continuous elastic thread or strand is preferably a continuous filament and can be present in the form of one or more individual filaments or one or more coalesced grouping of filaments. However, it is preferred to use only one coalesced grouping of filaments for each continuous elastic thread. Whether present as one or more individual filaments or one or more coalesced groupings of filaments, the overall linear density of the continuous elastic thread in the relaxed state is generally between 200 and 1200 dtex with the preferred linear density range being 600 to 900 dtex.

[0067] In some embodiments the protective coverall is a single-use garment, that is, it is used only once and then disposed of or responsibly recycled. In some embodiments the protective coverall is a limited-use garment that is used, decontaminated, and re-used for a limited number of times; for example, 2 to 5 times.

[0068] The protective coverall can preferably be made from a protective apparel fabric. The term protective apparel fabric is meant to include a wide variety of protective garment fabrics, barrier fabrics, laminates, and films, including microporous films. The term protective apparel fabric also includes nonwoven and/or woven fabrics and laminates of such materials with films or multilayer films. In some embodiments, the protective fabric comprises a chemically-resistant outer layer. In some preferred embodiments the protective apparel fabric, and therefore the coverall material, is a multilayer-film-and-nonwoven laminate. In some embodiments the overall material is a nonwoven that resists penetration by liquids and/or particulates, such as a nonwoven like DuPont Tyvek spunbonded polyethylene, or other types of nonwovens, like polyester or polypropylene, etc., spunbonded and melt-blown sheets and laminates, and other nonwoven constructions, including coated and film-laminated versions. In some embodiments the protective fabric is flame resistant or provided with a flame retardant; in some embodiments the protective fabric is flame resistant or provided with a flame retardant in addition to providing particulate, liquid, and/or chemical-or bio-challenge protection. One preferred protective coverall fabric is Dupont Tychem 2000 fabrics, which feature a coated Tyvek fabric. These fabrics provide barrier protection against a wide range of inorganic chemical and biological hazards yet are lightweight and comfortable. Other useful fabrics can include other film-laminated Tyvek fabric styles from DuPont, including styles such as Tyvek 800, Tychem 2000, Tychem 2000SFR, Tychem 4000, Tychem 5000, Tychem 6000, Tychem 6000 SFR. In addition, other useful protective coverall fabrics that protect against a wide variety of threats can be used and include but are not limited to those generally disclosed in U.S. Pat. No. 5,626,947 (Hauer et al.); U.S. Pat. No. 4,855,178 (Langley); U.S. Pat. No. 4,272,851 (Goldstein); U.S. Pat. No. 4,772,510 (McClure); U.S. Pat. No. 5,035,941 (Blackburn); U.S. Pat. No. 4,214,321 (Nuwayser); U.S. Pat. No. 4,920,575 (Bartasis); U.S. Pat. No. 5,162,148 (Boye); and U.S. Pat. No. 4,833,010 (Langley).