Protective garment and method for manufacturing such a protective garment

Abstract

The present invention relates to a protective garment 10; 10A; 10B, in particular for motorcyclists, at least partially made with a material resistant to abrasion, comprising at least one accordion stretch insert 18; 18A; 18B, wherein said at least one accordion stretch insert 18; 18A; 18B comprises at least one outer layer 20, made of an abrasion-resistant material, and at least one inner layer 22, made of a stretchable material. According to the invention, the protective garment 10; 10A; 10B comprises a cover layer 26; 26A; 26B applied over said at least one accordion stretch insert 18; 18A; 18B, thereby covering the least one accordion stretch insert 18; 18A; 18B. Moreover the invention relates to a method for manufacturing such a protective garment 10; 10A; 10B.

Description

[0001] PROTECTIVE GARMENT AND METHOD FOR MANUFACTURING SUCH A PROTECTIVE GARMENT

[0002] ★ ★★★★

[0003] The present invention relates to a protective garment. In particular, the present invention refers, even if in a non-exclusive way, to a protective garment for motorcyclists. More preferably, the present invention refers to a protective suit for motorcyclists, namely a garment wherein a pair of trousers is inseparably joined to a body-piece.

[0004] However, as it will be clear from the following description, the teachings of the present patent application might also be applied to different types of protective garments, like for example jackets, vests and trousers.

[0005] Moreover, the present invention refers to a method for manufacturing such a protective garment.

[0006] The protective garments used by motorcyclists need, from one side, to offer to the body of the user an adequate protection against abrasion and, on the other side, to be sufficiently comfortable so as not to hinder the movements of the user, especially when the latter is sitting on the saddle of the motorcycle.

[0007] Generally, these protective garments are mainly made of leather which is a material that assures an optimum protection against abrasion. However, the leather is not sufficiently elastic.

[0008] Consequently, it is known to insert elasticized parts in the protective garment not to hinder the user’s movements when he assumes a driving position or he is in an erect position so as to make the garment more comfortable. Moreover, thanks to the provision of the elasticized parts, the garment can fit adherent to the user’s body so as to obtain better aerodynamics.

[0009] Furthermore, the protective garments are usually provided with a plurality of rigid or semi-rigid protections applied at the outer surface of the garment. Thanks to the elasticized parts, such protections offer an improved protection since they are able to better adhere to the user’s body.

[0010] Generally, a protective suit designed for motorcyclists is provided with a plurality of elastic inserts.

[0011] A first kind of elastic insert is generally applied along the inner side of each sleeve, at the groin portion and at the rear lower part of each leg portion.

[0012] These inserts are generally formed by a single layer of elastic fabric. The fabric is usually based on aramid fibers, like Kevlar®, or on a combination of polyesters and elastane fibers.

[0013] A second kind of elastic insert is usually applied at the lower back portion, along the sides of the trunk and above the knees.

[0014] These elastic inserts are manufactured by using a technique which is well- known in the art, namely by superimposing and joining a layer of thin elastic fabric to a layer of leather. A series of closely arranged transverse seams are applied to the assembly formed by the elastic fabric and the leather when the layer of elastic fabric is fully tensioned with the result that a plurality of folds is created when the layer of elastic fabric is released to return to its rest condition.

[0015] Advantageously, these inserts are identified in the technical jargon as “accordion leather stretch inserts” and are able to offer high abrasion resistance combined with a high level of elasticity. Even if the single-layer elastic inserts and the accordion stretch leather inserts are widely used in protective garments designed for motorcyclists, both inserts have some drawbacks.

[0016] With first reference to the single-layer elastic inserts, these inserts have undoubtedly the advantage that, being formed by a single material, do not interrupt the continuity of the leather structure of the garment.

[0017] In this way the portion of the suit wherein they are applied can have a smooth appearance which offers a pleasant aesthetic and an optimal aerodynamics.

[0018] To the contrary, these elastic inserts are not able to match the abrasion resistance offered by the leather. Therefore, these inserts are generally applied in zones having a low risk of damages.

[0019] As a matter of fact, to improve the abrasion resistance of the fabric forming such inserts, the composition of the fabric needs to be varied to obtain a higher melting point, but in this way the elasticity of the insert is affected.

[0020] Consequently, the elastic inserts formed by a single layer are the result of a compromise between two conflicting factors: elasticity and abrasion resistance.

[0021] The accordion stretch leather inserts in turn offer a high degree of elasticity and a high abrasion resistance.

[0022] Due to a provision of a leather layer, the accordion stretch leather inserts permit to obtain a garment having an outer surface which assures the same level of protection in the elastic zones and in the non-elastic zones.

[0023] However, the accordion stretch leather inserts have a corrugated outer surface and thus they represent a discontinuity in the structure of the garment.

[0024] This occurrence affects the aesthetic of the garment and, more important, the aerodynamics thereof.

[0025] As a matter of fact, the presence of such a discontinuity creates turbulence and thus causes an undesirable increase in aerodynamic drag.

[0026] Moreover, the accordion stretch leather inserts are manufactured by using a large amount of leather and consequently they are costly.

[0027] However, the provision of accordion stretch insert made with a different material, even if possible, would inevitably affect the aesthetics of the garment, creating a further discontinuity in the structure of the garment, the main part of which needs to be made with leather or leather like material.

[0028] Furthermore, the printing of logos and designs onto the accordion stretch insert is a critical process due to the fact that the outer surface is corrugated.

[0029] A further possible alternative to accordion stretch leather inserts is disclosed in the PCT patent application published as WO2022 / 243859 in the name of the same applicant.

[0030] Such a solution envisages the use of a base stretch fabric layer which is at least partially covered by an abrasion resistant coating layer. In particular, the abrasion resistant coating layer permanently adheres to the base stretch fabric layer.

[0031] This solution is greatly appreciated since it permits to simplify the structure of the suit and to obtain a garment which perfectly fits on the user’s body, with evident advantages in terms of comfort and aerodynamics.

[0032] However, even if the elastic inserts according to WO2022 / 243859 offer an optimum elasticity and a high abrasion resistance, they do not completely match the elasticity and the abrasion resistance of the accordion stretch leather inserts.

[0033] As a matter of fact, also in this case, as previously mentioned, the elasticity and the abrasion resistance of the base stretch fabric layer are the result of a compromise between opposite requirements.

[0034] The object of the present invention is thus to provide a protective garment, particularly for motorcyclists, which solves at least partly the above mentioned problems and drawbacks.

[0035] In particular, an aim of the present invention is to provide a protective garment, particularly for motorcyclists, having an improved aerodynamics without affecting the abrasion resistance of the garment.

[0036] Moreover, an aim of the present invention is to provide a protective garment, particularly for motorcyclists, having uniform performances.

[0037] Furthermore, an aim of the present invention is to provide a protective garment, particularly for motorcyclists, having a more pleasant aesthetics without involving high costs.

[0038] Lastly, an aim of the present invention is to provide a method for manufacturing such a protective garment.

[0039] These and other objects and aims are achieved by the protective garment according to claim 1 and by the method according to claim 11 .

[0040] The advantages and the characteristic features of the invention will appear more clearly from the following description of preferred, but not exclusive, embodiments of the protective garment with reference to the accompanying figures in which: - figures 1 -3 show respectively a front view, a side view and a rear view of a protective garment according to the present invention;

[0041] - figures 4-6 correspond to figures 1 -3 wherein, for sake of clarity, the cover layers applied on the accordion stretch inserts of the protective garment have been omitted;

[0042] - figure 7 shows a front view of a further protective garment according to the present invention;

[0043] - figure 8 corresponds to figure 7 wherein, for sake of clarity, the cover layers applied on the accordion stretch inserts of the protective garment have been omitted;

[0044] - figure 9 shows a perspective view of an additional protective garment according to the present invention;

[0045] - figure 10 corresponds to figure 9 wherein, for sake of clarity, the cover layers applied on the accordion stretch inserts of the protective garment have been omitted;

[0046] - figure 11 shows a simplified perspective view of an accordion stretch insert of the protective garment of the present invention; the accordion stretch insert being in a rest condition;

[0047] - figure 12 shows the accordion stretch insert of figure 11 in a tensioned condition;

[0048] - figure 13 is similar to figure 11 wherein a cover layer has been applied over the accordion stretch insert;

[0049] - figure 14 shows the assembly formed by the cover layer and the accordion stretch insert of figure 13 in a tensioned condition;

[0050] - figure 15 shows a simplified cross-section view taken along the plane XV- XV of figure 14;

[0051] - figure 16 shows a simplified cross-section view taken along the plane XVI-

[0052] XVI of figure 3;

[0053] - figure 17 corresponds to figure 16, wherein the assembly formed by the cover layer and the accordion stretch insert is in a tensioned condition;

[0054] - figure 18 is similar to figure 16, but it refers to a different embodiment;

[0055] - figure 19 corresponds to figure 18, wherein the cover layer and the accordion stretch inserts are in a tensioned condition.

[0056] With reference to figures 1 -6, an example of a protective garment according to the invention is indicated as a whole by the reference 10. The protective garment 10 is suitable for being used in particular by motorcyclists.

[0057] In figures 1 -6 a one-piece suit 10 is shown. However, a protective garment according to the present invention can also be manufactured as a jacket 10A (see figures 7-8) or a vest.

[0058] Alternatively, the protective garment may consist of a body-piece removably joined to a pair of trousers.

[0059] The protective garment can also consist of a pair of trousers 10B (see figures 9-10).

[0060] Advantageously, the protective garment 10 may comprise an inflatable protection device designed to offer an additional protection to the user.

[0061] The protective garment 10, 10A, 10B is at least partially made with a material resistant to abrasion.

[0062] For example, the protective garment 10, 10A, 10B can be at least partially made of leather or leather-like material.

[0063] Alternatively, the protective garment 10, 10A, 10B can be at least partially made with a woven or knitted abrasion resistant fabric obtained from threads made of polymeric material, like for example polyester or polyamide fibers.

[0064] As shown in figures 1 -8, the protective garment 10, 10A can comprise rigid impact protections 14, 14A applied on an outer surface of the garment 10, 10A.

[0065] The rigid impact protections 14, 14A are generally positioned in parts of the protective garment 10, 10A that have a high risk of damage, as caused e.g. by impact, abrasion and tearing.

[0066] In the protective garment of figures 1 -6, the rigid impact protections 14 are positioned at portions of the protective garment 10 designed to be superimposed over the shoulders, elbows, knees and front lower limbs of the user. Obviously, different and / or further arrangements of the rigid impact protections 14 are possible in order to meet other specific needs. For example, a rigid impact protection can be positioned in only one of the above mentioned portions of the protective garment 10.

[0067] In the protective garment 10B of figures 9-10 the impact protections 14B are applied internally at a zone of the garment 10B designed to be superimposed over the knee of the user.

[0068] The protective garment 10, 10A can also comprise stretch inserts 16, 16A formed by a single layer of elastic material.

[0069] As shown in figures 1 -8, the stretch inserts 16, 16A can be positioned along the inner side of each sleeve, from the wrist up to the armpit, wherein as inner side of the sleeve it is indicated the portion of the sleeve closer to the user’s body, when the user extends his arms along the sides. Additional stretch inserts 16 can be positioned at the groin portion and / or at the rear lower limb portion of the protective garment 10.

[0070] The stretch inserts 16 are generally inserted in parts of the protective garment 10 having a low risk of damage.

[0071] Furthermore, as it is clearly shown in figures 4-6, 8, 10, the protective garment 10, 10A, 10B comprises at least one accordion stretch insert 18, 18A, 18B.

[0072] Said accordion stretch insert 18, 18A, 18B comprises at least one outer layer 20, made of an abrasion-resistant material, and at least one inner layer 22, made of a stretchable material (see for example figure 15).

[0073] The inner layer 22 is applied to an inner surface of the outer layer 20, namely to the surface of the layer 20 closer to the user’s body during the use of the protective garment 10, 10A, 10B.

[0074] In other words, the inner layer 22 corresponds to the portion of the accordion stretch insert 18 that, when the garment is in use, i.e. is worn by a user, is near to the body of the user, while the outer layer 20 corresponds to the portion of the accordion stretch insert 18 that, when the garment is in use, is opposite to the inner layer 22.

[0075] As clearly visible in figure 11 , the accordion stretch insert 18 has a corrugated outer surface, namely the outer surface of the accordion stretch insert has a series of alternating peaks and valleys. The height of the peaks decreases when the insert is stretched.

[0076] Preferably, the inner layer 22 is coupled to the outer layer 20 by means of a plurality of seams 24.

[0077] As it is well known in the art, the accordion stretch insert 18, 18A, 18B is manufactured by stretching the stretchable inner layer 22 on a suitable frame and by applying on it the outer layer 20 made of an abrasion resistant material.

[0078] The stretchable inner layer 22 and the outer layer 20 are then coupled to each other by means of the seams 24 which are substantially parallel to each other.

[0079] The stretchable direction of the accordion stretch insert 18 is substantially perpendicular to the direction along which the seams 24 extend.

[0080] By way of example, the stretchable direction of the accordion stretch insert is identified by a double arrow S in figure 6 and in figures 11 -14, 16-19.

[0081] The outer layer 20 of the accordion stretch insert 18, 18A, 18B can be made of leather, imitation leather or fabric materials resistant to abrasion. Preferably, the outer layer 20 has a thickness between 0,5 mm and 1 ,5 mm.

[0082] The inner layer 22 of the accordion stretch insert 18, 18A, 18B can be made of an elastic polymeric material. For example, the inner layer 22 can be made of a woven elastic polymeric material. Preferably, such a woven elastic polymeric material can be polyester or polyamide blended with spandex. This material is similar to the material used for manufacturing swimsuits.

[0083] Preferably, the inner layer 22 has a thickness between 0,3 mm and 1 ,0 mm. According to the invention, the protective garment 10, 10A, 10B comprises a cover layer 26, 26A, 26B applied over the at least one accordion stretch insert 18, 18A, 18B, thereby covering the at least one accordion stretch insert 18, 18A, 18B (see for example figures 1 -3, 7, 9 and 13-19). In particular, the cover layer can cover the outer surface of the accordion stretch insert.

[0084] In detail, the cover layer 26, 26A, 26B is designed to hide from view the corrugated outer surface of the accordion stretch insert 18, 18A, 18B of the protective garment 10, 10A, 10B.

[0085] Preferably, in the protective garment 10, 10A, 10B the number of cover layers 26, 26A, 26B corresponds to the number of the accordion stretch inserts 18, 18A, 18B.

[0086] However, in a further embodiment not shown in the enclosed figures, a single cover layer can be applied over two or more accordion stretch inserts.

[0087] As it will appear clearly from the following description, the provision of said cover layer 26, 26A, 26B over the corrugated outer surface of the accordion stretch inserts 18, 18A, 18B of the protective garment 10, 10A, 10B permits to eliminate the discontinuity introduced by the insertion of the accordion stretch inserts 18, 18A, 18B in the structure of the protective garment 10, 10A, 10B.

[0088] In this way, the outer surface of the protective garment remains smooth and continuous, not being longer visible the peaks and valleys of the accordion stretch inserts.

[0089] This results in a protective garment 10, 10A, 10B having an improved aerodynamics and a more pleasant aesthetics.

[0090] Preferably, the cover layer 26, 26A, 26B is made of a stretchable material. Advantageously, the cover layer 26, 26A, 26B can be made of an elastic polymeric material. For example, the cover layer 26, 26A, 26B can be made of a woven elastic polymeric material. Preferably, such a woven elastic polymeric material can be polyester or polyamide blended with spandex. This material is similar to the material used for manufacturing swimsuits.

[0091] Preferably, the cover layer 26, 26A, 26B has a thickness between 0,5 mm and 1 ,1 mm.

[0092] Advantageously, the cover layer 26, 26A, 26B has a modulus of elasticity Ec lower or equal than a modulus of elasticity Es of the stretch accordion insert 18, 18A, 18B over which it is applied.

[0093] In this way, the cover layer 26, 26A, 26B does not hinder the elastic deformation of the accordion stretch insert 18, 18A, 18B during the use of the protective garment, being able at the same time to remain adherent to the underneath accordion stretch insert.

[0094] Preferably, the cover layer 26, 26A, 26B comprises an outer substrate on which a logo, a drawing or an image can be printed by means of a printing process. Said outer substrate can coincide with the outer surface of the cover layer.

[0095] In this way, a logo can be advantageously printed on the outer surface of the cover layer 26, 26A, 26B by means of screen printing, sublimation printing or digital printing.

[0096] Advantageously, even if provided with a logo or similar items, the outer surface of the cover layer can remain smooth.

[0097] Preferably, the cover layer 26, 26A, 26B is directly coupled to the accordion stretch insert 18, 18A, 18B over which it is applied by means of coupling means 28, like a seam or other securing means (see figures 13-15). In this case, the cover layer and the accordion stretch insert form an elastic assembly. As shown in the enclosed figures, the cover layer is preferably coupled to the accordion stretch insert in a tensioned configuration so as to remain adherent to the underlying accordion stretch insert.

[0098] Preferably the coupling means 28 are applied along two perimeter opposite sides of the accordion stretch insert 18, 18A, 18B.

[0099] If the coupling means are in the form of seams, such seams 28 can be arranged parallel to the seams 24 by means of which the outer layer 20 of the accordion stretch insert 18 is coupled to the inner layer 22.

[0100] Consequently, the seams 28 connecting the cover layer 26 to the accordion stretch insert 18 are arranged along a direction substantially perpendicular to the stretchable direction S of the accordion stretch insert 18.

[0101] As it is clearly shown in figures 11 and 13, the cover layer 26 has preferably shape and dimensions corresponding to shape and dimensions of the accordion stretch insert 18 over which it is applied, when the accordion stretch insert 18 is in a rest condition, namely not-tensioned.

[0102] In this way, the cover layer 26 is able to adapt itself to the underneath accordion stretch insert 18, even when the latter is in a tensioned conditioned because subjected to an external force F (see figures 12 and 14), without the risk that folds or wrinkles appear on the outer surface of the cover layer 26. In figures 11 -14, the inner layer 22 of the accordion stretch insert 18 has been omitted for sake of clarity.

[0103] The cover layer 26 can be applied over the accordion stretch insert 18 so that a perimeter outline of the cover layer 26 substantially corresponds to a perimeter outline of the accordion stretch insert 18.

[0104] In some circumstances a free border can be left between the outline of the cover layer and the outline of the accordion stretch insert (see for example figures 13-15).

[0105] As it is shown in figures 16-17, the accordion stretch insert 18 can be fastened at an insertion zone 32 of the protective garment 10 defined between a first edge 34 and a second edge 36. In other words the insertion zone corresponds to an aperture provided in the protective garment, the outline of such an aperture being delimited by the first edge 34 and the second edge 36. The second edge 36 is preferably opposite to the first edge 34.

[0106] Advantageously, thanks to the mutual arrangement between the cover layer 26 and the accordion stretch insert 18, once the accordion stretch insert 18 is fastened at the insertion zone 32, the cover layer 26 is substantially flush with the first edge 34 and the second edge 36.

[0107] As previously mentioned, the insertion zone 32 is usually positioned at zones of the protective garment considered at moderate risk of damage due to impacts, abrasion and tearing.

[0108] Such zones usually correspond to the zones identified as Zone 2 in the EN 17092:2020 standard.

[0109] At the same time, the insertion zone 32 can be positioned at zones of the protective garment considered at high risk of damage, namely the zone identified in the previously mentioned standard as Zone 1 , if the accordion stretch insert and the cover layer are used in combination with an impact protection.

[0110] As shown in figures 16 and 17, the elastic assembly formed by the cover layer 26 and the accordion stretch insert 18 can be fastened to the protective garment 10 by means of a perimeter seam 38 in a similar way as the known accordion stretch inserts are fastened to the protective garments.

[0111] The perimeter seam 38 advantageously joins first and second edges 34, 36 of the insertion zone 32 with corresponding edges of the assembly formed by the cover layer 26 and the accordion stretch insert 18.

[0112] In case the cover layer 26 has dimensions slightly lower than those of the accordion stretch insert 18, the perimeter seam 38 can be arranged so as to only join first and second edges 34, 36 of the insertion zone 32 with corresponding edges of the accordion stretch insert 18.

[0113] The coupling between the cover layer 26 and the accordion stretch insert 18 is in any case guaranteed by the coupling means 28.

[0114] In an alternative embodiment, as shown in figures 18 and 19, the cover layer 26 can be applied over the accordion stretch insert 18 by being directly fastened at the first edge 34 and at the second edge 36 of the insertion zone 32.

[0115] Preferably, the cover layer 26 is fastened at the first edge 34 and at the second edge 36 of the insertion zone 32 by means of coupling means 40.

[0116] In this embodiment, the cover layer 26 is positioned over the accordion stretch insert 18 without being directly connected to the latter.

[0117] In any case, also in this embodiment, due to the reduced thickness of the cover layer and, in case, to its elasticity, the cover layer once is fastened to the first edge and the second edge of the insertion zone 32 is substantially flush with the outer surface of the garment.

[0118] Such an embodiment is useful in the event that the cover layer needs to be replaced with a new one, since the replacement can be made without detaching the accordion stretch insert from the garment.

[0119] As anticipated, the present invention also relates to a method for manufacturing the protective garment 10 previously disclosed.

[0120] The claimed method comprises the following steps:

[0121] - manufacturing at least one accordion stretch insert 18, 18A, 18B by stretching at least one stretchable inner layer 22 on a suitable frame and by applying on it at least one outer layer 20 made of an abrasion resistant material; the at least one inner layer 22 and the at least one outer layer 20 being then coupled to each other by means of a plurality of seams 24 which are preferably parallel to each other;

[0122] - fastening said at least one accordion stretch insert 18A, 18B at an insertion zone 32 of the protective garment 10, 10A, 10B; said insertion zone 32 being defined between a first edge 34 and a second edge 36;

[0123] - pre-tensioning a cover layer 26, 26A, 26B;

[0124] - applying the pre-tensioned cover layer 26, 26A, 26B over said at least one accordion stretch insert 18, 18A, 18B so as to cover said at least one accordion stretch insert 18, 18A, 18B while said at least one accordion stretch insert 18, 18A, 18B is maintained in a rest condition wherein the at least one stretchable inner layer 22 is not tensioned or only minimally tensioned.

[0125] Preferably, the applying step of the pre-tensioned cover layer 26, 26A, 26B over the accordion stretch insert 18, 18A, 18B is carried out before fastening the accordion stretch insert 18, 18A, 18B at the insertion zone 32. In particular, the applying step of the pre-tensioned cover layer 26, 26A, 26B can be carried out by directly fastening the cover layer 26, 26A, 26B to the accordion stretch insert 18, 18A, 18B so as to form an elastic assembly. Preferably, the pre-tensioned cover layer 26 is fastened to the accordion stretch insert 18 around a perimeter outline of the accordion stretch insert. Advantageously, thanks to the pre-tensioning of the cover layer 26, 26A, 26B, the latter does not have folds or wrinkles once it is applied over the accordion stretch insert 18, 18A, 18B. The outer surface of the cover layer 26, 26A, 26B is maintained smooth and thus the assembly formed by the cover layer and the accordion stretch insert will have as a whole a smooth appearance like the portion of the garment to which it is applied.

[0126] At the same time, such a pre-tensioning of the cover layer permits the latter to follow the expansions and the contractions undergone by the accordion stretch insert during the use of the protective garment, without affecting the stretchability of the accordion stretch insert.

[0127] In a further embodiment, the applying step of the pre-tensioned cover layer 26, 26A, 26B over the accordion stretch insert 18, 18A, 18B is carried out after having fastened the accordion stretch insert 18, 18A, 18B at the insertion zone 32.

[0128] In particular, the applying step of the pre-tensioned cover layer 26, 26A, 26B can be carried out by directly fastening the cover layer 26, 26A, 26B at the first edge 34 and at the second edge 36 of the insertion zone 32.

[0129] It is thus clear how the predefined objects may be achieved with the protective garment and the method of the present invention.

[0130] The provision of the cover layers over the accordion stretch inserts results in an improvement of the aerodynamics of the protective garment since the outer corrugated surfaces of the accordion stretch inserts are no longer exposed.

[0131] As a matter of fact, the turbulence which can arise at high speed over the accordion stretch inserts is reduced.

[0132] Even if accordion stretch inserts are applied on the protective garment, the outer surface of the latter does not have any discontinuity, since the cover layers assure a substantial aerodynamic continuity, being substantially flush with the remaining portions of the garment.

[0133] Moreover, the provision of the cover layers assures a more pleasant aesthetics and it offers the possibility to add in a simple way logo, images or drawings in correspondence of the zones of the garment occupied by the accordion stretch inserts.

[0134] Furthermore, the provision of the cover layers does not affect the elasticity and the abrasion resistance of the accordion stretch inserts.

[0135] Moreover, the replacement of the cover layers, in case of an accident or a tearing, is simple and it does not imply the complete replacement of the assembly formed by the cover layer and the accordion stretch insert.

[0136] Lastly, the provision of the cover layers permits the use of accordion stretch inserts having outer layers not necessarily made with leather or leather like materials. For example, it will be possible to use materials having improved breathability, resistance, elasticity, lightness, without being limited in such a use by aerodynamic or aesthetics restrictions, since the structural continuity of the garment is in any case assured by the cover layers.

[0137] With regard to the embodiments of the protective garment and to the method described above, the person skilled in the art may, in order to satisfy specific requirements, make modifications to and / or replace elements described with equivalent elements, without thereby departing from the scope of the accompanying claims.

Claims

Claims1. Protective garment (10; 10A; 10B), in particular for motorcyclists, at least partially made with a material resistant to abrasion, comprising at least one accordion stretch insert (18; 18A; 18B), wherein said at least one accordion stretch insert (18; 18A; 18B) comprises at least one outer layer (20), made of an abrasion-resistant material, and at least one inner layer (22), made of a stretchable material, the protective garment (10; 10A; 10B) being characterized by comprising a cover layer (26; 26A; 26B) applied over said at least one accordion stretch insert (18; 18A; 18B), thereby covering said at least one accordion stretch insert (18; 18A; 18B).

2. Protective garment (10; 10A; 10B) according to claim 1 , characterized in that said cover layer (26; 26A; 26B) is made of a stretchable material.

3. Protective garment (10; 10A; 10B) according to any one of the preceding claims, characterized in that said cover layer (26; 26A; 26B) has a modulus of elasticity (Ec) lower or equal than a modulus of elasticity (Es) of said at least one accordion stretch insert (18; 18A; 18B).

4. Protective garment (10; 10A; 10B) according to any one of the preceding claims, characterized in that said cover layer (26; 26A; 26B) comprises an outer substrate on which a logo, a drawing or an image is printed by means of a printing process.

5. Protective garment (10; 10A; 10B) according to any one of the preceding claims, characterized in that said at least one accordion stretch insert (18; 18A; 18B) is fastened at an insertion zone (32) of the protective garment (10; 10A; 10B) defined between a first edge (34) and a second edge (36);the cover layer (26; 26A; 26B) being substantially flush with the first edge (34) and the second edge (36).

6. Protective garment (10; 10A; 10B) according to any one of the preceding claims, characterized in that the cover layer (26, 26A, 26B) is directly coupled to the accordion stretch insert (18, 18A, 18B) over which it is applied by means of coupling means (28).

7. Protective garment (10; 10A; 10B) according to claim 6, characterized in that said coupling means (28) are applied along two perimeter opposite sides of said at least one accordion stretch insert (18; 18A; 18B).

8. Protective garment (10; 10A; 10B) according to claim 5, characterized in that the cover layer (26; 26A; 26B) is applied over said at least one accordion stretch insert (18; 18A, 18B) by being directly fastened at the first edge (34) and at the second edge (36) of the insertion zone (32).

9. Protective garment (10; 10A; 10B) according to any one of the preceding claims, characterized in that said cover layer (26; 26A; 26B) is applied over said at least one accordion stretch insert (18; 18A; 18B) so that a perimeter outline of the cover layer (26; 26A; 26B) substantially corresponds to a perimeter outline of said accordion stretch insert (18; 18A; 18B).

10. Protective garment (10; 10A; 10B) according to any one of the preceding claims, characterized in that said outer layer (20) of the at least one accordion stretch insert (18; 18A; 18B) is made of leather, imitation leather or fabric materials resistant to abrasion.

11. Method for manufacturing a protective garment (10; 10A, 10B), in particular for motorcyclists, according to any one of the preceding claims, said method comprising the following steps:- manufacturing at least one accordion stretch insert (18; 18A; 18B) by stretching at least one stretchable inner layer (22) on a suitable frame and by applying on said at least one stretchable inner layer (22) at least one outer layer (20) made of an abrasion resistant material, the at least one stretchable inner layer (22) and the at least one outer layer (20) made of an abrasion resistant material being then coupled to each other by means of a plurality of seams (24);- fastening said at least one accordion stretch insert (18; 18A, 18B) at an insertion zone (32) of the protective garment (10; 10A; 10B); said insertion zone (32) being defined between a first edge (34) and a second edge (36);- pre-tensioning a cover layer (26A; 26B; 26C);- applying the pre-tensioned cover layer (26A; 26B; 26C) over said at least one accordion stretch insert (18; 18A; 18B) so as to cover said at least one accordion stretch insert (18; 18A; 18B) while said at least one accordion stretch insert (18; 18A; 18B) is maintained in a rest condition wherein the at least one stretchable inner layer (22) is not tensioned or only minimally tensioned.

12. Method according to claim 11 , characterized in that the applying step of the pre-tensioned cover layer (26, 26A, 26B) over said at least one accordion stretch insert (18, 18A, 18B) is carried out before fastening said at least one accordion stretch insert (18, 18A, 18B) at the insertion zone (32).

13. Method according to claim 12, characterized in that the applying step of the pre-tensioned cover layer (26, 26A, 26B) is carried out by directly fastening the cover layer (26, 26A, 26B) to said at least one accordionstretch insert (18, 18A, 18B) so as to form an elastic assembly14. Method according to claim 13, characterized in that the pre-tensioned cover layer (26A; 26B; 26C) is fastened to the at least one accordion stretch insert (18; 18A; 18B) around a perimeter outline of the at least one accordion stretch insert (18; 18A; 18B).

15. Method according to claim 11 , characterized in that the applying step of the pre-tensioned cover layer (26, 26A, 26B) over said at least one accordion stretch insert (18, 18A, 18B) is carried out after having fastened said at least one accordion stretch insert (18, 18A, 18B) at the insertion zone (32).

16. Method according to claim 15, characterized in that the applying step of the pre-tensioned cover layer (26, 26A, 26B) is carried out by directly fastening the cover layer (26, 26A, 26B) at the first edge (34) and at the second edge (36) of the insertion zone (32).

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