Insulated composite fabric

• US 10,130,129 B2
• Filed: 06/15/2017
• Issued: 11/20/2018
• Est. Priority Date: 11/24/2009
• Status: Active Grant

• Current Assignee: MMI-IPCO LLC
• Original Assignee: MMI-IPCO LLC
• Inventors: Rock, Moshe, Zeiba, James, Vainer, Gadalia, Hunter, Jane, Haryslak, Charles, Costello, David, Flavin, Shawn, Webster, Marcus
• Primary Examiner(s): Piziali, Andrew T
• Application Number:
  US15/623,717
• Publication Number:
  US 20170280799A1
• Time in Patent Office: 523 Days
• CPC Class Codes: A41D 31/065 using layered materials
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2437/00 Clothing
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D05B 1/02 for making single-thread seams
• CPC Class Codes: D05B 11/00 Machines for sewing quilts or mattresses control of workpiece-holding frames, or of sewing machines, in order to obtain particular seam configuration D05B21/00
• CPC Class Codes: D05C 15/04 Tufting
• CPC Class Codes: D06C 27/00 Compound processes or apparatus, for finishing or dressing textile fabrics, not otherwise provided for
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/23914 Interlaminar

Abstract

An insulated composite fabric has an inner fabric layer, an outer fabric layer, and an insulating-filler layer enclosed there between. The insulating-filler layer is a textile fabric with at least one raised surface. One side of the insulating-filler layer comprises a first surface with relatively high pile, including regions of no pile or relatively low pile interspersed among regions of relatively high pile. The other side of the insulating-filler layer comprises a second surface with relatively high pile, including regions of no pile or relatively low pile interspersed among regions of relatively high pile. Interconnecting piles are formed with regions of the relatively high pile of the first pile surface and regions of the relatively high pile of the second pile surface.

Claims

1. A method comprising forming an insulated composite fabric including:

enclosing an insulating-filler fabric layer between an inner fabric layer and an outer fabric layer, wherein the insulating-filler fabric layer is a textile fabric with at least one raised surface on the fabric;

one side of the insulating-filler layer comprising a first surface with relatively high pile, including regions of no pile or relatively low pile interspersed among regions of relatively high pile, the other side of the insulating-filler layer comprising a second surface with relatively high pile, including regions of no pile or relatively low pile interspersed among regions of relatively high pile, wherein the regions of the relatively high pile of the first pile surface and the regions of the relatively high pile of the second pile surface are interconnected with one another; and

coupling at least one of a fleece and velour that is respectively lower than the relatively high pile of the first surface or the relatively high pile of the second surface to at least one of the first surface and the second surface in one or more of the regions of no pile or relatively low pile.

2. The method of claim 1, wherein enclosing the insulating-filler fabric layer comprises sewing the insulating-filler fabric layer to one or both of the inner fabric layer and the outer fabric layer.

3. The method of claim 1, wherein the at least one of the fleece and velour is coupled to the respective surface by one or more of stitching yarn and backing yarn.

4. The method of claim 1, wherein the insulating-filler layer comprises no pile interspersed among the regions of relatively high pile and relatively low pile interspersed among the regions of relatively high pile.

5. The method of claim 1, wherein enclosing the insulating-filler fabric layer comprises laminating the insulating-filler fabric layer to one or both of the inner fabric layer and the outer fabric layer.

6. The method of claim 1, further comprising laminating a waterproof membrane to an inner surface of the outer fabric layer, and so that the waterproof membrane is disposed between the outer fabric layer and the insulating-filler fabric layer, and wherein the waterproof membrane is a vapor permeable membrane, or wherein the waterproof membrane is selected from a porous hydrophobic membrane, a hydrophilic non-porous membrane, and an electrospun membrane.

7. The method of claim 1, wherein the inner fabric layer has an air permeability that is different from an air permeability of the outer fabric layer, and wherein the inner fabric layer has an air permeability that is relatively greater than an air permeability of the outer fabric layer, or wherein the inner fabric layer has an air permeability that is relatively less than an air permeability of the outer fabric layer.

8. The method of claim 1, further comprising stitching the insulating-filler fabric layer to one or both of the inner fabric layer and the outer fabric layer along a periphery of the insulated composite fabric.