Waterproof, breathable composite material

• US 20070082189A1
• Filed: 10/11/2005
• Published: 04/12/2007
• Est. Priority Date: 10/11/2005
• Status: Abandoned Application

• Current Assignee: William Gillette
• Original Assignee: William Gillette
• Inventors: Gillette, William
• Application Number:
  US11/248,034
• Publication Number:
  US 20070082189A1
• Time in Patent Office: Days
• US Class Current: 428/304.400
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 37/06 characterised by the heating method
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249976 Voids specified as closed
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 442/647 Including a foamed layer or component
• CPC Class Codes: Y10T 442/651 Plural fabric layers

Abstract

A composite material that may be used to form, among other things, sports clothing, such as jackets, gloves, boots or fishing waders, is waterproof, breathable and insulated. The composite material includes at least an insulating layer of open-cell foam a waterproof layer on one side of the insulating layer. The composite material also preferably includes a protective layer on the side of the insulating layer opposite the waterproof layer. The composite material may have additional layers on either side or both sides of the insulating layer. The open-cell foam of the insulating layer is preferably, but not necessarily, a thermoplastic that can be re-shaped through the use of a thermal forming process.

Claims

1. A waterproof, breathable, insulated composite material comprising (a) an insulating layer of open-cell foam, the insulating layer having a first side and a second side, (b) a protective layer positioned on the first side of the insulating layer, and (c) a waterproof layer positioned on the second side of the open-cell foam.

2. The material of claim 1 wherein the protective layer is fleece.

3. The material of claim 1 wherein the waterproof layer comprises GORE-TEX.

4. The material of claim 1 that further comprises at least one additional layer between the insulating layer and the waterproof layer.

5. The material of claim 1 that further includes at least one additional layer between the insulating layer and the protective layer.

6. The material of claim 1 wherein the insulating layer is a polyurethane foam.

7. The covering of claim 1 wherein the insulating layer is a thermoplastic material.

8. The material of claim 6 wherein the polyurethane foam is a thermoplastic material.

9. The covering of claim 1 wherein the insulating layer can be molded after being formed.

10. The material of claim 6 wherein the polyurethane can be molded after being formed.

11. The material of claim 8 wherein the polyurethane can be molded after being formed.

12. The material of claim 6 wherein the polyurethane is HYPUR-CEL T0503.

13. The material of claim 1 wherein the thickness of the insulating layer is between 0.30 mm and 25.0 mm

14. The material of claim 1 wherein the protective layer is attached directly to the insulating layer.

15. The material of claim 14 wherein the protective layer is attached to the insulating layer by an adhesive.

16. The material of claim 14 wherein the protective layer is attached to the insulating layer by heat welding.

17. The material of claim 1 wherein the waterproof layer is attached directly to the insulating layer.

18. The material of claim 17 wherein the waterproof layer is attached to the insulating layer by an adhesive.

19. The material of claim 17 wherein the waterproof layer is attached to the insulating layer by heat welding.

20. The material of claim 1 that further includes an outer face layer adjacent the waterproof layer.

21. The material of claim 20 wherein the outer face material has a pattern thereon.

22. Waders formed of the material of claim 1.

23. A boot formed of the material of claim 1.

24. The material of claim 6 wherein the insulating layer is between 0.30 mm and 25.0 mm thick.

25. The material of claim 6 wherein the polyurethane is selected from one or more of the group consisting of:

HYPUR-CEL T0812, HYPUR-CEL T2040, HYPUR-CEL T0805, HYPUR-CEL S0702, HYPUR-CEL S1203, HYPUR-CEL T1515.