Perforated Functional Textile Structures

• US 20080038512A1
• Filed: 06/15/2005
• Published: 02/14/2008
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Adidas AG
• Original Assignee: Textronics Incorporated (Adidas AG)
• Inventors: Armitage, Roger, Burr, Stacey, Hassonjee, Qaizar
• Granted Patent: US 7,781,051 B2
• Time in Patent Office: Days
• US Class Current: 428/137
• CPC Class Codes: A41D 31/265 using layered materials
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2437/00 Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 3/04 characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• 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: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/036 Heaters specially adapted for garment heating
• CPC Class Codes: H05B 3/342 heaters used in textiles
• CPC Class Codes: H05K 1/00 Printed circuits
• CPC Class Codes: H05K 9/009 comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1049 Folding only
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face
• CPC Class Codes: Y10T 29/49947 by applying separate fastener
• CPC Class Codes: Y10T 428/24 : Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24008 : including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/2419 : Fold at edge
• CPC Class Codes: Y10T 428/24207 : with strand[s] or strand-portion[s] between layers [e.g., upholstery trim, etc.]
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24281 : Struck out portion type
• CPC Class Codes: Y10T 428/24289 : Embedded or interlocked
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24306 : Diamond or hexagonal
• CPC Class Codes: Y10T 428/24314 : Slit or elongated
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24339 : Keyed
• CPC Class Codes: Y10T 428/24347 : From both sides
• CPC Class Codes: Y10T 428/24479 : including variation in thickness
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249922 : Embodying intertwined or helical component[s]
• CPC Class Codes: Y10T 428/2848 : Three or more layers
• CPC Class Codes: Y10T 442/3008 : Woven fabric has an elastic quality
• CPC Class Codes: Y10T 442/3016 : Including a preformed layer other than the elastic woven fabric [e.g., fabric or film or foil or sheet layer, etc.]
• CPC Class Codes: Y10T 442/3024 : Including elastic strand or strip
• CPC Class Codes: Y10T 442/339 : Metal or metal-coated strand
• CPC Class Codes: Y10T 442/40 : Knit fabric [i.e., knit strand or strip material]
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/601 : Nonwoven fabric has an elastic quality
• CPC Class Codes: Y10T 442/602 : Nonwoven fabric comprises an elastic strand or fiber material
• CPC Class Codes: Y10T 442/655 : Metal or metal-coated strand or fiber material

Abstract

The invention provides a functional stretch laminate composite puckered fabric which is robust, laundry-durable and adaptable for securing about any three dimensional body, and a method for forming such puckered fabric. The functional stretch laminate fabric is provided with at least one functional element which can conduct electricity, conduct light, provide electromagnetic fields or provide shielding from electromagnetic fields. In addition, at least one via is provided in the functional stretch laminate allowing the functional element to extend or loop outwardly from the at least one via when the laminate is in a relaxed or unstretched state. Generally, the functional stretch laminate fabric is sufficiently robust for incorporation into garments and for applications in so-called wearable electronics.

Claims

1. A functional stretch laminate with a substantially puckered appearance comprising:

(a) first and second outer layers of a fabric or film;

(b) at least one stretch and recovery element and at least one functional element co-extending with the stretch and recovery element; and

(c) an adhesive composition for bonding the stretch and recovery element and the functional element between the outer layers;

wherein the substantially puckered appearance results when the stretch and recovery element is in a relaxed or unstretched state; and

wherein a portion of the at least one functional element extends or loops outwardly from at least one via provided in the functional stretch laminate.

2. The functional stretch laminate of claim 1, wherein the outer layers of a fabric or film are of substantially equal width.

3. The functional stretch laminate of claim 1, wherein each outer layer of fabric or film has an inside surface in contact with the stretch and recovery element and an outer surface, and wherein the adhesive only partially covers the inside surface of at least one outer layer and penetrates to the outer surface of each layer.

4. The functional stretch laminate of claim 1, wherein the at least one stretch and recovery element and the at least one functional element are substantially parallel or coextensive.

5. The functional stretch laminate of claim 1, wherein the stretch and recovery element comprises spandex.

6. The functional stretch laminate of claim 1, wherein the functional element is selected from the group consisting of:

insulated single and multi-stranded metallic wires, non-insulated single and multi-stranded metallic wires, metallic coated polymeric fibers, inherently conductive polymer fibers, plastic optical fiber, silica glass optical fibers, and metallic coated films.

7. The functional stretch laminate of claim 1, wherein the functional element comprises at least one material having functional properties that is intermingled, twisted, core spun, or covered together with:

(i) at least one other material having functional properties, or (ii) a material having stretch and recovery properties.

8. The functional stretch laminate of claim 7, wherein the material having stretch and recovery properties comprises spandex, and the material having functional properties is selected from the group consisting of metal wire, an electrically or optically functional composite yarn that comprises an elastic member surrounded by at least one functional covering filament, an electrically conductive elastomeric composition that exhibits variable resistance, and silver plated textile nylon filament.

9. The functional stretch laminate of claim 1, wherein the fabric or film outer layers are selected from the group consisting of nonwoven fabric, woven fabric, knit fabric, paper, and polymer film.

10. The functional stretch laminate of claim 7, wherein the fabric or film outer layers are selected from the group consisting of nonwoven fabric, woven fabric, knit fabric, paper, and polymer film.

11. The functional stretch laminate of claim 1, wherein each outer layer has an outer surface and wherein a distal end of the functional stretch laminate is folded back onto itself at least one time and such folded end is fastened to the outer surface of one outer layer.

12. The functional stretch laminate of claim 11, wherein the folded end is fastened by a mechanical fastening mechanism selected from the group consisting of gluing, riveting, snapping, stitching, stapling, welding, and encasing.

13. The functional stretch laminate of claim 1, wherein the laminate is adaptable for attachment to at least one connector, wherein said connector is adaptable for connecting the functional element in the laminate to a source selected from the group consisting of electricity and radiation.

14. The functional stretch laminate of claim 1, wherein at least a portion of the stretch laminate is conductive.

15. The functional stretch laminate of claim 14, wherein at least a portion of the stretch laminate conducts electricity.

16. The functional stretch laminate of claim 14, wherein at least a portion of the stretch laminate conducts light.

17. The functional stretch laminate of claim 14, wherein at least a portion of the stretch laminate is able to provide an electromagnetic field.

18. The functional stretch laminate of claim 14, wherein at least a portion of the stretch laminate is able to provide shielding from electromagnetic fields.

32. A garment or wearable incorporating the composite stretch laminate of claim 1.

19. A method for preparing a functional stretch laminate with a substantially puckered appearance, comprising:

providing a length of a first piece of inextensible material having a first surface and a second surface;

extending and fixing at least one length of a stretch and recovery element to at least 50% of its undeformed recoverable extension limit, and extending and fixing at least one length of a functional element coextensively with the stretch and recovery element, and securing the extended lengths of the stretch and recovery element and the functional element to the first surface of said first piece of inextensible material along a substantial portion of the fixed length thereof;

providing a second piece of inextensible material having a first surface and second surface, and securing said second piece of inextensible material either to the stretch and recovery element or to the first surface of said first piece of inextensible material along a substantial portion of the length thereof coextending with said stretch and recovery element to form the functional stretch laminate; and

relaxing the extended length of said stretch and recovery element substantially and allowing the functional stretch laminate to pucker such that a portion of the at least one functional element extends or loops outwardly from at least one via provided in the functional stretch laminate.

20. The method of claim 19, wherein the at least one stretch and recovery element and the at least one functional element are substantially parallel or coextensive when extended and fixed.

21. The method of claim 19, wherein the stretch and recovery element comprises spandex.

22. The method of claim 19, wherein the functional element is selected from the group consisting of:

insulated single and multi-stranded metallic wires, noninsulated single and multi-stranded metallic wires, metallic coated polymeric fibers, inherently conductive polymer fibers, plastic optical fiber, silica glass optical fibers, and metallic coated films.

23. The method of claim 19, wherein the inextensible material is a fabric or film selected from the group consisting of nonwoven fabric, woven fabric, knit fabric, paper, and polymer film.

24. The method of claim 19, further comprising perforating the first piece of inextensible material to form a via opening.

25. The method of claim 24, wherein the via opening is selected from the group consisting of a hole, a slit or a slot.

26. The method of claim 24, further comprising perforating the second piece of inextensible material to form a via opening.

27. The method of claim 19, further comprising the steps of:

(i) folding a distal end of the functional stretch laminate back onto itself at least one time; and

(ii) fastening such folded end to an outer surface of one outer layer.

28. The method of claim 27, wherein fastening is by a mechanical fastening mechanism selected from the group consisting of gluing, riveting, snapping, stitching, stapling, welding, and encasing.

29. The method of claim 19, further comprising the step of attaching at least one connector to the functional stretch laminate, wherein said connector is adaptable for connecting the at least one functional element in the laminate to a source selected from the group consisting of electricity and radiation.

30. The method of claim 29, further comprising:

connecting a source of electricity to the at least one functional element.

31. The method of claim 29, further comprising connecting a source of radiation to the at least one functional element.