Windproof and water resistant composite fabric with barrier layer

• US 5,364,678 A
• Filed: 12/06/1993
• Issued: 11/15/1994
• Est. Priority Date: 10/17/1989
• Status: Expired due to Term

• Current Assignee: MMI-IPCO LLC
• Original Assignee: Malden Mills Industries Incorporated (Polartec LLC)
• Inventors: Rock, Moshe, Lumb, Douglas
• Primary Examiner(s): Cannon, James C.
• Application Number:
  US08/163,021
• Time in Patent Office: 344 Days
• Field of Search: 428/96, 428/248, 428/246, 428/252, 428/253, 428/309.9, 428/315.9, 156/235, 156/238
• US Class Current: 428/96
• CPC Class Codes: A41D 31/102 Waterproof and breathable
• CPC Class Codes: A41D 31/145 using layered materials
• CPC Class Codes: A41D 31/185 using layered materials
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/728 Hydrophilic
• 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 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/026 Knitted fabric
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D06M 17/10 Polyurethanes polyurea
• CPC Class Codes: D06N 3/14 with polyurethanes
• CPC Class Codes: Y10T 428/23986 With coating, impregnation, or bond
• CPC Class Codes: Y10T 428/24996 With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
• CPC Class Codes: Y10T 428/24998 Composite has more than two layers
• CPC Class Codes: Y10T 442/3634 At least one layer comprises paper
• CPC Class Codes: Y10T 442/365 At least one layer is a preformed synthetic polymeric film or sheet
• CPC Class Codes: Y10T 442/3667 : Composite consisting of at least two woven fabrics bonded by an interposed adhesive layer [but not two woven fabrics bonded together by an impregnation which penetrates through the thickness of at least one of the woven fabric layers]
• CPC Class Codes: Y10T 442/3976 : Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/456 : Including additional strand inserted within knit fabric

Abstract

A stretchable, drapable, windproof, water resistant and water vapor permeable composite fabric including an inner layer of fabric, a first adhesive layer, a non-porous hydrophilic barrier layer, a second adhesive layer and an outer layer of fabric. At least one of the adhesive layers is of a hydrophilic material and may be continuous, and which joins the inner fabric layer to one side of the barrier layer, the second adhesive layer adhering the barrier layer to the outer fabric layer. The adhesive layers and the barrier layer are constructed to allow water vapor molecules to travel therethrough by a process of absorption-diffusion-desorption, but restrict the passage of wind and liquid water. The inner layer is formed of a hydrophobic material rendered sufficiently hydrophilic to permit wicking or formed with an inner surface formed of said material and an outer surface formed of a naturally absorbent material.

Claims

1. A stretchable, drapable, water vapor permeable, windproof and water resistant composite fabric for use in a garment comprising:

an outer layer of fabric;

an inner layer of fabric having a raised inner surface and a plain outer surface and formed from sufficiently hydrophilic material to permit wicking of moisture from the raised inner surface of the inner layer to said plain outer surface thereof;

barrier means for providing resistance to wind and liquid water while providing for water vapor transport through absorption-diffusion-desorption, including a non-porous hydrophilic barrier layer;

a hydrophilic adhesive layer, said adhesive layer affixing at least one of said outer surface of said inner layer of fabric or the inner surface of said outer layer of fabric to said barrier means; and

said other of said outer surface of said inner layer of fabric or said inner surface of said outer layer of fabric being disposed on and adhered to said barrier layer.

2. The composite fabric of claim 1, wherein said adhesive layer is continuous.

3. The composite fabric of claim 1, wherein said adhesive layer joins said barrier layer to said outer surface of said inner layer of fabric.

4. The composite fabric of claim 1, wherein said adhesive layer joins said barrier layer to said inner surface of said outer layer of fabric.

5. The composite fabric of claim 1, wherein said adhesive layer joins said outer surface of said inner layer of fabric to said barrier layer, and including a second hydrophilic adhesive layer joining said barrier layer to said inner surface of said outer layer of fabric.

6. The composite fabric of claim 5, wherein said second adhesive layer is continuous.

7. The composite fabric of claim 1, wherein said inner layer of fabric is formed from an essentially hydrophobic material which has been rendered sufficiently hydrophilic.

8. The composite fabric of claim 1, wherein said inner layer of fabric is formed from polyester which has been rendered sufficiently hydrophilic.

9. The composite fabric of claim 1, wherein said inner fabric layer includes an inner surface formed of a polyester which has been rendered sufficiently hydrophilic and an outer surface formed of a naturally absorbent material.

10. The composite fabric of claim 1, wherein said naturally absorbent material is cotton.

11. The composite fabric of claim 1, wherein said outer fabric layer is hydrophobic.

12. The composite fabric of claim 11, wherein said outer fabric layer has a raised outer surface and a plain inner surface on the side adjacent said barrier layer.

13. The composite fabric of claim 11, wherein said outer fabric is an essentially flat shell material.

14. The composite fabric of claim 1, wherein said outer fabric layer is treated to be water repellant.

15. The composite fabric of claim 14, wherein said outer fabric layer has a raised outer surface and a plain inner surface adjacent said barrier layer.

16. The composite fabric of claim 14, wherein said inner fabric layer includes an inner layer formed of a polyester which has been rendered sufficiently hydrophilic and an outer layer formed of a naturally absorbent material.

17. The composite fabric of claim 16, wherein said outer fabric is an essentially flat shell material.

18. The composite fabric of claim 1, wherein said outer layer of fabric is essentially formed of polyester.

19. The composite fabric of claim 1, wherein said barrier means includes a second hydrophilic barrier layer disposed on and adhered to said first-mentioned barrier layer, said first-mentioned barrier layer being disposed on and adhered to said inner fabric layer, and said second barrier layer being disposed on and adhered to said outer fabric layer, said adhesive layer joining at least one of said outer surface of said inner layer of fabric to the first-mentioned of said barrier layers or said second barrier layer to said inner surface of said outer layer of fabric.

20. The composite fabric of claim 19, and including a second hydrophilic adhesive member joining the other of said outer surface of said inner layer of fabric to the first-mentioned of said barrier layers or said second barrier layer to said inner surface of said outer layer of fabric.

21. The composite fabric of claim 20, wherein said second adhesive layer is continuous.

22. The composite fabric of claim 19, wherein said inner fabric layer includes an inner layer formed of a polyester which has been rendered sufficiently hydrophilic and an outer layer formed of a naturally absorbent material.

23. The composite fabric of claim 1, wherein said barrier layer is formed from an essentially non-porous hydrophilic material.

24. The composite fabric of claim 1, wherein said outer layer of fabric and said inner layer of fabric are both a stretchable material.

25. The composite fabric of claim 1, wherein said outer layer of fabric and said inner layer of fabric are both raised surface knit fabrics.

26. The composite fabric of claim 19, wherein said first-mentioned and second barrier layers are adhered to each other with the use of a non-porous hydrophilic material.

27. A stretchable, drapable, water vapor permeable, windproof and water resistant composite fabric for use in a garment comprising:

an outer layer of fabric;

an inner layer of fabric having a raised inner surface and a plain outer surface and formed from sufficiently hydrophilic material to permit wicking of moisture from the raised inner surface of the inner layer to said plain outer surface thereof;

barrier means for providing resistance to wind and liquid water while providing for water vapor transport through absorption-diffusion-desorption including an essentially non-porous hydrophilic first barrier layer disposed on and adhered to said outer surface of said inner fabric layer and an essentially non-porous hydrophilic second barrier layer disposed on and adhered to said inner surface of said outer fabric layer; and

a hydrophilic adhesive layer joining said first and second barrier layers.

28. The composite fabric of claim 27, wherein said adhesive layer is continuous.

29. The composite fabric of claim 27, wherein said inner layer of fabric is formed from an essentially hydrophobic material which has been rendered sufficiently hydrophilic.

30. The composite fabric of claim 27, wherein said inner layer of fabric is formed from polyester which has been rendered sufficiently hydrophilic.

31. The composite fabric of claim 27, wherein said inner fabric layer includes an inner layer formed of a polyester which has been rendered sufficiently hydrophilic and an outer layer formed of a naturally absorbent material.

32. The composite fabric of claim 27, wherein said naturally absorbent material is cotton.

33. The composite fabric of claim 27, wherein said outer fabric layer is treated to be water repellant.

34. The composite fabric of claim 27, wherein said outer fabric layer is formed of a hydrophobic material.