Triple layer, laminated fabric with waterproof, non-breathable inner layer

• US 6,319,864 B1
• Filed: 11/08/1999
• Issued: 11/20/2001
• Est. Priority Date: 03/10/1999
• Status: Expired due to Fees

• Current Assignee: RBH Designs LLC
• Original Assignee: RBH Designs LLC
• Inventors: Hannigan, Ryan B., Shehata, Hussein A.
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): RUDDOCK, ULA CORINNA
• Application Number:
  US09/435,908
• Time in Patent Office: 743 Days
• Field of Search: 442/246, 442/247, 442/250, 442/255, 442/261, 442/279, 442/293, 442/85, 442/268, 442/277, 442/281, 442/286, 442/394
• US Class Current: 442/281
• CPC Class Codes: A41D 31/065 using layered materials
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: Y10T 442/3707 Woven fabric including a nonwoven fabric layer other than paper
• CPC Class Codes: Y10T 442/378 Coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/3813 Coating or impregnation contains synthetic polymeric material
• CPC Class Codes: Y10T 442/3854 Woven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/674 Nonwoven fabric with a preformed polymeric film or sheet

Abstract

A fabric for garments to be used in cold temperatures or at high altitudes includes an inner layer comprising a thin, comfortable fabric having relatively poor moisture absorption, such as silk, nylon tricot, or polyester tricot, is laminated to a barrier layer comprising a hydrophobic, moisture and air impervious film such as polyethylene, which in turn is laminated to an insulating layer such as fleece or polyurethane fiberfill. The fabric is laminated using an adhesive comprising a mixture of acrylic and polyurethane with a cross linkage catalyst which reacts with active hydrogen groups in polyurethane, heated for about one minute between 180° F. and 220° F. to dry and cure the lamination.

Claims

1. A fabric for use in garments designed for cold temperatures and high altitudes, comprising:

an insulation layer;

a thin, moisture and air impervious, hydrophobic, stretchable barrier layer, a first surface of which is laminated to said insulation layer; and

an inner layer comprising a thin, comfortable fabric having relatively poor moisture absorption laminated to a second surface of said barrier layer.

2. A fabric according to claim 1 wherein said layers are laminated to each other by means of a water based adhesive cross linked with a hydrogen group reactive catalyst.

3. A fabric according to claim 1 wherein:

said insulation layer consists of fleece or polyester fiberfill.

4. A fabric according to claim 1 wherein:

said barrier layer comprises polyurethane.

5. A fabric according to claim 1 wherein:

said inner layer consists of silk, nylon tricot, or polyester tricot.

6. A fabric for use in garments designed for cold temperatures and high altitudes made by the process comprising:

(a) preparing an adhesive comprising a mixture of acrylic and polyurethane with a cross linkage catalyst which reacts with active hydrogen groups in polyurethane;

(b) coating a first side of a thin, moisture and air impervious, hydrophobic, stretchable barrier layer with said adhesive and applying an insulation layer thereto;

(c) forcing said barrier and insulating layers together through a roller, and heating said resulting lamination to a temperature of between 180°

F. and 220°

F. for about one minute, to dry and cure the lamination;

(d) coating the unlaminated side of said barrier layer with said adhesive and applying an inner layer thereto, said inner layer comprising a thin, comfortable fabric having relatively poor moisture absorption; and

(e) forcing the layers of the resulting three ply lamination together through a roller and heating the three ply lamination to a temperature of between 180°

F. and 220°

F. for about one minute, to dry and cure the three ply lamination.

7. A fabric according to claim 6 wherein:

said insulation layer consists of fleece or polyester fiberfill.

8. A fabric according to claim 6 wherein:

said barrier layer comprises polyurethane.

9. A fabric according to claim 6 wherein:

said inner layer consists of silk, nylon tricot, or polyester tricot.

10. A fabric according to claim 6 wherein:

said steps (c) and (e) comprise forcing said layers together through a nip roller.

11. A fabric according to claim 6 wherein:

said steps (c) and (e) comprise heating said laminations over a heated drum.