Multi-layer composite fabric garment

• US 7,560,399 B2
• Filed: 10/07/2004
• Issued: 07/14/2009
• Est. Priority Date: 08/28/1998
• Status: Expired due to Fees

• Current Assignee: MMI-IPCO LLC
• Original Assignee: MMI-IPCO LLC
• Inventors: Rock, Moshe, Haryslak, Charles, Vainer, Gadalia, Hunter, Jane
• Primary Examiner(s): JOHNSON, JENNA LEIGH
• Application Number:
  US10/960,402
• Publication Number:
  US 20050075028A1
• Time in Patent Office: 1,741 Days
• Field of Search: 442/76, 442/85, 442/86, 428/91, 2 6/9, 2 8/2, 2 8/7, 2 9/7
• US Class Current: 442/76
• CPC Class Codes: A41D 13/00 Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches helmets A42B3/00; clothing affording protection against chemical agents or for use at high altitudes A62B17/00; life-saving garments for use at sea, diving suits B63C; bulletproof or armoured clothing F41H; clothing affording protection against radiation G21F3/02
• CPC Class Codes: A41D 2400/422 into a pocket
• CPC Class Codes: A41D 27/04 Removable linings
• CPC Class Codes: A41D 3/005 with pullover structure
• CPC Class Codes: A41D 31/065 using layered materials
• CPC Class Codes: A41D 31/085 using layered materials
• CPC Class Codes: A41D 31/102 Waterproof and breathable
• CPC Class Codes: A41D 31/125 Moisture handling or wicking function through layered materials
• CPC Class Codes: A41D 31/145 using layered materials
• CPC Class Codes: B32B 2038/0028 Stretching, elongating
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2437/00 : Clothing anti-ballistic clothing B32B2571/02
• CPC Class Codes: B32B 2459/00 : Nets, e.g. camouflage nets
• 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 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 37/1284 : Application of adhesive
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted 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: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D04B 1/04 : characterised by thread material
• CPC Class Codes: D04B 1/14 : Other fabrics or articles characterised primarily by the use of particular thread materials
• CPC Class Codes: D04B 1/24 : wearing apparel
• CPC Class Codes: D04B 21/14 : Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes pile fabrics D04B21/02; non-woven fabrics in general D04H
• CPC Class Codes: D06N 2209/123 : Breathable
• CPC Class Codes: D06N 2209/141 : Hydrophilic
• CPC Class Codes: D06N 2209/142 : Hydrophobic
• CPC Class Codes: D10B 2331/021 : aromatic polyamides, e.g. aramides
• CPC Class Codes: D10B 2401/022 : hydrophylic
• CPC Class Codes: Y10T 428/2395 : Nap type surface
• CPC Class Codes: Y10T 428/24636 : Embodying mechanically interengaged strand[s], strand-portion[s] or strand-like strip[s] [e.g., weave, knit, etc.]
• CPC Class Codes: Y10T 442/2139 : Coating or impregnation specified as porous or permeable to a specific substance [e.g., water vapor, air, etc.]
• CPC Class Codes: Y10T 442/2213 : Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant
• CPC Class Codes: Y10T 442/2221 : Coating or impregnation is specified as water proof
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3301 : Coated, impregnated, or autogenous bonded
• CPC Class Codes: Y10T 442/3317 : Woven fabric contains synthetic polymeric strand material
• CPC Class Codes: Y10T 442/335 : Plural fabric layers
• CPC Class Codes: Y10T 442/3358 : Including a nonwoven fabric layer
• CPC Class Codes: Y10T 442/3366 : Woven fabric is coated, impregnated, or autogenously bonded
• CPC Class Codes: Y10T 442/3472 : Woven fabric including an additional woven fabric layer
• CPC Class Codes: Y10T 442/3504 : Woven fabric layers comprise chemically different strand material
• CPC Class Codes: Y10T 442/3512 : Three or more fabric layers
• CPC Class Codes: Y10T 442/40 : Knit fabric [i.e., knit strand or strip material]
• CPC Class Codes: Y10T 442/413 : Including an elastic strand
• CPC Class Codes: Y10T 442/425 : Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/488 : Including an additional knit fabric layer

Abstract

A composite fabric garment includes a first garment portion disposed in one or more upper regions of the fabric garment, i.e. those regions relatively more likely in use to be exposed to wind and rain, and a second garment portion disposed in one or more lower regions of the fabric garment, i.e. those regions relatively less likely in use to be exposed to wind and rain. The first garment portion is formed of a first composite fabric having first inner and outer fabric layers and a first intermediate barrier layer disposed between and bonded to at least one of the first inner and outer fabric layers, the first intermediate barrier layer being breathable and substantially impermeable to wind and liquid water. The second garment portion is formed of a second composite fabric formed of second inner and outer fabric layers and having predetermined air permeability. In one embodiment, the second garment portion further includes a second intermediate, breathable, air-permeable barrier layer disposed between and bonded to at least one of the second inner and outer fabric layers. In another embodiment, the second garment portion is formed of a composite fabric having controlled air permeability in a non-laminate absent a barrier.

Claims

1. A composite fabric garment having an upper region that is relatively more likely in use to be exposed to wind and rain, and a lower region that is relatively less likely in use to be exposed to wind and rain, the garment comprising:

a first garment portion, forming the upper region, wherein said first garment portion is formed of a first composite fabric comprising;

a first inner fabric layer;

a first outer fabric layer; and

a first intermediate barrier layer disposed between and bonded to at least one of said first inner fabric layer and said first outer fabric layer, said first intermediate barrier layer being breathable and substantially impermeable to wind and liquid water; and

a second garment portion forming the lower region, wherein said second garment portion is formed of a second composite fabric having predetermined air permeability and comprising;

a second inner fabric layer; and

a second outer fabric layer,

wherein said second garment portion has no intermediate barrier layer and has a relatively higher level of breathability and air permeability than said first garment portion.

2. The composite fabric garment of claim 1, wherein said one or more lower regions of said fabric garment include a wearer'"'"'s lower chest region and below.

3. The composite fabric garment of claim 1, wherein at least one of the first inner fabric layer and the second inner fabric layer comprises yarn with a plurality of synthetic fibers rendered hydrophilic.

4. The composite fabric garment of claim 3, wherein the synthetic fibers of at least one of the first inner fabric layer and the second inner fabric layer are selected from the group consisting of polyester and nylon.

5. The composite fabric garment of claim 1, wherein the first inner fabric layer is hydrophilic.

6. The composite fabric garment of claim 1 or claim 5, wherein the first outer fabric layer is hydrophobic.

7. The composite fabric garment of claim 1, wherein at least one of the first inner fabric layer and the second inner fabric layer defines a surface comprising discrete pillar regions of relatively deeper pile, said discrete pillar regions of relatively deeper pile being spaced apart and isolated from each other by regions of relatively shorter pile or no pile that form a plurality of channels passing among said discrete pillar regions, said plurality of channels defining insulation regions to contain a cushion of air for promoting warmth under static conditions during periods of wearer inactivity and defining circulation regions creating avenues for flow of air and enhanced evaporation of moisture from the skin of the wearer for creating a heat dissipation or cooling effect during periods of physical activity by the wearer.

8. The composite fabric garment of claim 7, wherein the plurality of channels formed along at least one of the first inner fabric layer and the second inner fabric layer comprises a plurality of intersecting vertical and horizontal channels.

9. The composite fabric garment of claim 8, wherein the vertical channels formed along at least one of the first inner fabric layer and the second inner fabric layer are constructed by tipped and tipless sinkers, high and low sinkers, or a combination thereof.

10. The composite fabric garment of claim 1, wherein at least one of the first outer fabric layer and the second outer fabric layer comprises a knit construction of multi-filament, interlaced yarns with one or more outer surface regions having a non-continuous coating comprising discrete coating segments of coating material applied to bind individual yarn fibers together for enhanced resistance of the outer surface region to abrasion, pilling or fraying.

11. The composite fabric garment of claim 1, wherein at least one of the first inner fabric layer and the second inner fabric layer has a raised surface in a form selected from the group consisting of:

velour, shearling, and loop terry.

12. The composite fabric garment of claim 1, wherein at least one of the first outer fabric layer and the second outer fabric layer has a construction selected from the group consisting of:

woven construction, circular knit construction, single face knit construction, double face knit construction, and warp knit construction.

13. The composite fabric garment of claim 12, wherein at least one of the first outer fabric layer and the second outer fabric layer has at least one-way stretch.

14. The composite fabric garment of claim 13, wherein at least one of the first outer fabric layer and the second outer fabric layer has two-way stretch.

15. The composite fabric garment of claim 12, claim 13 or claim 14, wherein at least one of the first outer fabric layer and the second outer fabric layer has a raised surface in one or more regions.

16. The composite fabric garment of claim 12, claim 13 or claim 14, wherein at least one of the first outer fabric layer and the second outer fabric layer has an unraised surface in one or more regions.

17. The composite fabric garment of claim 1, wherein, in the upper portion of the composite fabric garment, at least the outer layer has a construction with minimal seams for improved resistance to penetration of water.

18. The composite fabric garment of claim 1, wherein at least one of the first outer fabric layer and the second outer fabric layer comprises a fabric of knitted or woven construction of multi-filament, interlaced yarns with one or more outer surface regions having a non-continuous coating of binder material adhered to yarns and to yarn fibers at least at interlacing intersections for enhanced durability of the outer surface region to pilling or fraying.

19. The composite fabric garment of claim 18, wherein adhering of the binder material to yarn fibers is limited in a manner to substantially avoid restriction of air permeability through the second composite fabric article.

20. The composite fabric garment of claim 1, wherein the first inner fabric layer comprises a raised inner surface and a plain outer surface, the first inner fabric layer being formed of essentially hydrophobic material rendered hydrophilic to permit wicking of moisture from the raised inner surface to the plain outer surface, and wherein the first intermediate barrier layer comprises a first hydrophilic layer bonded to at least one of the first inner fabric layer and the first outer fabric layer, the first intermediate barrier layer permitting moisture vapor transmission.

21. The composite fabric garment of claim 1, wherein the first inner fabric layer comprises a raised inner surface and a plain outer surface, the first inner fabric layer being formed of essentially hydrophilic material to permit wicking of moisture from the raised inner surface to the plain outer surface, and wherein the first intermediate barrier layer comprises a non-porous hydrophilic layer, the first intermediate barrier layer permitting water vapor transport, and wherein a first hydrophilic adhesive layer affixes the first intermediate barrier layer to at least one of an outer surface of the first inner fabric layer and an inner surface of the first outer fabric layer.

22. The composite fabric garment of claim 1, wherein said second garment portion has a construction selected from the group consisting of:

woven construction, circular knit construction and warp knit construction, with predetermined air permeability achieved in a non-laminate absent an intermediate barrier.

23. The composite fabric garment of claim 22, wherein said predetermined air permeability is in the range of about 10 CFM to about 100 CFM.

24. The composite fabric garment of claim 1, wherein said predetermined air permeability is in the range of about 10 CFM to about 100 CFM.

25. The composite fabric garment of claim 1, wherein said second garment portion consists of:

a second inner fabric layer; and

a second outer fabric layer.

26. The composite fabric garment of claim 1, wherein said second garment portion has relatively higher water vapor permeability in moving air and relatively lower water vapor permeability in static air.

27. The composite fabric garment of claim 1, wherein the second garment portion comprises a woven second outer fabric layer, and the second garment portion has an air permeability of about 0 CFM to about 60 CFM.

28. The composite fabric garment of claim 1, wherein the second garment portion comprises a fabric selected from the group consisting of:

single face knit construction and double face knit construction.