Functional elastic textile structures

• US 7,901,756 B2
• Filed: 06/15/2005
• Issued: 03/08/2011
• Est. Priority Date: 06/18/2004
• Status: Expired due to Fees

• Current Assignee: Adidas AG
• Original Assignee: Textronics Incorporated (Adidas AG)
• Inventors: Armitage, Roger, Burr, Stacey B., Schultze, Claudia
• Primary Examiner(s): O'Hern; Brent T
• Application Number:
  US11/570,304
• Publication Number:
  US 20080318002A1
• Time in Patent Office: 2,092 Days
• Field of Search: 428/123, 428/121, 428/98, 442/229, 223/74, 661/71, 219/529, 429/120
• US Class Current: 428/123
• 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. 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 usable in a garment comprising:

(a) a first outer layer of a fabric or film defining an inner surface and an outer surface opposite the inner surface;

(b) a second outer layer of a fabric or film defining an inner surface and an outer surface opposite the inner surface;

(c) at least one stretch and recovery element having a relaxed strand length and a stretched strand length, and when stretched to its stretched strand length co-extending along a length of the first outer layer and interposed between the inner surfaces of each of the first and second outer layers so as to be sandwiched therebetween;

(d) at least one functional element having a strand length and spaced apart from, and substantially parallel or co-extending along its length with the at least one stretch and recovery element, and interposed between the inner surfaces of each of the first and second layers so as to be sandwiched therebetween in a same plane as the at least one stretch and recovery element, wherein the at least one functional element extends out of a distal end of the functional stretch laminate in a machine direction, 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; and

(e) an adhesive composition for bonding the stretch and recovery element and the functional element as a middle layer of the laminate between the outer layers;

wherein as the stretch and recovery element is at its relaxed length, the functional stretch laminate has its substantially puckered appearance.

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

3. The functional stretch laminate of claim 1, wherein the adhesive only partially covers the inner 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 stretch and recovery element comprises spandex.

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

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

6. The functional stretch laminate of claim 5, 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.

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

8. The functional stretch laminate of claim 5, wherein the first and second fabric or film outer layers are selected from the group consisting of nonwoven fabric, woven fabric, knit fabric, paper, and polymer film.

9. The functional stretch laminate of claim 1, further comprising at least one folded distal end in which the functional stretch laminate is folded back onto itself at least one time, with such folded end fastened to the outer surface of one of the first and second outer layers, and 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.

10. The functional stretch laminate of claim 1, further comprising at least one connector that is adaptable for connecting the functional element in the laminate to a source selected from the group consisting of electricity and radiation.

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

12. The functional stretch laminate of claim 11, wherein at least a portion of the stretch laminate conducts electricity.

13. The functional stretch laminate of claim 11, wherein at least a portion of the stretch laminate conducts light.

14. The functional stretch laminate of claim 11, wherein at least a portion of the stretch laminate is able to provide an electromagnetic field.

15. The functional stretch laminate of claim 11, wherein at least a portion of the stretch laminate is able to provide shielding from electromagnetic fields.

16. A garment or wearable incorporating the functional stretch laminate of claim 1.