Perforated functional textile structures

• US 8,263,215 B2
• Filed: 08/10/2010
• Issued: 09/11/2012
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Adidas AG
• Original Assignee: Textronics Incorporated (Adidas AG)
• Inventors: Burr, Stacey B., Hassonjee, Qaizar N., Armitage, Roger
• Primary Examiner(s): Steele, Jennifer A
• Application Number:
  US12/853,340
• Publication Number:
  US 20100293698A1
• Time in Patent Office: 763 Days
• Field of Search: 222/3, 224/31, 428/99, 428/123, 428/130, 428/131, 428/136, 428/137, 428/156, 128/102.1, 128/873, 442/181, 442/327
• US Class Current: 428/221
• CPC Class Codes: A41D 31/265 using layered materials
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2437/00 Clothing
• 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, comprising:

(a) a first outer layer of a fabric or film defining an inner surface and an outer surface and a length, and defining two or more perforations therethrough, with each perforation defining a hole opening with a maximum outer dimension;

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

(c) two or more threadlines of stretch and recovery elements extending along at least a portion of the length of the first outer layer;

(d) two or more wires, yarns or strands of functional elements substantially parallel to or co-extending with the stretch and recovery elements, said functional elements having a threadline length and having an outer diameter or maximum outer width less than the maximum outer dimension of a corresponding perforation hole opening, with the stretch and recovery elements and functional elements sandwiched between the inner surfaces of the outer layers; and

(e) at least one adhesive composition for bonding the stretch and recovery elements and the functional elements between the inner surfaces of the outer layers;

wherein portions of one functional element are exposed to an environment outside of the laminate through the two or more perforations, and wherein a puckered appearance results when the stretch and recovery elements are in a relaxed or unstretched state.

2. The functional stretch laminate of claim 1, wherein when the stretch and recovery elements are in a relaxed or unstretched state, at least one portion of at least one functional element loops beyond the outer surface of the first outer layer through at least one of the perforations in a direction substantially perpendicular to a plane defined by the outer surface of the first outer layer, and at least one other portion of at least one functional element loops beyond the outer surface of the first outer layer through at least one other of the perforations in a direction substantially perpendicular to a plane defined by the outer surface of the first outer layer.

3. The functional stretch laminate of claim 1, wherein the functional elements are present in an amount from 1 to 20 per inch of width of the laminate.

4. The functional stretch laminate of claim 1, wherein the perforations are formed in the first outer layer at predetermined intervals along the length.

5. The functional stretch laminate of claim 1, wherein the perforations are formed in the first outer layer at predetermined intervals along the length before the stretch and recovery elements and functional elements are bonded between the first outer layer and second outer layer.

6. The functional stretch laminate of claim 1, wherein the perforations have a shape selected from the group consisting of a hole, a slit, a slot, and combinations thereof.

7. The functional stretch laminate of claim 2, wherein at least two functional elements loop beyond the outer surface of the first outer layer through the same perforation.

8. The functional stretch laminate of claim 1, wherein the retractive force of the laminate is at least 0.22 lb/in (38.9 g/cm) when the laminate is stretched to 150% of its original length.

9. The functional stretch laminate of claim 1, wherein the stretch and recovery elements comprise spandex.

10. The functional stretch laminate of claim 1, wherein the functional elements are 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, metallic coated films, and combinations thereof.

11. The functional stretch laminate of claim 1, wherein at least one 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.

12. The functional stretch laminate of claim 11, 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.

13. 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.

14. The functional stretch laminate of claim 1, 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.

15. The functional stretch laminate of claim 14, 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.

16. 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.

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

29. The functional stretch laminate of claim 1, wherein the second outer layer defines two or more perforations therethrough, and wherein at least a portion of another one of the two or more functional elements is exposed to an environment outside of the laminate through the two or more perforations of the second outer layer.

17. A method for preparing a functional stretch laminate, comprising:

providing a length of a first piece of inextensible material having an inner surface and an outer surface and a length, and defining two or more perforations therethrough, with each perforation defining a hole opening with a maximum outer dimension;

providing a second piece of inextensible material having an inner surface and an outer surface,

extending two or more threadlines of stretch and recovery elements to at least 50% of their undeformed recoverable extension limit and fixing said stretch and recovery elements along at least a substantial portion of the length of the first piece of inextensible material,

extending two or more wires, yarns or strands of functional elements coextensively with the stretch and recovery elements and fixing said functional elements along at least a substantial portion of the length of the first piece of inextensible material, said functional elements having a threadline length and having an outer diameter or maximum outer width less than the maximum outer dimension of a corresponding perforation hole opening,

securing the extended stretch and recovery elements and the functional elements to the inner surface of said first piece of inextensible material along a substantial portion of the length thereof;

bonding the stretch and recovery elements and the functional elements between the inner surface of said first piece of inextensible material and the inner surface of the second piece of inextensible material to form the functional stretch laminate; and

relaxing the extended length of said stretch and recovery elements substantially and allowing the functional stretch laminate to pucker, such that portions of the functional elements are exposed to an environment outside of the laminate through the holes provided in the first piece of inextensible material.

18. The method of claim 17, wherein the stretch and recovery elements and the functional elements are substantially parallel when extended.

19. The method of claim 17, wherein the stretch and recovery elements comprise spandex.

20. The method of claim 17, wherein the functional elements are 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.

21. The method of claim 17, 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.

22. The method of claim 17, further comprising perforating the first piece of inextensible material to form the perforations before securing the extended stretch and recovery elements and the functional elements to the inner surface of the first piece of inextensible material.

23. The method of claim 22, wherein the hole opening is selected from the group consisting of a hole, a slit or a slot.

24. The method of claim 22, further comprising perforating the second piece of inextensible material to form one or more hole openings before securing the extended stretch and recovery elements and the functional elements to the second piece of inextensible material.

25. The method of claim 17, 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 the outer surface of one piece of inextensible material.

26. The method of claim 25, wherein fastening is by a mechanical fastening mechanism selected from the group consisting of gluing, riveting, snapping, stitching, stapling, welding, and encasing.

27. The method of claim 17, 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 of the functional elements in the laminate to a source selected from the group consisting of:

electricity and radiation.