Process of making a two-way stretchable fabric laminate and articles made from it

• US 5,804,011 A
• Filed: 06/28/1996
• Issued: 09/08/1998
• Est. Priority Date: 05/25/1994
• Status: Expired due to Term

• Current Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Original Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Inventors: Dutta, Anit, Daniel, Edward J., Willmann, Robert C.
• Primary Examiner(s): CHOI, KATHLEEN L
• Application Number:
  US08/672,801
• Time in Patent Office: 802 Days
• Field of Search: 156/160, 156/163, 156/229, 156/290, 156/291
• US Class Current: 156/160
• CPC Class Codes: A41D 31/102 Waterproof and breathable
• CPC Class Codes: A41D 31/185 using layered materials
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2305/073 partially
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2323/00 Polyalkenes
• CPC Class Codes: B32B 2327/18 PTFE, i.e. polytetrafluoroethylene
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2371/00 Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2377/00 Polyamides
• CPC Class Codes: B32B 2437/02 Gloves, shoes
• CPC Class Codes: B32B 2437/04 Caps, helmets
• CPC Class Codes: B32B 27/065 of foam
• 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 27/285 comprising polyethers
• CPC Class Codes: B32B 27/286 : comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 37/144 : using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding constructional features for tensioning B32B38/1825
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/24446 : Wrinkled, creased, crinkled or creped
• CPC Class Codes: Y10T 428/24645 : with folds in parallel planes
• CPC Class Codes: Y10T 428/24694 : Parallel corrugations
• CPC Class Codes: Y10T 428/24826 : Spot bonds connect components
• CPC Class Codes: Y10T 428/249955 : Void-containing component partially impregnated with adjacent component
• CPC Class Codes: Y10T 428/249975 : Void shape specified [e.g., crushed, flat, round, etc.]
• CPC Class Codes: Y10T 428/24998 : Composite has more than two layers
• CPC Class Codes: Y10T 428/249981 : Plural void-containing components
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic
• CPC Class Codes: Y10T 442/3008 : Woven fabric has an elastic quality

Abstract

The invention is a stretchable layered fabric laminate which is air impermeable and waterproof while being permeable to water vapor. The stretchable fabric laminate includes a stretchable composite material layer consisting of a hydrophobic protective layer of a porous polymeric material on each side of a layer of hydrophilic water-vapor-permeable synthetic polymer. The composite material layer is laminated to at least one layer of stretchable fabric. The stretchable layered fabric laminate has excellent stretch and recovery properties in both machine and transverse directions, and is useful for the manufacture of form-fitting articles of protective clothing and other end uses.

Claims

1. A process for making a stretchable layered fabric laminate stretchable in both the machine and transverse directions comprising the steps of:

(a) forming a composite of two microporous polymeric outer layers capable of elongating at least 50% of the original length in a transverse direction;

said layers joined by an intermediate layer of a non-porous water-vapor-permeable polymer partially impregnated into the micropores of the polymeric layers;

(b) stretching an elastic fabric in the machine direction so as to reduce its width to a width of 90 percent or less of its initial relaxed width,

said fabric having elastic properties in at least the machine direction;

(c) maintaining said fabric in the stretched state while adhesively laminating said composite to said stretched fabric with a non-continuous pattern of adhesive,

(d) reducing the force stretching said fabric, thereby allowing said fabric to elastically retract to a relaxed state whereby in the machine direction said composite layer is bunched and folded as said fabric elastically recovers from being stretched.

2. The process for making a stretchable layered fabric laminate as recited in claim 1 wherein the microporous polymeric layers are microporous polytetrafluoroethylene.

3. The process for making a stretchable layered fabric laminate as recited in claim 1 wherein the non-porous water-vapor-permeable polymer is poly(oxyethylene) polyurethane.