U.S. patent application number 09/772052 was filed with the patent office on 2002-08-01 for article with moisture resistance properties.
Invention is credited to Sullivan, Michael J..
Application Number | 20020103046 09/772052 |
Document ID | / |
Family ID | 25093755 |
Filed Date | 2002-08-01 |
United States Patent
Application |
20020103046 |
Kind Code |
A1 |
Sullivan, Michael J. |
August 1, 2002 |
Article with moisture resistance properties
Abstract
An article having resistance to moisture includes a base layer,
a screening layer, and an outer layer. The screening layer is
resistant to penetration by moisture in the liquid phase and may be
permeable to moisture in the vapor phase. In one embodiment the
screening layer has a moisture vapor transmission rate in the range
of 0 to 0.5 g per mil/100 in.sup.2 per day as determined according
to ASTM D-96 at 90% relative humidity and 100.degree. F. The
screening layer may comprise one or more layers. Optionally, a
screening layer may be resistant to penetration both by moisture in
the liquid and in the vapor phase.
Inventors: |
Sullivan, Michael J.;
(Barrington, RI) |
Correspondence
Address: |
Diane F. Covello, Esq.
Spalading Sports Worldwide, Inc.
425 Meadow Street
P.O. Box 901
Chicopee
MA
01021-0901
US
|
Family ID: |
25093755 |
Appl. No.: |
09/772052 |
Filed: |
January 29, 2001 |
Current U.S.
Class: |
473/599 |
Current CPC
Class: |
A63B 71/143 20130101;
B32B 9/02 20130101; A63B 41/08 20130101 |
Class at
Publication: |
473/599 |
International
Class: |
A63B 041/08 |
Claims
What is claimed is:
1. A composite material having resistance to water comprising: a
first layer of leather; and a screening layer substantially
coextensive with and joined to a side of the first layer, the
screening layer being resistant to penetration by moisture in the
liquid phase.
2. The material of claim 1 further comprising a second layer of
leather substantially coextensive with and joined to a free side of
the screening layer.
3. The material of claim 1 further comprising a second layer of
leather substantially coextensive with and joined to a free side of
the screening layer wherein the first layer, screening layer and
second layer are bonded to form a laminate.
4. The material of claim 1, wherein the screening layer
additionally has a moisture vapor transmission rate in the range of
about 0 to 0.5 grams per mil/100 inches.sup.2 per day when tested
according to ASTM D-96 at 90 percent relative humidity and
100.degree. F.
5. The material of claim 1, wherein the screening layer
additionally has a moisture vapor transmission rate in the range of
about 0.0001 to 0.3 grams per mil/100 inches.sup.2 per day when
tested according to ASTM D-96 at 90 percent relative humidity and
100.degree. F.
6. The material of claim 1, wherein the screening layer
additionally has a moisture vapor transmission rate in the range of
about 0.01 to 0.2 grams per mil/100 inches.sup.2 per day when
tested according to ASTM D-96 at 90 percent relative humidity and
100.degree. F.
7. The material of claim 1, wherein the screening layer comprises
discontinuities.
8. The material of claim 1, wherein the screening layer comprises
more than one layer.
9. The material of claim 1, wherein the screening layer comprises a
preformed layer.
10. The material of claim 1, wherein the screening layer comprises
a coating over the side of the first layer.
11. The material of claim 1, wherein the screening layer comprises
at least one material selected from the group consisting of
polyolefin, halogenated polyolefin, polyethylene terephthalate,
polytrimethylene terephthalate, polybutadiene terephthalate,
polyester, polyamide, polyurethane, polyvinylidene chloride,
polyvinyl chloride, polyvinyl alcohol, rubber, epoxy,
polytetrafluoroethylene and metal.
12. The material of claim 1, wherein the screening layer comprises
at least one coating material selected from the group consisting of
polyurethane, polyvinyidiene chloride, polyvinyl chloride,
polyvinyl alcohol, rubber, epoxy, polytetrafluoroethylene and
metal.
13. An article comprising an outer layer of leather; and a
screening layer substantially coextensive with and joined to the
outer layer, the screening layer being resistant to penetration by
moisture in the liquid phase.
14. The article of claim 13, wherein said article is selected from
the group consisting of a glove, a fielders glove, a shoe and a
game ball.
15. The article of claim 13 further comprising an underlying layer
of leather substantially coextensive with a free side of the
screening layer and adhesive disposed between the adjacent layers
wherein the outer layer, screening layer and underlying layer are
bonded to form a laminate.
16. A game ball comprising an outer layer overlying a reinforcing
lining and a screening layer substantially coextensive with the
outer layer and disposed between the outer layer and the
reinforcing lining, wherein the screening layer is resistant to
penetration by liquid water.
17. The game ball of claim 16, wherein the outer layer consists
essentially of natural leather or synthetic leather.
18. The game ball of claim 16, wherein the screening layer is
laminated to an inner surface of the outer layer.
20. A game ball having resistance to water comprising an outer
layer and a screening layer substantially coextensive with and
joined to an inner side of the outer layer, the screening layer
being resistant to penetration by moisture in the liquid phase.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a composite
material and an article made therefrom having moisture resistance
properties. More particularly the present invention relates to a
composite material and an article made therefrom that is a barrier
to water penetration but allows passage of moisture vapor in one
aspect of the invention and is a barrier to water penetration and a
barrier to moisture vapor in another aspect of the invention.
BACKGROUND OF THE INVENTION
[0002] Certain articles of clothing, such as shoes, hats and
gloves; articles of sports clothing, such as baseball and softball
fielding gloves, gloves for batters, football players and golfers,
sporting shoes; and any other articles of sporting goods, such as
game balls (referred to herein as "sports clothing and
accessories") may be subjected to exposure to moisture in the
normal course of use. For example, sports clothing commonly comes
in contact with the perspiration of the wearer; and dew, rain, and
even snow as are commonly found on the playing surface and
surrounding areas. During the normal course of use, sports clothing
may even be subject to complete immersion in water.
[0003] It is well known that exposure to water can have deleterious
effects on sports clothing and accessories. Some of the effects of
moisture absorption are immediate and obvious, including increased
weight of the article, the sensation of dampness experienced by the
wearer, and a general decrease in the performance qualities of the
goods.
[0004] In the case of items made of leather, wetting and drying can
lead to noticeable stiffness and hardening of the leather. Use of
the leather article, particularly when subject to multiple cycles
of wetting, drying and subsequent use, can lead to cracking and
splitting of the leather. The subsequent performance of the article
even when dry may be degraded because of the noticeable stiffness
of the recently wetted and dried leather. Other effects of wetting
and drying of materials such as shrinkage can occur to materials
that are fabric, leather or synthetic leather. For example,
shrinkage can not only cause a change in size or shape of the
article, but it could also induce tearing of panels of the material
at stitches or other locations.
[0005] Imparting water resistance to sports clothing and
accessories has been addressed in several ways. One way of making
such goods resistant to water is to treat the outer surfaces with
substances to impart a water repellant finish. Leather and fabrics
have been treated with waxes in an attempt to seal the pores or the
weave of the fabric or otherwise repel water. Various waxes such as
SNO-SEAL, commercially available from ATSKO/Sno-Seal, Inc.,
Orangeburg, South Carolina, are commonly used for this purpose.
More advanced materials have also been used for treating leather
and other materials to impart water repellence, including a
polyfluoralkyl material disclosed in U.S. Pat. No. 5,069,935 and
silica materials disclosed in U.S. Pat. No. 5,204,088.
[0006] While waxes, oils, polyfluoralkyl and silica materials do
provide water repellance, there can be significant drawbacks with
the use of each one of these materials. In particular, these water
repellant materials reduce the ability of the player to "feel" a
club or bat through the sports clothing and accessories.
Additionally, the performance of shoes intended to make contact
with a ball, such as in soccer, can be degraded when treated with
such waterproofing materials. Hence, playability may be changed.
Further, the color of sports clothing and accessories is typically
darkened by the use of these water repellant substances and thus,
the overall appearance of the articles can be negatively impacted.
Importantly, waxes and oils can make leather surfaces slippery,
lessening the desired "tack" of leather articles such as gloves or
game balls that are waterproofed.
[0007] It is further known that water repellant surface treatments,
such as waxes, oils, and other chemical materials, are applied to
only the outer surface of the article. Therefore, these treatments
often have a limited life span due to wear and abrasion the outer
surfaces encounter under conditions of normal use.
[0008] Water resistant synthetic materials have been used as a
replacement for leather and fabric in various structures. However,
materials such as molded rubber, polyvinyl chloride, and certain
other synthetic materials do not have the optimal combination of
flexibility, feel, tack and appearance, making these materials much
less desirable for many uses in sports clothing and
accessories.
SUMMARY OF THE INVENTION
[0009] An object of the present invention is to provide a composite
material for use in sports clothing and accessories which is
resistant to penetration by moisture in liquid form.
[0010] Another object of the present invention is to provide a
composite material, which possesses the desirable characteristics
of natural leather yet, is resistant to penetration by moisture in
liquid form.
[0011] A further object of the invention is to provide a natural
leather replacement material for use in sports clothing and
accessories which is resistant to penetration by moisture in the
liquid state, yet which permits penetration by water vapor.
[0012] These and related objects are achieved in one aspect of the
invention by providing a composite material which is resistant to
penetration by moisture. The material includes in its structure one
or more screening layers. The screening layer is resistant to
penetration by moisture in the liquid state but is permeable to
moisture in the vapor state.
[0013] In another aspect of the invention the composite material
includes a screening layer which is resistant to penetration by
moisture in the liquid state and resistant to penetration by
moisture in the vapor state.
[0014] The invention also encompasses various sports clothing and
accessories manufactured or constructed from the composite material
of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will be better understood and its
numerous objects and advantages will become apparent to those
skilled in the art by reference to the accompanying drawings in
which:
[0016] FIG. 1 is an enlarged, partially exploded view of a portion
of an inventive composite material;
[0017] FIG. 2 is a plan view of a baseball glove incorporating an
embodiment of the inventive composite material;
[0018] FIG. 3 is an enlarged, partially exploded view of a portion
of one embodiment of a screening layer; and
[0019] FIG. 4 is a partially exploded perspective view of a game
ball incorporating an embodiment of the inventive composite
material.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIG. 1 illustrates a portion of composite material 10 that
may be used in connection with sports clothing and accessories and
which is made in accordance with an aspect of the present
invention. The composite material 10 comprises an exterior layer
12, an underlying layer 14 and a screening layer 16. The exterior
layer 12 preferably comprises natural leather or synthetic leather.
The underlying layer 14 underlies the exterior layer 12. The
underlying layer 14 preferably comprises natural leather or
synthetic leather.
[0021] The screening layer 16 is disposed between the underlying
layer 14 and the exterior layer 12. Preferably the screening layer
16 is coextensive with at least one of the exterior layer 12 and/or
the underlying layer 14. The screening layer 16 may be formed
solely of a single layer of a sheet-like material or a coating
material. Alternatively the screening layer may be formed of
multiple layers of sheet-like materials, which may be the same or
different, or multiple layers of coating materials, which may be
the same or different. The screening layer may optionally be formed
from a combination of one or more layers of sheet-like materials in
combination with one or more layers of coating materials. In any
variation the screening layer 16 comprises one or more layers of a
material having a low transmission rate to moisture in the liquid
state. In one embodiment, the material of the screening layer 16
resists penetration of moisture in both the liquid and vapor
states. In another embodiment, the material of the screening layer
16 resists penetration of moisture in the liquid state, but permits
penetration or permeation of moisture which is in the vapor state.
In the latter embodiment the screening layer 16 may be said to be
"breathable". The composition and structure of the screening layer
used in the present invention will vary according to whether the
barrier layer is intended to be permeable to moisture vapor or
resistant to penetration by water vapor.
[0022] The screening layer 16 may take the form of one or more
layers of a sheet-like material which, as used herein, refers to a
material having a heterogeneous, planar structure. In this form,
the sheet-like material is relatively thin in cross section, is
sufficiently flexible and resilient to conform readily to the shape
of the object in which it is incorporated and flex as necessary as
the object is flexed. Examples of sheet-like materials, which may
be used in the practice of the invention, include polymeric films
and metal foils. The polymeric films include, for example,
polyolefins, such as polyethylene and polypropylene; halogenated
polyolefins, such as polyvinyl chloride; polyesters, such as
polyethylene terephthalate; polyamides, such as nylons; and
homopolymers, such as polytetrafluoroethylene. Preferred materials
for use in this invention include polyethylene terephthalates which
are commercially available under the trademark MYLAR from DuPont,
Wilmington, Delaware, polytrimethylene terephthalates,
polybutadiene terephthalate, and expanded polytetrafluoroethylene
materials such as those sold under the trademark GORE-TEX,
commercially available from W. L. Gore and Associates, Wilmington,
Del. Metal foils for use in this invention should be thin,
sufficiently flexible so as to readily conform to the shape of the
object to which they are incorporated and to allow the article to
flex and move appropriately, and they should also be of
sufficiently low mass. Furthermore, the metal material should not
readily oxidize or otherwise deteriorate when exposed to moisture
or through the normal use of the article in which it is
incorporated. Aluminum foil is highly suitable for use in this
invention. Other metal foils such as, for example, copper foil may
be useful as well. Although the metallic screening layer has been
discussed in terms of a metallic foil layer it should be
appreciated that a layer of metal may be deposited in a process
such as vacuum deposition to provide a metallic screening layer 16
between the underlying layer 14 and exterior layer 12.
[0023] The screening layer 16 may be comprised of multiple layers
having different functions. As an example, FIG. 3 illustrates one
embodiment of a screening layer 16 having a central moisture
resistant layer 26 disposed between two adhesive layers 28, 30. The
adhesive layers function to allow bonding of the screening layer 16
to the exterior layer 12 and/or underlying layer 14. Naturally, if
the screening layer is intended to be permeable to moisture vapor
the adhesive layers 28, 30 should be discontinuous.
[0024] The particular embodiment illustrated in FIG. 1 shows a
material wherein the screening layer 16 is permeable to moisture
vapor, but resistant to penetration by moisture in the liquid
state. The screening layer 16 has discontinuities 20 (such as
pores) therein which are of a size sufficient for moisture vapor,
for example, to pass through from an area of higher concentration
to an area of lower concentration. The discontinuities 20 are small
enough so that the screening layer is resistant to penetration of
moisture in the liquid state. It will be understood that the
screening layer 16 may also be a completely occlusive barrier, that
is, it may be a screening layer which resists the penetration of
water in either the vapor or the liquid state.
[0025] The underlying layer 14, screening layer 16 and exterior
layer 12 are preferably laminated to form a seamless composite
material. If the screening layer 16 comprises a thermoplastic
material the lamination may be performed by applying heat and
pressure to an underlying layer 14, screening layer 16, exterior
layer 12 sandwich to securely integrate the discrete layers into a
unitary composite material. Alternatively, the underlying layer 14,
screening layer 16, exterior layer 12 may be laminated using an
adhesive or other binder 22 between the layers. The adhesive may be
any type of adhesive or binder which will securely adhere the
screening layer to the base layer and outer layer without
compromising the integrity, appearance, or performance of the
various components of the material. In the case of a material that
is intended to be permeable to moisture vapor, care must be taken
in the application of the adhesive or binder 22. Completely coating
any of the layers of the material with a continuous layer of
adhesive will occlude the pores 20 of the screening layer 16 and
reduce moisture vapor permeability of the composite material. It is
preferred, therefore, that the adhesive or binder 22 be applied in
a discontinuous fashion, such as in a dot pattern or other
discontinuous pattern to avoid occluding the pores 20 in the
screening layer 16. Such care need not be taken when the material
is intended to have a screening layer 16 which is resistant to
penetration of moisture in both the vapor and liquid states.
[0026] The screening layer 16 may also take the form of one or more
layers of a coating material. Typically, the coating material
initially is in a fluid form that dries, cures, or otherwise reacts
in situ to form a layer of a moisture resistant material. When the
screening layer 16 is in the form of a coating material, the
coating material must be of sufficient durability and resilience to
withstand incorporation into sports clothing and accessories such
as for example, a shoe, glove, or game ball. Coating materials
which are suitable for forming the screening layer 16 include, for
example, polyvinylidene chloride (such as those materials sold
under the trademark SARAN, commercially available from Dow Chemical
Company, Midland, Mich.), polyamides, epoxy resins, polyurethanes,
latex rubber, polyvinyl chloride, and polyvinyl alcohol.
[0027] It will be appreciated that a screening layer which is
non-permeable to moisture in both the liquid and vapor states will
prevent the penetration of moisture from the outside of an article
to the interior of the article. In addition, moisture that is
generated within the article, such as through perspiration of the
individual wearing a shoe or glove, may be trapped by the screening
layer. While such a non-permeable composite material would be
suitable for short term wear, or for conditions in which internal
moisture generation is not a concern or kept to a minimum, this
material and articles made from this material may not provide
optimum comfort to the wearer in other situations. Therefore, it is
advantageous to use clothing articles and sporting goods which are
made from a composite material having a "breathable" screening
layer which is resistant to penetration by moisture in the liquid
state, while permitting the transmission of moisture in the vapor
state. Such a breathable composite material allows the article to
be water resistant, while at the same time remaining relatively
comfortable to the wearer.
[0028] To be effective a breathable screening layer should have a
water vapor transmission rate that is appropriate for the given
article or sporting good and the conditions under which it is to be
used. For example, a shoe or glove which is intended for use in
warm weather and under conditions where perspiration of the wearer
is likely should have a relatively high water vapor transmission
rate. On the other hand, a shoe, glove or other article which will
be used in relatively cool temperatures and under conditions which
are not conducive to the wearer producing a great deal of
perspiration, may appropriately have a lower water vapor
transmission rate. It will be appreciated that the layer (exterior
12, screening 16 or underlying 14) in an article or composite
material that has the lowest water vapor transmission controls the
overall rate in which water vapor transmission occurs for the
entire article.
[0029] A suitable test for determining the water vapor transmission
rate of a material layer is set forth in ASTM D-96. This test
expresses water vapor transmission rate in terms of units of grams
of water transmitted per mil thickness of material per 100 in.sup.2
of material per day at 90% relative humidity and 100.degree. F. (g
per mil/100 in.sup.2 per day). For the purpose of this invention,
it is adequate that the screening layer 16 be rated in the range of
from about 0 to about 0.5 g per mil/100 in.sup.2 per day.
Preferably the screening layer 16 may be rated in the range from
about 0.0001 g per mil/100 in.sup.2 per day to about 0.3 g per
mil/100 in.sup.2 per day and most preferably from about 0.0002 g
per mil/100 in.sup.2 per day to about 0.2 g per mil/100 in.sup.2
per day.
[0030] In FIG. 2, a fielder's glove 34 is shown incorporating the
composite material comprising the underlying layer 14, screening
layer 16, and exterior layer 12 described above. The fielder's
glove or mitt 34 includes a palm 36, glove fingers 38, a thumb 40,
and webbing 42 for catching and trapping a baseball or softball.
The layers of material from which the glove is manufactured are
pierced to define lacing holes 48 to accommodate lacing 46 that is
used to bind the various edges of the material. The screening layer
is incorporated within the glove and functions to reduce the
transmission of moisture from the exterior to the wearer's hand.
While FIG. 2 illustrates a baseball fielder's glove, as discussed
above, the present invention may be employed in connection with
other sports clothing and accessories.
[0031] In another aspect of the invention the composite material is
incorporated into a game ball such as, for example, a basketball,
volleyball, soccer ball, baseball, softball, tennis ball, football,
golf ball, etc. For clarity of description and ease of
understanding, the invention will be described in connection with a
football as shown in FIG. 4. It will be noted that other game balls
can employ the various features of the present invention. The
invention is especially advantageous in connection with game balls
having natural or synthetic leather covers as the tendency of such
leather covers to absorb water is well known.
[0032] FIG. 4 shows a game ball 52 comprising an air bladder 54
that is commonly made of a highly durable, stretchable, air
impermeable material such as butyl rubber or a polyurethane
material. The bladder 54 is sealed to retain air pressure within.
Disposed directly over the air bladder 54 is the lining 56. The
lining is employed in the structure of the game ball to help the
ball retain the proper shape and to provide additional strength and
mechanical reinforcement to the cover material. Traditionally, the
linings of game balls were formed from one or more plies of fabric
or scrim made from highly water absorbent natural fibers such as
cotton or linen. Synthetic fibers such as polyester, nylon and even
glass fibers have more recently been used in forming the lining
material. Overlying the lining material is a cover 58. The cover is
formed of a material that has been cut into panels. The above
described composite material comprising an underlying layer 14,
screening layer 16 and exterior layer 12 is used to form the panels
of the game ball 52. In this fashion the screening layer 16 will
function to reduce moisture infiltration into the game ball 52. The
panels are joined to create seams 64. Traditionally, one seam 64 is
only partially joined to form an opening between adjacent panels
60, 62 through which the bladder 54 may be inserted. The edges of
the panels 60, 62 include lacing holes 66 through which laces 68
can be woven to join the panels 60, 62.
[0033] In a different embodiment, not shown, a cover material
comprised of the outer layer 12 and the screening layer 16 is used
to form the panels. This embodiment dispenses with the underlying
layer, placing the screening layer 16 adjacent the underlying game
ball structure. Alternatively, and also not shown, the screening
layer 16 is not bonded to the outer layer and can be disposed as a
discreet layer between the cover 58 and the lining 56 or bladder 54
to reduce moisture infiltration into the game ball 52.
[0034] While the present invention has been described in connection
with what are presently considered to be the most practical and
preferred embodiments, it is to be understood that the present
invention is not limited to the disclosed embodiments. Rather, it
is intended to cover all of the various modifications and the
equivalent arrangements included within the spirit and scope of the
appended claims.
* * * * *