U.S. patent application number 13/433955 was filed with the patent office on 2013-03-28 for temperature responsive smart textile.
This patent application is currently assigned to MMI-IPCO, LLC. The applicant listed for this patent is Moshe Rock. Invention is credited to Moshe Rock.
Application Number | 20130078415 13/433955 |
Document ID | / |
Family ID | 47911574 |
Filed Date | 2013-03-28 |
United States Patent
Application |
20130078415 |
Kind Code |
A1 |
Rock; Moshe |
March 28, 2013 |
Temperature Responsive Smart Textile
Abstract
A textile fabric includes a smooth surface with one or more
regions having coating material exhibiting thermal expansion or
contraction in response to change in temperature, adjusting
insulation performance of the textile fabric in response to ambient
conditions.
Inventors: |
Rock; Moshe; (Brookline,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rock; Moshe |
Brookline |
MA |
US |
|
|
Assignee: |
MMI-IPCO, LLC
Lawrence
MA
|
Family ID: |
47911574 |
Appl. No.: |
13/433955 |
Filed: |
March 29, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11740716 |
Apr 26, 2007 |
8187984 |
|
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13433955 |
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60804334 |
Jun 9, 2006 |
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Current U.S.
Class: |
428/96 ; 28/169;
428/212 |
Current CPC
Class: |
D04B 1/00 20130101; D06M
23/16 20130101; A41D 31/065 20190201; D06N 3/128 20130101; D06B
19/00 20130101; D06N 2209/06 20130101; D10B 2403/0112 20130101;
D06N 3/042 20130101; D06M 15/564 20130101; Y10T 428/23986 20150401;
D06N 3/183 20130101; D06M 15/263 20130101; A41D 2400/10 20130101;
D06N 2211/10 20130101; Y10T 428/24942 20150115; D06N 7/0092
20130101; D06M 15/643 20130101; D06N 3/045 20130101; D06N 3/14
20130101 |
Class at
Publication: |
428/96 ; 428/212;
28/169 |
International
Class: |
D04B 1/00 20060101
D04B001/00; D06B 19/00 20060101 D06B019/00 |
Claims
1. A bi-component layer for use in a textile fabric, the layer
comprising: a first coating material comprising a polymer that
expands or contracts gradually over a temperature range; and a
second coating material, at least a portion of the first coating
material directly contacting and overlying or underlying at least a
portion of the second coating material, the second coating material
comprising a polymer that remains soft and rubbery over the
temperature range, and, in response to changing temperature, the
first coating material and the second coating material respectively
exhibiting different thermal expansion or contraction over the
temperature range, thereby to change a three dimensional
configuration of the bi-component layer gradually and reversibly in
response to gradual temperature changes in ambient conditions.
2. The bi-component layer of claim 1, wherein the first coating
material comprises a crystallizing polymer.
3. The bi-component layer of claim 2, wherein the second coating
material comprises a soft rubbery polymer.
4. The bi-component layer of claim 1, wherein the first coating
material comprises polyurethane.
5. The bi-component layer of claim 1, wherein the second coating
material comprises polyurethane, silicone, or acrylate.
6. The bi-component layer of claim 1, wherein the temperature range
is between about -20.degree. C. and about 40.degree. C.
7. The bi-component layer of claim 1, wherein the temperature range
is between about 50.degree. F. and about 100.degree. F.
8. The bi-component layer of claim 1, wherein the polymer of the
second coating material remains soft and rubbery without
substantial expansion or contraction over the temperature
range.
9. The bi-component layer of claim 1, wherein the second coating
material comprises polypropylene or polyethylene.
10. The bi-component layer of claim 1, wherein the second coating
material is chemically bonded to the first coating material.
11. The bi-component layer of claim 1, wherein the second coating
material is physically bonded to the first coating material.
12. A textile fabric comprising: a textile fabric substrate having
a smooth surface; and discrete bi-component coatings disposed upon
and bonded to one or more regions of the smooth surface, each
bi-component coating comprising a first coating material and a
second coating material, at least a portion of the first coating
material directly contacting and overlying or underlying at least a
portion of the second coating material, the first coating material
comprising a crystallizing polymer, and the second coating material
comprising a soft rubbery polymer, and, in response to changing
temperature within a temperature range, the first coating material
expanding or contracting gradually over the temperature range, and
the second coating material remaining soft and rubbery over the
temperature range, the first coating material and the second
coating material exhibiting respectively different thermal
expansion or contraction characteristics in response to change in
temperature over the temperature range, thereby to adjust
insulation performance of the textile fabric by changing three
dimensional configuration of the textile fabric substrate gradually
in response to gradual temperature changes in ambient
conditions.
13. The textile fabric of claim 12, wherein the first coating
materials and the second coating material gradually change the
three dimensional configuration of the bi-component layer
reversibly.
14. The textile fabric of claim 12, wherein the temperature range
is between about -20.degree. C. and about 40.degree. C.
15. The textile fabric of claim 12, wherein the polymer of the
second coating material remains soft and rubbery without
substantial expansion or contraction over the temperature
range.
16. The textile fabric of claim 12, wherein the second coating
material comprises polypropylene or polyethylene.
17. The textile fabric of claim 12, wherein the second coating
material is chemically bonded to the first coating material.
18. The textile fabric of claim 12, wherein the second coating
material is physically bonded to the first coating material.
19. The textile fabric of claim 12, wherein the textile fabric
substrate has a construction selected from the group consisting of:
circular knit construction, warp knit construction, and woven
construction.
20. The textile fabric of claim 12, wherein the textile fabric
substrate comprises elastic yarn.
21. The textile fabric of claim 20, wherein the elastic yarn
comprises spandex yarn selected from the group consisting of: bare
spandex yarn, air entangled yarn, core-spun yarn, and wrap
yarn.
22. The textile fabric of claim 12, wherein the textile fabric
substrate has a knitting construction selected from the group
consisting of: single jersey, double knit, and terry loop.
23. The textile fabric of claim 22, wherein the terry loop is
formed in plaited construction.
24. The textile fabric of claim 22, wherein the terry loop is
formed in reverse plaited construction.
25. The textile fabric of claim 22, wherein the terry loop is
raised by napping.
26. The textile fabric of claim 12, wherein the textile fabric
substrate comprises a two-end fleece or a three-end fleece.
27. A method of forming a textile fabric element for use in an
engineered thermal fabric garment, the method comprising: forming a
textile fabric substrate having at least one smooth surface; and
disposing on and bonding to one or more regions of the smooth
surface discrete bi-component coatings, each bi-component coating
comprising a first coating material and a second coating material,
at least a portion of the first coating material directly
contacting and overlying or underlying at least a portion of the
second coating material, the first coating material comprising a
crystallizing polymer, and the second coating material comprising a
soft rubbery polymer, and, in response to changing temperature
within a temperature range, the first coating material expanding or
contracting gradually over the temperature range, and the second
coating material remaining soft and rubbery over the temperature
range, each of the first coating material and the second coating
material exhibiting respectively different thermal expansion or
contraction in response to change in temperature over the
temperature range, thereby to adjust insulation performance of the
textile fabric by changing three dimensional configuration of the
textile fabric substrate gradually and reversibly in response to
gradual temperature changes in ambient conditions.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No.
11/740,716, filed Apr. 26, 2007, now allowed, which claims benefit
from U.S. Provisional Patent Application 60/804,334, filed Jun. 9,
2006, now expired. The entire contents of both applications are
incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to textile fabrics, and more
particularly to textile fabrics responsive to change in ambient
temperature.
BACKGROUND
[0003] Standard textile fabrics have properties set during fabric
construction that are maintained despite changes in ambient
conditions and/or physical activity. These standard products are
quite effective, especially when layered with other textile fabrics
for synergistic effect and enhancement of comfort.
SUMMARY
[0004] According to one aspect, a textile fabric includes a smooth
surface with one or more regions of a first coating material
exhibiting thermal expansion or contraction in response to change
in temperature, adjusting insulation performance of the textile
fabric in response to ambient conditions.
[0005] Preferred implementations may include one or more of the
following additional features. The textile fabric can include one
or more regions of a second coating material overlying one or more
regions of the first coating material, the first coating material
together with the second coating material forming a bi-component
coating at the smooth surface of the textile fabric. The second
coating material may be chemically and/or physically bonded to the
first coating material. The second coating material is disposed on
a first surface of the first coating material opposite the smooth
surface of the textile fabric. The first coating material and the
second coating material exhibit differential thermal expansion to
cause a change in a three dimensional configuration of the textile
fabric in response to change in temperature. The first coating
material and the second coating material exhibit differential
thermal expansion in response to change in temperature over a
predetermined temperature range. In some cases, the predetermined
temperature range is between about -40.degree. F. and about
140.degree. F. In some examples, the predetermined temperature
range is between about 50.degree. F. and about 100.degree. F. In
other examples, the predetermined temperature range is between
about -40.degree. F. and about 60.degree. F., e.g., between about
-20.degree. F. and about 40.degree. F. The first coating material
may be a polymer, such as polyurethane. The polymer exhibits volume
change by crystallization. The polymer is configured to crystallize
at a temperature of between about -40.degree. F. and about
100.degree. F. For example, in some cases, the polymer is
configured to crystallize at a temperature of between about
50.degree. F. and about 100.degree. F., e.g., between about
60.degree. F. and about 98.degree. F., e.g., between about
69.degree. F. and about 73.degree. F. In another example, the
polymer is configured to crystallize at a temperature of between
about -40.degree. F. and about 60.degree. F., e.g., between about
-20.degree. F. and about 40.degree. F.
[0006] The second coating material comprises polymer, selected,
e.g., from the group consisting of: polyurethanes, silicones, and
acrylates. In some embodiments, one or more regions of the second
coating material are disposed on the smooth surface of the textile
fabric, and the first coating material overlies one or more regions
of the second coating material. In some cases, the first coating
material is arranged in overlapping relationship with the second
coating material such that at least a portion of the first coating
material contacts the smooth surface of the textile fabric. The
textile fabric includes one or more regions of a second material
disposed in side-by-side relationship with the first coating
material on the smooth surface of the textile fabric. The textile
fabric has a circular knit construction, warp knit construction,
and/or woven construction. In any of the above knit constructions,
elastic yarn may be added (e.g., spandex such as Lycra.RTM. or
Lycra.RTM. T-400) to, e.g., the stitch yarn. The spandex yarn can
include, for example, bare spandex yarn, core spun yarn, wrap yarn,
and/or air entangled yarn. The circular knit construction is formed
in single jersey construction, double knit construction, or terry
sinker loop construction. The terry sinker loop is formed in
plaited construction. The terry sinker loop is formed in reverse
plaited construction. The terry sinker loop may be raised by
napping or may remain in an un-napped condition. The first coating
material is disposed in a plurality of predetermined discrete
regions on the smooth surface of the textile fabric. The plurality
of predetermined discrete regions may be in the form of discrete
dots. The first coating material covers between about 5% and about
80% of the surface area of the smooth surface.
[0007] According to another aspect, a method of forming a
temperature responsive textile fabric element for use in an
engineered thermal fabric garment includes combining yarns and/or
fibers to form a continuous web; finishing the continuous web to
form at least one smooth surface; and depositing first coating
material on the smooth surface, the first coating material
exhibiting thermal expansion or contraction in response to change
in temperature, adjusting insulation performance of the textile
fabric in response to ambient conditions.
[0008] Preferred implementations may include one or more of the
following additional features. The step of combining yarn and/or
fibers in a continuous web includes combining yarn and/or fibers by
circular knitting to form a circular knit fabric. The step of
combining yarn and/or fibers in a continuous web by circular
knitting includes combining yarn and/or fibers by reverse plaiting.
The step of finishing includes finishing one surface of the
continuous web to form a terry sinker loop construction. The step
of combining yarn and/or fibers in a continuous web by circular
knitting includes combining yarn and/or fibers by plaiting. The
step of finishing includes finishing one surface of the continuous
web to form a terry sinker loop construction. The step of finishing
includes finishing the continuous web to form a single jersey
construction. The step of finishing includes finishing the
continuous web to form a double knit construction. The step of
combining yarn and/or fibers in a continuous web includes combining
yarn and/or fibers by warp knitting. The step of combining yarn
and/or fibers in a continuous web includes combining yarn and/or
fibers to form a woven fabric element. The step of depositing the
first coating material includes depositing the first coating
material in one or more discrete regions on the smooth surface of
the textile fabric. The one or more discrete regions are disposed
in a pattern corresponding to predetermined areas on an engineered
thermal fabric garment typically subjected to relatively high
levels of liquid sweat. The predetermined discrete regions are in
the form of a plurality of discrete dots. The step of depositing
the first coating material includes depositing the first coating
material over substantially the entire smooth surface of the
textile fabric. The method can include depositing second coating
material to overlie the first coating material, thereby forming a
bi-component coating at the smooth surface of the textile fabric,
wherein the first coating material and the second coating material
exhibit differential thermal expansion to cause change in a three
dimensional configuration of the textile fabric in response to
change in temperature. The second coating material may be bonded to
the first coating material, e.g., with a chemical and/or physical
bond. The method may also include drying the first coating material
prior to depositing the second coating material. In some cases,
depositing the second coating material comprises depositing the
second coating material to overlie one or more regions of the first
coating material. The step of depositing the second coating
material may include depositing the second coating material to
overlie one or more regions of the first coating material such that
at least a portion of the second coating material is disposed upon
the smooth surface of the textile fabric (e.g., for bonding at
least a portion of the second coating material to the surface of
the textile fabric). The step of depositing the second coating
material includes depositing the second coating material in
side-by-side relationship with the first coating material on the
smooth surface of the textile fabric. At least one of the first and
second coating materials include crystallizing polymer. Depositing
the first coating material includes depositing the first coating
material by a process selected from the group consisting of:
coating, lamination, and printing. Printing includes hot melt
printing, gravure roll printing, screen printing, or hot melt
gravure roll (i.e., hot melt by gravure roll application).
[0009] In yet another aspect, a temperature responsive textile
fabric garment includes a thermal fabric having a smooth outer
surface and a plurality of discrete regions of first coating
material. The plurality of discrete regions of the first coating
material are disposed in a pattern corresponding to one or more
predetermined regions of a user's body. The first coating material
exhibits thermal expansion or contraction in response to change in
temperature, thereby adjusting insulation performance of the
textile fabric in response to ambient conditions.
[0010] Preferred implementations may include one or more of the
following additional features. The first coating material comprises
shape memory polymer. The shape memory polymer exhibits volume
change by crystallization. The shape memory polymer is configured
to crystallize at a temperature of between about -40.degree. F. and
about 100.degree. F. For example, in some cases, the shape memory
polymer is configured to crystallize at a temperature of between
about 60.degree. F. and about 98.degree. F., e.g., between about
69.degree. F. and about 73.degree. F. In another example, the shape
memory polymer is configured to crystallize at a temperature of
between about -40.degree. F. and about 60.degree. F., e.g., between
about -20.degree. F. and about 40.degree. F. The shape memory
polymer is polyurethane. The textile fabric garment may be in the
form of an article of outerwear, e.g., for use in relatively lower
temperature environments (e.g., between about -40.degree. F. and
about 60.degree. F.). For example, the textile fabric garment may
be in the form of a jacket and/or outer shell. In some cases, for
example, the thermal fabric is a substantially flat outer shell
material, wherein the shape memory polymer exhibits expansion
and/or contraction in response to change in temperature to cause
change in a two-dimensional planar configuration of the thermal
fabric in response to change in temperature, thereby increasing
insulation performance of the textile fabric garment in response to
a decrease in temperature. The thermal fabric can include spandex
yarn or high stretch synthetic yarn for enhanced fit, comfort, and
shape recovery (e.g., to aid in the reversibility of three
dimensional changes in configuration of the thermal fabric). For
example, in some cases, the spandex is incorporated in the stitch
(e.g., in the form of bare spandex yarn, air entangled yarn,
core-spun yarn, and/or wrap yarn, etc.). A plurality of discrete
regions of a second coating material are disposed adjacent and
corresponding to the plurality of discrete regions of the first
coating material, wherein the first coating material and the second
coating material exhibit differential thermal expansion to cause
change in a three dimensional configuration of the garment in
response to change in temperature, thereby adjusting insulation
performance of the textile fabric.
[0011] In another aspect, a temperature response textile fabric
garment system includes an inner thermal fabric layer formed of a
first, inner textile fabric having a smooth outer surface with one
or more regions of a first coating material exhibiting thermal
expansion or contraction in response to change in temperature,
adjusting insulation performance of the first, inner textile fabric
in response to ambient conditions, and having an inner surface
towards a wearer's skin. The temperature response textile fabric
garment system may also include an outer thermal fabric layer
formed of a second, outer textile fabric having a smooth outer
surface with one or more regions of an other coating material
exhibiting thermal expansion or contraction in response to change
in temperature, adjusting insulation performance of the second,
outer textile fabric in response to ambient conditions, and having
an inner surface towards the smooth outer surface of the inner
thermal fabric layer.
[0012] Preferred implementations may include one or more of the
following additional features. At least one of the first coating
material and the other coating material includes polymer that
exhibits volume change by crystallization. The polymer is
configured to crystallize at a temperature of between about
-40.degree. F. and about 100.degree. F. For example, the polymer of
the first, inner textile fabric may be configured to crystallize at
a temperature of between about 50.degree. F. and about 100.degree.
F., e.g., between about 60.degree. F. and about 98.degree. F., and
preferably between about 69.degree. F. and about 73.degree. F., and
the polymer of the second, outer textile fabric may be configured
to crystallize at a temperature of between about -40.degree. F. and
about 60.degree. F., e.g., between about -20.degree. F. and about
40.degree. F. The first, inner textile fabric may include one or
more regions of second coating material underlying one or more
regions of the first coating material, wherein the first coating
material and the second coating material exhibit differential
thermal expansion to cause change in three-dimensional
configuration of the inner thermal fabric layer in response to
change in temperature. The second, outer textile fabric may include
one or more regions of second coating material underlying one or
more regions of the other coating material, wherein the other
coating material and the second coating material exhibit
differential thermal expansion to cause change in three-dimensional
configuration of the outer thermal fabric layer in response to
change in temperature.
[0013] In another aspect, a bi-component layer for use in a textile
fabric comprises a first coating material and a second coating
material. The first material comprises a polymer that expands or
contracts gradually over a temperature range. At least a portion of
the first coating material directly contacts and overlies or
underlies at least a portion of the second coating material. The
second coating material comprises a polymer that remains soft and
rubbery, e.g., without substantial expansion or contraction, over
the temperature range. In response to changing temperature, the
first coating material and the second coating material respectively
exhibit different thermal expansion or contraction over the
temperature range. A three dimensional configuration of the
bi-component layer is changed gradually and reversibly in response
to gradual temperature changes in ambient conditions.
[0014] Preferred implementations may include one or more of the
following additional features. The first coating material comprises
a crystallizing polymer. The second coating material comprises a
soft rubbery polymer. The first coating material comprises
polyurethane. The second coating material comprises polyurethane,
silicone, polypropylene, polyethylene, or acrylate. The temperature
range is between about -40.degree. F. and about 140.degree. F.,
e.g., between about -20.degree. C. about 40.degree. C. The
temperature range is between about 50.degree. F. and about
100.degree. F. The temperature range is between about -40.degree.
F. and about 60.degree. F. The temperature range is between about
-20.degree. F. and about 40.degree. F. The second coating material
is chemically bonded to the first coating material. The second
coating material is physically bonded to the first coating
material.
[0015] In another aspect, a textile fabric comprises a textile
fabric substrate having a smooth surface and discrete bi-component
coatings disposed upon and bonded to one or more regions of the
smooth surface. Each bi-component coating comprises a first coating
material and a second coating material. At least a portion of the
first coating material directly contacts and overlies or underlies
at least a portion of the second coating material. The first
coating material comprises a crystallizing polymer. The second
coating material comprises a soft rubbery polymer. In response to
changing temperature within a temperature range, the first coating
material expands or contracts gradually over the temperature range,
and the second coating material remains soft and rubbery, e.g.,
without substantial expansion or contraction, over the temperature
range. The first coating material and the second coating material
exhibit respectively different thermal expansion or contraction
characteristics in response to change in temperature over the
temperature range. Insulation performance of the textile fabric is
adjusted by changing three dimensional configuration of the textile
fabric substrate gradually in response to gradual temperature
changes in ambient conditions.
[0016] Preferred implementations may include one or more of the
following additional features. The first coating materials and the
second coating material gradually change the three dimensional
configuration of the bi-component layer reversibly. The temperature
range is between about -40.degree. F. and about 140.degree. F.,
e.g., between about -20.degree. C. and about 40.degree. C. The
temperature range is between about 50.degree. F. and about
100.degree. F. The temperature range is between about -40.degree.
F. and about 60.degree. F. Temperature range is between about
-20.degree. F. and about 40.degree. F. The second coating material
is chemically bonded to the first coating material. The second
coating material is physically bonded to the first coating
material. The textile fabric substrate has a construction selected
from the group consisting of: circular knit construction, warp knit
construction, and woven construction. The textile fabric substrate
comprises elastic yarn. The elastic yarn comprises spandex yarn
selected from the group consisting of: bare spandex yarn, air
entangled yarn, core-spun yarn, and wrap yarn. The textile fabric
substrate has a knitting construction selected from the group
consisting of: single jersey, double knit, and terry loop, or is a
two-end fleece or a three-end fleece. The terry loop is formed in
plaited construction. The terry loop is formed in reverse plaited
construction. The terry loop is raised by napping.
[0017] In another aspect, a method of forming a textile fabric
element for use in an engineered thermal fabric garment comprises
forming a textile fabric substrate having at least one smooth
surface and disposing on and bonding to one or more regions of the
smooth surface discrete bi-component coatings. Each bi-component
coating comprises a first coating material and a second coating
material. At least a portion of the first coating material directly
contacts and overlies or underlies at least a portion of the second
coating material. The first coating material comprises a
crystallizing polymer. The second coating material comprises a soft
rubbery polymer. In response to changing temperature within a
temperature range, the first coating material expands or contracts
gradually over the temperature range, and the second coating
material remains soft and rubbery, e.g., without substantial
expansion or contraction, over the temperature range. Each of the
first coating material and the second coating material exhibits
respectively different thermal expansion or contraction in response
to change in temperature over the temperature range. Insulation
performance of the textile fabric is adjusted by changing three
dimensional configuration of the textile fabric substrate gradually
and reversibly in response to gradual temperature changes in
ambient conditions.
[0018] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0019] FIGS. 1A-B are cross-sectional views of a textile fabric
with a temperature responsive coating material.
[0020] FIGS. 2A-2B are cross-sectional views of a temperature
responsive textile fabric with a temperature responsive
bi-component coating material.
[0021] FIG. 3A is a front perspective view of a temperature
responsive textile fabric garment.
[0022] FIGS. 3B-3C are detailed cross-sectional views of the
temperature responsive textile fabric garment of FIG. 3A.
[0023] FIG. 4A is a front perspective view a temperature responsive
textile fabric having first and second discrete regions of coating
that exhibit contrasting thermal elongation/contraction in response
to changes in temperature.
[0024] FIG. 4B is a detailed cross-sectional view of the
temperature responsive textile fabric garment of FIG. 4A.
[0025] FIG. 5A is a front perspective view of a temperature
response textile fabric garment system having inner and outer
fabric layers that change in three-dimensional configuration in
response to changes in temperature.
[0026] FIGS. 5B and 5C are detailed cross-sectional views of the
temperature responsive textile fabric garment system of FIG.
5A.
[0027] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0028] Referring to FIGS. 1A-1B, a temperature responsive smart
textile fabric 10 has a smooth fabric surface 12 with a region of
coating material 14. The textile fabric 10 can be circular knit
(e.g., single jersey, double knit, terry sinker loop in plaited or
reverse plaited construction, two-end fleece, and/or three-end
fleece), warp knit, or woven construction. Preferred textile
fabrics contain spandex for enhanced fit, comfort, and shape
recovery. As illustrated in FIG. 1B, the coating material responds
to change in temperature by exhibiting thermal expansion or
contraction, thereby changing the three dimensional configuration
of the fabric 10. As shown in FIGS. 1A and B, the coating material
14 is a single polymer layer capable of changing volume through
crystallization. The polymer is capable of crystallization in a
temperature range of between about -40.degree. F. and about
100.degree. F. In some cases, e.g., where the textile fabric is
incorporated next to the wearer's skin or as an inner layer of a
garment, the polymer is selected to be capable of crystallization
in a temperature range of between about 60.degree. F. to about
98.degree. F. (e.g., a skin temperature range), e.g., between about
69.degree. F. and about 73.degree. F. (e.g., a room temperature
range). In some other cases, e.g., where the temperature responsive
textile fabric is incorporated as an outer layer in a garment of
outerwear, e.g., a jacket and/or an outer shell, for cold weather
applications, the polymer preferably is selected to be capable of
crystallizing in a temperature range of between about -40.degree.
F. and about 60.degree. F., e.g., between about -20.degree. F. and
about 40.degree. F.
[0029] Preferred materials include shape memory polymer, e.g.,
polyurethane, which can be designed (formulated) to have a
crystalline melting temperature selected from a wide range of
temperatures. Crystallization is accompanied by the change in
volume. Referring again to FIG. 1B, as the ambient temperature is
reduced (indicated by arrow 20) below a threshold temperature, the
coating material 14 shrinks (i.e., contracts) and buckles, thereby
changing the surface geometry of the fabric 10. This process is
also highly reversible (as indicated by arrow 22).
[0030] As shown in FIG. 2A, a second coating material 16 is
introduced between the first layer of coating material 14 and the
fabric surface 12, forming a bi-component coating layer 18. The
second coating material 16 is added to adjust the effect of the
first coating material 14 has on the textile fabric 10. For
example, in some embodiments, the first layer 14 includes a
crystallizing polymer, of the type described above, and the second
layer 16 includes a soft rubbery polymer (e.g., polyurethanes,
silicones, polypropylene, polyethylene and/or acrylates). The
crystallizing polymer shrinks as the temperature drops below the
crystallization temperature (preferably, below 100.degree. F.),
while the second polymer remains soft at the same temperature,
resulting in differential shrinkage that changes the three
dimensional configuration of the textile fabric 10. As a result, a
convex dome is formed on the surface of the fabric.
[0031] A contrasting effect can be achieved by reversing the
sequence of the first and second coating layers 14, 16. As
illustrated in FIG. 2B, the sequence of the layers is reversed,
placing the first coating material (i.e., crystallizing polymer) in
contact with the fabric surface 12, while the second polymer
material is disposed above the first polymer material, forming the
bi-component coating layer 18. As temperature decreases, the
differential shrinkage of the two polymer layers causes a concave
dome to form on the surface of the fabric.
[0032] In the embodiment depicted in FIG. 3A, a temperature
responsive textile fabric 10 is incorporated in a fabric garment
30. The temperature responsive garment 30 consists of a fabric
formed as a woven or knit textile fabric, e.g. as single jersey,
plaited jersey, double knit, terry sinker loop in plaited or
reverse plaited construction, two-end fleece, or three-end fleece,
with or without spandex stretch yarn. The textile fabric 10 will
preferably still have other comfort properties, e.g. good water
management, good stretch recovery, and/or kindness to the wearer's
skin. The inner surface of the textile knit fabric, i.e. the
surface opposite the wearer's skin, can be raised, e.g. raised
terry loop, to reduce the touching points to the skin
[0033] A plurality of discrete regions 18 of single component
coating (as illustrated for example in FIGS. 1A and 1B) or
bi-component coating 18 (as shown, e.g., in FIGS. 3A-3D) are
arranged on a smooth outer surface 12 of the garment 30. Referring
to FIG. 3B, for example, as the ambient temperature drops, the
first and second coating materials 14, 16, of the bi-component
coating 18 exhibit differential thermal contraction causing a
change in the three dimensional configuration of the textile
fabric. More specifically, the change in the three dimensional
configuration of the textile fabric generates increased bulk, and,
as a result, increased thermal insulation, thereby providing
enhanced overall comfort in cooler temperatures. In addition, the
change in three dimensional configuration can reduce clinging of
the textile fabric to the user's skin (e.g., when saturated with
liquid sweat), thereby to minimize user discomfort.
[0034] FIG. 3C illustrates the behavior of the fabric garment 30 as
the temperature increases above a threshold value. In this example,
as the ambient temperature increases, the first and second coating
materials 14, 16 of the bi-component coating 18 exhibit
differential thermal expansion, again causing a change in the three
dimensional configuration of the textile fabric. However, as the
ambient temperature increases, the change in the three dimensional
configuration of the textile fabric increases the air gap between
the user's skin S and the fabric garment 30, thereby allowing
increased air flow in the area between the user's skin S and the
fabric garment 30, while at the same time reducing the thermal
insulation provided by the fabric garment.
[0035] FIGS. 4A and 4B illustrate another embodiment in which a
temperature responsive textile fabric 10 is incorporated in a
fabric garment 40. The temperature responsive fabric garment 40
includes a plurality of first discrete regions of coating 20 and a
plurality of second discrete regions of coating 22 disposed on a
smooth outer surface of the garment 40, the first and second
discrete regions of coating 20, 22 exhibiting differential thermal
contraction in response to change in temperature. As shown in FIG.
4B, the first discrete regions of coating 20 are a bi-component
coating having a first layer 14, including a crystallizing polymer,
and a second layer 16, including a soft rubbery polymer (e.g.,
polyurethanes, silicones, polypropylene, polyethylene, and/or
acrylates). Referring still to FIG. 4B, the second discrete regions
of coating 22 are also a bi-component coating; however, the
sequence of the layers is reversed, placing the first coating
material 14 (i.e., the crystallizing polymer) in contact with the
fabric surface 12 while the second polymer material 16 is disposed
above the first polymer material 14, forming the second discrete
region(s) of bi-component coating 22. In this manner, three
dimensional changes in bulk and thermal insulation of the fabric
garment can be adjusted as a function of differential thermal
expansion/contraction of the selected polymers, and the pattern and
density of the coating regions.
[0036] Referring to FIGS. 5A and 5B, a temperature response textile
fabric garment system 100, e.g., as shown, embodied in a jacket
constructed for use in cold weather conditions, consists of an
inner fabric layer 110 and an outer fabric layer 120. The inner
fabric layer 110 is disposed in contact with, or relatively close
to, the wearer's skin when the garment 100 is worn. In contrast,
the outer fabric layer 120 is disposed at, or relatively close to,
the exterior surface of the garment, and spaced from the wearer's
skin, when the garment 100 is worn.
[0037] The inner fabric layer has a smooth outer surface 112 with
discrete regions of coating material 114. The coating material 114
expands or contracts in response to change in temperature, thereby
changing the three-dimensional configuration of the inner fabric
layer (as shown, for example, in FIG. 5B) in response to change in
temperature, e.g. at a temperature of between about -40.degree. F.
and about 60.degree. F., e.g. between about -20.degree. F. and
about 40.degree. F., and, as a result, adjusting the insulation
performance of the inner fabric layer 110.
[0038] The outer fabric layer 120 also includes a smooth outer
surface 122 with discrete regions of another coating material 124.
The outer fabric layer 120 may be, for example, a jacket or an
outer shell. The other coating material 124 expands or contracts in
response to change in temperature, e.g. at a temperature of between
about 50.degree. F. and about 100.degree. F., e.g. between about
60.degree. F. and about 98.degree. F., e.g. between about
69.degree. F. and about 73.degree. F., thereby changing the
three-dimensional configuration of the outer fabric layer 120, and,
as a result, adjusting the insulation performance of the outer
fabric layer 120.
[0039] The respective coating materials 114, 124 may be of the type
described above with respect to FIGS. 1A and 1B. Referring to FIG.
5C, the inner fabric layer 110 and/or the outer fabric layer 120
may also include a second coating material 130, for example, of the
type described above with respect to FIGS. 2A and 2B (i.e., second
coating material 16). The second coating material 130 and the
coating material 114 exhibit differential thermal expansion in
response to change in temperature, thereby adjusting the effect
that the coating material 114 has on the inner fabric layer 110.
Similarly, the second coating material 130 exhibits differential
thermal expansion with respect to the other coating material 124,
thereby adjusting the effect of the other coating material 124 on
the outer fabric layer 120.
[0040] The respective changes in three-dimensional configuration of
the inner and outer fabric layers 110 and 120 generate enhanced
bulk and increased thermal insulation in response to decrease in
the ambient temperature, thereby providing enhanced comfort in
cooler climate applications.
[0041] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. For example, the polymer or polymer layers
may be applied on a textile fabric garment in a body mapping
pattern. The polymer layers may be applied over high coverage area
(i.e., a large part of the surface of the textile fabric is
covered), or low coverage area. The polymer or polymer layers may
be deposited on the textile fabric utilizing coating, laminating,
and/or printing techniques, e.g., hot melt printing, gravure roll
printing, and/or screen printing. The first polymer layer may be
applied by itself directly on the fabric or over the second polymer
layer. The polymer layers may be deposited on the surface of the
textile fabric in side-by-side relationship.
[0042] Also, the temperature responsive textile fabric garment
system shown in FIG. 5A has a first, inner textile fabric layer
responsive in a first range of temperatures and a second, outer
textile fabric layer responsive in a second, contrasting range of
temperatures. In other embodiments, a temperature responsive
textile fabric garment system may have only single fabric layer
responsive to temperature or it may have multiple fabric layers
responsive to temperature. Also, each fabric layer may be
responsive in a desired range or ranges of temperatures selected on
the basis of one or more factors, including, e.g., sequential
position of the fabric layer in constructions of the garment,
expected temperature and other environmental conditions of use,
etc.
[0043] Accordingly, other embodiments are within the scope of the
following claims.
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