U.S. patent application number 14/085896 was filed with the patent office on 2014-05-22 for method for manufacturing a waterproof and breathable article of clothing.
This patent application is currently assigned to DECATHLON, S.A.. The applicant listed for this patent is Mimoun Aamer, Sylvain Borreau, Serge Piranda. Invention is credited to Mimoun Aamer, Sylvain Borreau, Serge Piranda.
Application Number | 20140137307 14/085896 |
Document ID | / |
Family ID | 47833182 |
Filed Date | 2014-05-22 |
United States Patent
Application |
20140137307 |
Kind Code |
A1 |
Borreau; Sylvain ; et
al. |
May 22, 2014 |
Method for Manufacturing a Waterproof and Breathable Article of
Clothing
Abstract
The invention relates to a method for manufacturing a waterproof
and breathable article of clothing 1 comprising an envelope 2 that
has inner 3 and outer 4 surfaces, the method involving: at least
one step of coating (100), during which the inner surface 3 is
outward-facing, comprising coating the outward-facing inner surface
with a solution 6 with a base of at least one polymer, with air A
under pressure being injected into the envelope during the coating,
then drying the envelope in order to form a first layer 10 of
waterproof and breathable polymer on the inner surface; and at
least one step of impregnation (200), during which the inner
surface 3 is inward-facing, comprising pouring into the envelope a
solution 11 with a base of at least one polymer, removing the
excess solution 11, injecting air A under pressure into the
envelope, and drying the envelope in order to form a second layer
15 of waterproof and breathable polymer on the first layer 10.
Inventors: |
Borreau; Sylvain;
(Villeneuve d'Ascq, FR) ; Aamer; Mimoun; (Marcq en
Baroeul, FR) ; Piranda; Serge; (Besancon,
FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Borreau; Sylvain
Aamer; Mimoun
Piranda; Serge |
Villeneuve d'Ascq
Marcq en Baroeul
Besancon |
|
FR
FR
FR |
|
|
Assignee: |
DECATHLON, S.A.
Villeneuve d'Ascq
FR
|
Family ID: |
47833182 |
Appl. No.: |
14/085896 |
Filed: |
November 21, 2013 |
Current U.S.
Class: |
2/69 |
Current CPC
Class: |
A41D 31/102 20190201;
A41D 19/001 20130101; A41D 19/01 20130101; A41D 19/0058
20130101 |
Class at
Publication: |
2/69 |
International
Class: |
A41D 31/00 20060101
A41D031/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 21, 2012 |
FR |
FR-12 61097 |
Claims
1. A method for manufacturing a waterproof and breathable article
of clothing comprising the steps of: providing an article of
clothing (1), said article comprising an envelope (2) that has an
inner surface (3) intended to be worn in the vicinity of a portion
of the body of a wearer and an outer surface (4) opposite said
inner surface; turning the envelope over in such a way that its
inner surface (3) is outward-facing; coating (100) the article,
wherein the step of coating the article comprises the steps of:
coating said inner surface with a first solution (6) comprising at
least one waterproof and breathable polymer, with air (A) under
pressure being injected into said envelope during said coating; and
drying said envelope in order to form a first layer (10) of
waterproof and breathable polymer on said inner surface; turning
the envelope over in such a way that its inner surface (3) covered
with the first layer (10) of polymer is inward-facing; and
impregnating (200) the article, wherein the step of impregnating
the article comprises the steps of: pouring into said envelope a
second solution (11) comprising at least one waterproof and
breathable polymer; removing the excess second solution (11) from
said envelope; injecting air (A) under pressure into said envelope;
and drying said envelope in order to form a second layer (15) of
waterproof and breathable polymer on the first layer (10).
2. The method according to claim 1, wherein the first solution (6)
and/or the second solution (11) comprises a hydrophilic polymer
with a polyurethane base.
3. A method according to claim 1, wherein the step of coating the
article (100) and/or the step of impregnating the article (200) is
repeated at least two times.
4. A method according to claim 3, wherein the step of coating said
inner surface with a first solution (6) utilizes first solutions
(6) of different compositions at each repetition, and/or the step
of pouring into said envelope (11) utilizes second solutions (11)
of different compositions at each repetition.
5. A method according to claim 1, wherein the step of coating the
inner surface (3) further comprises the step of immersing the
envelope (2) in a bath (9) containing the solution (6) of
polymer.
6. A method according to claim 1, wherein the step of coating the
inner surface (3) further comprises the step of spraying the
solution (6) of polymer on said inner surface.
7. A method according to claim 1, wherein the step of drying the
envelope to form a first layer (10) and/or the step of drying the
envelope to form a second layer (15) further comprises injecting
air under pressure into the envelope (2) while it is being
dried.
8. A method according to any of claims 1, further comprising the
step of arranging a lining in the envelope (2) after the excess
second solution (11) is removed and before drying said envelope, in
order to fix said lining to said envelope during said drying by the
intermediary of the second layer (15) of polymer.
9. A method according to claim 8, further comprising the step of
injecting air under pressure into the lining.
10. A method according to claim 8 wherein the lining comprises at
least one layer of material that has thermal insulation
properties.
11. A waterproof and breathable article of clothing obtained by
implementing the method of claim 1.
12. A method for manufacturing a waterproof and breathable article
of clothing comprising the steps of: providing an article of
clothing comprising an envelope having an inner surface and an
outer surface; coating said inner surface with a first solution
while pressure is applied to said outer surface; and impregnating
said inner surface with a second solution while pressure is applied
to said inner surface.
13. The method of claim 12, wherein the step of coating said inner
surface with a first solution further comprises the steps of:
turning the article of clothing such that said inner surface is
outward-facing; and applying said first solution to said inner
surface while applying air pressure to said outer surface.
14. The method of claim 12, wherein the step of impregnating said
inner surface with a second solution further comprises the steps
of; turning the article of clothing such that said inner surface is
inward-facing; applying said second solution to said inner surface;
and applying air pressure to said inner surface after said second
solution is applied.
15. The method of claim 13 wherein the step of applying said first
solution further comprises the step of immersing said article of
clothing at least partially into said first solution.
16. The method of claim 13 wherein the step of applying said first
solution further comprises the step of spraying said first solution
onto at least a portion of said article of clothing.
17. The method of claim 14 further comprising the steps of
arranging a liner to the inner surface after said second solution
is applied and pressing said liner against said inner surface.
18. A method for manufacturing a waterproof and breathable article
of clothing comprising the steps of: providing an article of
clothing comprising an envelope having an inner surface and an
outer surface; turning the article of clothing such that said inner
surface is outward-facing; coating said inner surface with a first
solution comprising at least one waterproof and breathable polymer
while applying air under pressure to the outer surface to form a
layer on said inner surface; turning the article of clothing such
that said inner surface is inward-facing; and impregnating said
inner surface with a second solution.
19. The method of claim 18, wherein the step of impregnating said
inner surface with a second solution further comprises the steps
of: applying said second solution to said layer on said inner
surface, wherein said second solution comprises at least one
waterproof and breathable polymer; and applying air pressure to
said inner surface to force said second solution into any pores and
voids in said layer; and
20. The method of claim 18, further comprising the steps of:
arranging a liner to the inner surface after impregnating said
inner surface with said second solution; and pressing said liner
against the second solution before the second solution is fully
dried or cured to fix the liner to the inner surface.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims priority under 35 USC 119 and/or 365
of French Patent Application No. FR-12 61097 filed on Nov. 21, 2012
with the French Institut National de la Propriete Industrielle
(INPI). The contents of the above-identified Application are relied
upon and incorporated herein in their entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method for manufacturing a
waterproof and breathable article of clothing, as well as such an
article obtained by implementing such a method.
[0004] It applies especially to sports articles intended for use in
difficult climatic conditions due to the cold and/or inclement
weather, such as for example gloves, shoes, insulated slippers,
bonnets or hoods.
[0005] 2. Description of the Related Art
[0006] During the practice of sports, the body gives off
perspiration, in particular in the form of water vapour. However,
wearing unsuitable articles of clothing, for example conventional
waterproof articles intended to protect against the cold and/or
inclement weather, can be uncomfortable, in that these articles do
not allow the water vapour to be removed towards the exterior.
[0007] In order to overcome these disadvantages, waterproof and
breathable articles of clothing are known which are arranged to
prevent the humidity coming from the exterior from penetrating
inside said articles while allowing the water vapour generated by
the body of the wearer to be removed to the outside.
[0008] To do so, waterproof and breathable articles are known
comprising an outer envelope generally at least water-repellent, an
inner lining having thermal insulation properties, as well as a
waterproof and breathable insert arranged between said envelope and
said lining. The insert comprises in particular an impermeable
membrane but which allows the water vapour to pass in order to
confer the expected breathability, for example by being microporous
or hydrophilic.
[0009] However, these articles do not provide entire satisfaction,
in that their manufacture is long and expensive. Moreover, when
used during high humidity conditions, the water coming from the
exterior can pass through the envelope via its seam holes, the
impermeability of which is generally lacking, then be stopped by
the insert, in such a way that said water is retained between said
envelope and said insert while waiting to be removed by
evaporation. However, this water, by being retained as such in the
article of clothing, can over time generate a sensation of cold
and/or humidity for the wearer, thus rendering the wearing of said
article unpleasant for said wearer.
[0010] Furthermore, the presence of water in the vicinity of the
insert compromises the removal of the water vapour generated by the
body of the wearer, in such a way that said water vapour remains
inside the article of clothing and is condensed, which also
constitutes discomfort for the wearer.
[0011] In addition, when the wearer is exposed to wind, the water
retained between the envelope and the insert evaporates slowly,
which also generates a sensation of cold for the wearer. Moreover,
the drying time of the article of clothing is very greatly
increased, which renders its use less pleasant after a first use in
high humidity conditions.
BRIEF SUMMARY OF THE INVENTION
[0012] The invention aims to improve prior art by proposing a
method for manufacturing an article of clothing wherein a
waterproof and breathable barrier is formed directly on the inner
surface of the envelope of said article, which makes it possible to
prevent water weight gain of said article when it is used in a wet
environment while improving its quality and its lifespan.
[0013] For this purpose, according to a first aspect, the invention
relates to a method for manufacturing a waterproof and breathable
article of clothing, said article comprising an envelope that has
an inner surface intended to be worn in the vicinity of a portion
of the body of a wearer and an outer surface opposite said inner
surface, said method providing for: [0014] at least one step of
coating (100), during which said envelope is turned over in such a
way that its inner surface is outward-facing, said step providing
for coating said inner surface with a solution with a base of at
least one waterproof and breathable polymer, with air under
pressure being injected into said envelope during said coating,
then for drying said envelope in order to form a first layer of
waterproof and breathable polymer on said inner surface; and [0015]
at least one step of impregnation (200), during which said envelope
is turned over in such a way that its inner surface covered with
the first layer of polymer is inward-facing, said step providing
for pouring into said envelope a solution with a base of at least
one waterproof and breathable polymer, for removing the excess
solution from said envelope, for injecting air under pressure into
said envelope, then for drying said envelope in order to form a
second layer of waterproof and breathable polymer on the first
layer.
[0016] According to a second aspect, the invention relates to a
waterproof and breathable article of clothing obtained by
implementing such a method.
[0017] Other particularities and advantages of the invention shall
appear in the following description, made in reference to the
annexed figures diagrammatically showing the steps of a method
according to an embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a flowchart depicting a method in accordance with
the invention.
[0019] FIG. 2 is a more detailed flowchart in accordance with the
invention shown in FIG. 1.
[0020] FIG. 3 is a more detailed flowchart in accordance with the
invention shown in FIG. 1.
[0021] FIG. 4A and FIG. 4B depict a side view and cutaway view
respectively of an exemplary article of clothing prepared for the
coating process of the method shown in FIG. 1.
[0022] FIG. 5A and FIG. 5B depict an exemplary article of clothing
being coated by the method shown in FIG. 1.
[0023] FIG. 6A and FIG. 6B depict a side view and cutaway view
respectively of an exemplary article of clothing after the coating
process of the method shown in FIG. 1.
[0024] FIG. 7A and FIG. 7B depict a side view and cutaway view
respectively of an exemplary article of clothing turned for the
impregnating process of the method shown in FIG. 1.
[0025] FIG. 8A depicts the addition and removal of the solution for
the impregnating process of the method shown in FIG. 1.
[0026] FIG. 8B depicts the injection of air during the impregnating
process of the method shown in FIG. 1.
[0027] FIG. 9A and FIG. 9B depict a side view and cutaway view
respectively of an exemplary article of clothing prepared by the
method shown in FIG. 1.
[0028] FIG. 10A and FIG. 10B depict a side view and cutaway view
respectively of an exemplary lined article of clothing prepared by
the method shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0029] In relation with the figures, a method for manufacturing a
waterproof and breathable article of clothing 1 is described, said
article of clothing comprising an envelope 2 which has an inner
surface 3 intended to be worn in the vicinity of a portion of the
body of a wearer and an outer surface 4 opposite said inner
surface. As shown in FIG. 1, the method comprises providing an
article of clothing (50), turning the envelope over in such a way
that the inner surface is facing outwards (60), coating the
outward-facing inner surface with polymer (100), turning the
envelope over in such a way that the inner surface is facing
inwards (150), and impregnating the inner surface with polymer
(200).
[0030] In the embodiment shown, the article of clothing 1 is a
glove of the mitten type, with a compartment for the thumb and a
shared compartment for the other fingers. In other embodiments, the
article of clothing 1 is for example a glove of another type, a
shoe, a slipper, a bonnet or a hood.
[0031] The method provides for forming a waterproof and breathable
barrier 5 directly on the inner surface 3 of the envelope 2, which
makes it possible to simply, inexpensively and in a manner that is
easy to automate manufacture articles of clothing 1 with complex
and varied shapes such as those described hereinabove. As such, the
method offers a wide range of choices as for the aesthetics of the
articles of clothing 1 to be manufactured.
[0032] To do so, the method provides at least one step of coating
(100), during which the envelope 2 is turned over in such a way
that its inner surface 3 is outward-facing (60), said step
providing for coating said inner surface with a first solution 6
with a base of at least one waterproof and breathable polymer.
[0033] In some embodiments, the step of coating (100) provides for
using a first solution 6 comprising a hydrophilic polymer, in
particular with a polyurethane base, as much as polyurethane is
recognised for its satisfactory properties as a barrier to liquid
water and for transferring the water vapour in order to confer the
expected breathability. In some embodiments, the polymer is used in
aqueous phase, which makes it possible to use a first solution 6
devoid of non-aqueous solvent.
[0034] Moreover, as shown in FIG. 2, FIG. 5A and FIG. 5B, the
outward-facing inner surface is coated with first solution 6 while
injecting air into the envelope (110). Air A under pressure is
injected into the envelope 2 during the coating in order to shape
it via inflating, which makes it possible to coat its inner surface
3 homogeneously and, in the case where said envelope is assembled
by stitching, to prevent the polymer from penetrating inside the
envelope 2 through the seams. Furthermore, the pressure of the air
A is sufficient to provide for the shaping of the envelope 2 so
that the coating perfectly hugs the three-dimensional shape of the
envelope 2.
[0035] To do so, the envelope 2 is placed, after having been turned
over, on a base 7 with a shape that is adapted to that of the
opening of said envelope, said base being connected to a device 8
for injecting air. The device 8 is arranged to inject air A under
pressure into said envelope by the intermediary of said base.
[0036] As shown in FIG. 3, in one embodiment, the step of coating
(100) provides for coating the inner surface 3 by immersing the
envelope 2 in a bath 9 containing the first solution 6 while
injecting air into the envelope (112). In some embodiments,
according to the type of the article of clothing 1 and the desired
performances for said article in terms of impermeability and
breathability, the temperature of the bath 9, the immersion time of
the envelope 2 in said bath and/or the concentration of polymer in
the solution 6 are varied.
[0037] In another embodiment, shown in FIG. 3, the step of coating
(100) provides for coating the inner surface 3 by spraying the
polymer solution 6 onto said inner surface 3 while injecting air
into the envelope (114), with the spraying time then being chosen
according to the type of the article of clothing 1 and the desired
performances.
[0038] The step of coating (100) then provides for drying the
envelope 2 in order to form a first layer 10 of waterproof and
breathable polymer on its outward-facing inner surface 3 (120). In
one embodiment, the envelope 2 is placed in an oven, in order to
form the layer 10 by cross-linking of the polymer.
[0039] In one embodiment, the step of coating (100) provides for
injecting air under pressure into the envelope 2 while it is being
dried, with the pressure of the air being sufficient to guarantee
the shaping of said envelope, which makes it possible to dry said
envelope homogeneously. As such, as the layer 10 is dried on the
shaped envelope 2, a perfect geometrical concordance is guaranteed
between said layer and said envelope in order to render the entire
inner surface 3 waterproof and breathable.
[0040] In some embodiments, in order to further improve the
homogeneity of the layer 10, the envelope 2 is subjected, after
coating and before drying, to a preliminary light drying, for
example by using a fan, in order to remove the bubbles that may
have formed on the inner surface 3.
[0041] As such, after drying of the envelope 2, the inner surface 3
is fully covered with a thin waterproof and breathable layer 10, as
shown in FIG. 6B. Furthermore, the layer 10 is formed by
cross-linking of the polymer, which allows said layer to be joined
with the envelope 2.
[0042] As shown in FIG. 2, according to the desired performances
for the article of clothing, in some embodiments the method
provides for repeating the steps of coating and drying (130) at
least two times, which makes it possible to vary the thickness of
the first layer 10 by superimposition of several sublayers. In some
embodiments, the step of coating (100) provides in particular for
using first solutions 6 of different compositions at each
iteration. In some embodiments, the step of drying is omitted or
shortened between repetitions to provide an incompletely dry or
cured sublayer, permitting better cohesion of the next application
of the first solution.
[0043] If the envelope 2 is formed by stitching, and in particular
by assembling several parts by stitching, the repetition of the
step of coating (130) makes it possible to guarantee a good
coverage of the holes formed by said seams, and therefore a good
impermeability of the final article of clothing.
[0044] The method then provides at least one step of impregnation
(200), during which the envelope 2 is turned over in such a way
that the inner surface 3 covered with the first layer 10 of polymer
is inward-facing (150), as shown in FIG. 7B. This step of
impregnation (200) provides for pouring into the envelope 2 a
solution 11 with a base of at least one waterproof and breathable
polymer (210).
[0045] To do so, as shown in FIG. 8A, in some embodiments the
turned envelope 2, inner surface 3 arranged facing inwards, is
arranged on a base 7 with a shape adapted to that of the opening of
said envelope, said base being connected to a device 12 for
injecting liquid supplied by a tank 13 containing the second
polymer solution 11.
[0046] Like the step of coating (100), in some embodiments, the
step of impregnation (200) uses, for the same reasons as said step
of coating, a second solution 11 comprising a hydrophilic polymer,
in particular with a polyurethane base. In some embodiments, the
polymer is used in aqueous phase, which makes it possible to use a
second solution 11 devoid of non-aqueous solvent. In some
embodiments, the composition of the first solution 6 is the same as
the composition of the second solution 11, which reduces
manufacturing costs and complexity. In other embodiments, the
composition of the second solution 11 is different from that of the
first solution 6, allowing the selection of advantageously higher
or lower viscosity solutions to ensure impregnation without
penetrating through the envelope, or for the selection of desired
surface properties on the finished product.
[0047] Once the first layer 10 of polymer has been covered by the
second solution 11, the step of impregnation (200) provides for
removing the excess solution 11 from the envelope 2 (220) and for
injecting air A under pressure into said envelope (230), in order
to force said solution to penetrate into the seams and into any
pores or voids in the first layer 10 in order to guarantee a
perfect sealing of the seams and the inner surface.
[0048] To apply the second solution 11, in some embodiments the
base 7 is connected to a device 14 for pumping arranged to pump the
second solution 11 into the envelope 2 and to return the excess
solution 11 into a tank, for example the same tank 13 as that used
previously, as shown in FIG. 8A. Then, the base 7 is connected to a
device 8 for injecting air arranged to inject air A under pressure
into the envelope 2 by the intermediary of said base as shown FIG.
8B.
[0049] According to the type of the article of clothing 1 and the
desired performances for said article in terms of impermeability
and breathability, the temperature of the solution 11, the
impregnation time, and/or the concentration in polymer of the
solution 11 can in particular be varied.
[0050] In some embodiments, in order to improve the aesthetics of
the article of clothing 1, the envelope 2 is subjected, after the
injection of air A under pressure, to a suitable rinsing in order
to remove the excess solution 11 of polymer that may have bled onto
the outer surface 4 of said envelope during said injection of
air.
[0051] The step of impregnation (200) then provides for drying the
envelope 2 in order to form a second layer 15 of waterproof and
breathable polymer on the first layer 10 (240). In some
embodiments, the envelope 2 is placed in an oven, in order to form
the second layer 15 by cross-linking of the polymer.
[0052] In some embodiments, the step of impregnation (200) also
provides for injecting air under pressure into the envelope 2 while
it is being dried, with the pressure of the air being sufficient to
guarantee the shaping of said envelope, which makes it possible to
dry said envelope homogeneously, including in the seams.
[0053] As such, after the drying of the envelope 2, the first layer
10 is covered with a second layer 15 of polymer that is thin,
waterproof and breathable, as shown in FIG. 9B. Advantageously, the
polymer of the second layer 15 is chosen for its chemical affinity
with the polymer of the first layer 10 or, if said first layer
comprises a superimposition of sublayers made of different
polymers, with the polymer of the last of said sublayers, which
allows said second layer to be joined with said first layer, in
order to form a waterproof and breathable barrier 5. For example,
in some embodiments, the first solution 6 and second solution 11
used by the steps of coating (100) and of impregnation (200) are
identical, which makes it possible to benefit from a maximum
chemical affinity.
[0054] In particular, if the envelope 2 is formed by stitching, and
in particular by assembling several parts by stitching, the step of
impregnation (200) makes it possible to seal the last seam holes or
any pores or voids that were not covered after the step of coating
(100), and as such to provide for optimum and reliable
impermeability.
[0055] According to the desired performances for the article of
clothing 1, in some embodiments, the method provides for repeating
the step of impregnation (200) at least two times (250), which
makes it possible to vary the thickness of the second layer 15 by
superimposition of several sublayers. In some embodiments, the step
of impregnation (200) also provides for using solutions 11 of
different compositions at each iteration, for example to select
desired surface properties for the outermost sublayer while
maintaining adequate cohesion of the inner sublayers to each other
and to first layer 10.
[0056] The combination of the two steps of coating (100) and of
impregnation (200) makes it possible to confer to the article of
clothing 1 a perfect global impermeability, in particular on the
seams, while making it possible to retain good grasping, good
sensations in terms of touch, and good breathability.
[0057] In some embodiments, a lining 16 is arranged in the envelope
2 in order to cover the inner surface 3 (225) as shown in FIG. 10B.
In particular, in some embodiments the step of impregnation (200)
provides for arranging the lining in the envelope 2 before it is
dried, in order to fix said lining 16 to said envelope during said
drying by the intermediary of the second layer 15 of polymer. In
particular, if the step of impregnation (200) is repeated several
times, the lining is arranged in the envelope 2 during the last
iteration.
[0058] In some embodiments, in particular for sports articles
intended to be used during difficult climatic conditions, the
lining 16 includes at least one layer of material that has thermal
insulation properties, for example with a base of cotton, foam or
polar fleece.
[0059] In some embodiments, air under pressure is injected into the
lining 16 before the second layer of polymer is fully dried or
cured, in order to allow said lining 16 to be in close contact with
the inner surface 3 of the envelope 2. To do so, the lining is
arranged in the envelope 2 after it is impregnated (225), then the
lining--envelope 2 unit is arranged on the base 7 connected to the
device 8 for injecting air and air pressure is injected (227), with
the whole then being placed in an oven for drying (245).
[0060] As such, during the drying, the second layer 15 is formed by
cross-linking of the polymer and makes it possible, thanks to said
cross-linking, to reliably fix the lining to the envelope 2.
* * * * *