U.S. patent application number 14/639604 was filed with the patent office on 2015-06-25 for insulated composite fabric.
The applicant listed for this patent is MMI-IPCO, LLC. Invention is credited to David Costello, Shawn Flavin, Charles Haryslak, Jane Hunter, Moshe Rock, Gadalia Vainer, Marcus Webster, James Zeiba.
Application Number | 20150173440 14/639604 |
Document ID | / |
Family ID | 48870476 |
Filed Date | 2015-06-25 |
United States Patent
Application |
20150173440 |
Kind Code |
A1 |
Rock; Moshe ; et
al. |
June 25, 2015 |
Insulated Composite Fabric
Abstract
An insulated composite fabric has an inner fabric layer, an
outer fabric layer, and an insulating-filler layer enclosed there
between. The insulating-filler layer is a textile fabric with at
least one raised surface. One side of the insulating-filler layer
comprises a first surface with relatively high pile, including
regions of no pile or relatively low pile interspersed among
regions of relatively high pile. The other side of the
insulating-filler layer comprises a second surface with relatively
high pile, including regions of no pile or relatively low pile
interspersed among regions of relatively high pile. Interconnecting
piles are formed with regions of the relatively high pile of the
first pile surface and regions of the relatively high pile of the
second pile surface.
Inventors: |
Rock; Moshe; (Brookline,
MA) ; Zeiba; James; (Derry, NH) ; Vainer;
Gadalia; (Melrose, MA) ; Hunter; Jane;
(Manassas, VA) ; Haryslak; Charles; (Groveland,
MA) ; Costello; David; (Marblehead, MA) ;
Flavin; Shawn; (Sandown, NH) ; Webster; Marcus;
(Pelham, NH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MMI-IPCO, LLC |
Lawrence |
MA |
US |
|
|
Family ID: |
48870476 |
Appl. No.: |
14/639604 |
Filed: |
March 5, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13786654 |
Mar 6, 2013 |
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14639604 |
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12817756 |
Jun 17, 2010 |
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13786654 |
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61263960 |
Nov 24, 2009 |
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61334248 |
May 13, 2010 |
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Current U.S.
Class: |
428/76 ;
112/475.08; 156/60; 28/158; 28/159 |
Current CPC
Class: |
D05C 15/04 20130101;
B32B 2307/304 20130101; B32B 5/024 20130101; B32B 2437/00 20130101;
B32B 2305/18 20130101; Y10T 156/10 20150115; A41D 31/065 20190201;
B32B 5/02 20130101; D06C 27/00 20130101; B32B 5/26 20130101; B32B
2250/04 20130101; B32B 37/18 20130101; B32B 2250/20 20130101; D05B
1/02 20130101; D05B 11/00 20130101; Y10T 428/23914 20150401; Y10T
428/239 20150115 |
International
Class: |
A41D 31/00 20060101
A41D031/00; B32B 5/26 20060101 B32B005/26; B32B 37/18 20060101
B32B037/18; D05B 1/02 20060101 D05B001/02; D05B 11/00 20060101
D05B011/00; B32B 5/02 20060101 B32B005/02; D05C 15/04 20060101
D05C015/04 |
Claims
1. An insulated composite fabric comprising: an inner fabric layer;
an outer fabric layer; and an insulating-filler layer enclosed
between the inner fabric layer and the outer fabric layer, wherein
the insulating-filler layer is a textile fabric with at least one
raised surface on the fabric, one side of the insulating-filler
layer comprising a first surface with relatively high pile,
including regions of no pile or relatively low pile interspersed
among regions of relatively high pile, the other side of the
insulating-filler layer comprising a second surface with relatively
high pile, including regions of no pile or relatively low pile
interspersed among regions of relatively high pile, and
interconnecting piles formed with regions of the relatively high
pile of the first pile surface and regions of the relatively high
pile of the second pile surface.
2. The insulated composite fabric of claim 1, wherein one or more
of the regions of relatively low pile comprises regions of fleece
or velour.
3. The insulated composite fabric of claim 1, wherein the
insulating-filler fabric layer comprises a terry sinker loop fabric
with the terry loop left un-napped.
4. The insulated composite fabric of claim 3, wherein the terry
sinker loop fabric has a reverse plaited construction.
5. The insulated composite fabric of claim 1, wherein the
insulating-filler fabric layer has a weight of about 1 ounce per
square yard to about 12 ounces per square yard, and a thickness
(bulk) of about 0.1 inch to about 4 inches; and wherein the
insulating-filler fabric layer provides insulation of 0.2
clo/oz.sup.2 to 1.6 clo/oz.sup.2.
6. The insulated composite fabric of claim 1, wherein the
insulating-filler fabric layer is quilted to one or both of the
inner fabric layer and the outer fabric layer.
7. The insulated composite fabric of claim 1, wherein the
insulating-filler fabric layer is stitched to one or both of the
inner fabric layer and the outer fabric layer along a periphery of
the insulated composite fabric.
8. The insulated composite fabric of claim 1, wherein the inner
fabric layer has an air permeability that is different from an air
permeability of the outer fabric layer, and wherein the inner
fabric layer has an air permeability that is relatively greater
than an air permeability of the outer fabric layer, or wherein the
inner fabric layer has an air permeability that is relatively less
than an air permeability of the outer fabric layer.
9. The insulated composite fabric of claim 1, wherein the insulated
composite fabric has an air permeability of about 1.0
ft.sup.3/ft.sup.2/min to about 300 ft.sup.3/ft.sup.2/min, tested
according to ASTM D-737 under a pressure difference of 1/2 inch of
water across the insulated composite fabric, and wherein the
insulated composite fabric provides insulation of 0.2
clo/oz.sup.2to 3.0 clo/oz.sup.2.
10. The insulated composite fabric of claim 1, further comprising a
waterproof membrane laminated to an inner surface of the outer
fabric layer, and disposed between the outer fabric layer and the
insulating-filler fabric layer, and wherein the waterproof membrane
is a vapor permeable membrane, or wherein the waterproof membrane
is selected from a porous hydrophobic membrane, a hydrophilic
non-porous membrane, and an electrospun membrane.
11. The insulated composite fabric of claim 1, wherein the
insulating-filler fabric layer has a terry sinker loop surface
including a plurality of discrete regions of no terry sinker loop
interspersed among regions of terry sinker loop.
12. The insulated composite fabric of claim 1, wherein the
insulating-filler fabric layer has a pile surface including a
plurality of first discrete regions having a first pile height
interspersed among a plurality of other discrete regions having
contrasting pile height relatively greater than the first pile
height.
13. The insulated composite fabric of claim 12, wherein yarns
forming the first discrete regions are relatively finer than yarns
forming the other discrete regions, and wherein yarns forming the
first discrete regions have a denier per filament (dpf) of less
than 1.0.
14. The insulated composite fabric of claim 1, wherein the
insulating-filler fabric layer is constructed to include face yarn
that is positioned perpendicular to stitching yarn or backing
yarn.
15. A method comprising forming an insulated composite fabric
including: enclosing an insulating-filler fabric layer between an
inner fabric layer and an outer fabric layer, wherein the
insulating-filler fabric layer is a textile fabric with at least
one raised surface on the fabric; one side of the insulating filler
fabric layer comprising a first relatively high pile surface, the
other side of the insulating filler fabric layer comprising a
second relatively high pile surface, the first relatively high pile
surface and the second relatively high pile surface including
regions of no pile interspersed between the regions of relatively
high pile; and forming an insulated composite fabric including
fleece/velour in regions of relatively low pile lower than the
relatively high pile of the first relatively high pile surface and
lower than the relatively high pile of the second relatively high
pile surface on at least one region of no pile on the first and
second pile surfaces.
16. The method of claim 15, wherein enclosing the insulating-filler
fabric layer comprises sewing the insulating-filler fabric layer to
one or both of the inner fabric layer and the outer fabric
layer.
17. The method of claim 15, wherein enclosing the insulating-filler
fabric layer comprises laminating the insulating-filler fabric
layer to one or both of the inner fabric layer and the outer fabric
layer.
18. The method of claim 15, wherein enclosing the insulating-filler
fabric layer comprises quilting the insulating-filler fabric layer
to one or both of the inner fabric layer and the outer fabric
layer.
19. The method of claim 15, wherein enclosing the insulating-filler
fabric layer comprises stitching the insulating-filler fabric layer
to one or both of the inner fabric layer and the outer fabric layer
along a periphery of the insulated composite fabric.
20. The method of claim 15, wherein forming the insulating-filler
fabric layer comprises including face yarn positioned perpendicular
to stitching yarn or backing yarn.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/786,654, filed on Mar. 6, 2013 (now
pending), which is a continuation-in-part of U.S. patent
application Ser. No. 12/817,756, on filed Jun. 17, 2010 (now
pending), which claims priority from U.S. Provisional Application
No. 61/263,960, filed on Nov. 24, 2009 (expired), and U.S.
Provisional Application No. 61/334,248, filed on May 13, 2010
(expired), the contents of all of which are incorporated herein by
reference in their entirety.
TECHNICAL FIELD
[0002] This disclosure relates to insulated composite fabrics that
incorporate a textile fabric with raised surface on one side or
both sides as an insulating filler material.
BACKGROUND
[0003] Conventional down fabric constructions often include
nonwoven filler material enclosed between two woven fabric "shell"
layers. These nonwoven filler materials are known to provide a
relatively high level of thermal insulation, and are lightweight
with very good packability.
[0004] Some known nonwoven filler materials, such as
Primaloft.RTM., available from Albany International Corp, and
Thinsulate.TM., available from 3M Company, are prone to movement
and fibers of the nonwoven filler material often have a tendency to
protrude through the woven fabric layers. To inhibit this fiber
migration, it is known to quilt the filler material to one or both
of the woven fabric layers. The quilting, however, tends to flatten
the nonwoven filler material, and, as a result, can reduce the
thermal insulation of the fabric construction. The quilting may
also inhibit the fabric construction from stretching.
[0005] To inhibit migrating fibers from protruding through the
woven fabric layers, the woven fabric layers are often made of a
very tight construction with an air permeability of less than 1.0
ft.sup.3/ft.sup.2/min and, in many cases, close to zero
ft.sup.3/ft.sup.2/min. In some cases, the woven fabric is
calendared, being passed through heated rolls under high pressure,
to seal voids in the tight woven construction. In certain
circumstances, a chemical system is applied to the woven fabric
prior to calendaring to help seal voids in the woven fabric. This
type of sealing may reduce the air permeability of the fabric
construction to almost zero ft.sup.3/ft.sup.2/min. As a result, a
garment made from the resulting fabric constructions may have
reasonable insulation, but poor air permeability and, as a result,
low breathability.
[0006] Nonwoven filler materials also tend to flatten under
compression and as a result may exhibit a loss in thermal
insulation.
SUMMARY
[0007] In general, this disclosure relates to insulated composite
fabrics that incorporate a textile fabric with raised surface on
one side or both sides as an insulating filler material.
[0008] One aspect of the disclosure, described below with
reference, e.g., to FIG. 12 and FIGS. 13A-13E of the drawings, is
directed to an insulated composite fabric comprising: an inner
fabric layer, an outer fabric layer, and an insulating-filler layer
enclosed between the inner fabric layer and the outer fabric layer,
wherein the insulating-filler layer is a textile fabric with at
least one raised surface on the fabric, one side of the
insulating-filler layer comprising a first surface with relatively
high pile and including regions of no pile or relatively low pile
interspersed among regions of the relatively high pile, the other
side of the insulating-filler layer comprising a second surface
with relatively high pile and including regions of no pile or
relatively low pile interspersed among the regions of relatively
high pile, and interconnecting piles formed with regions of the
relatively high pile of the first pile surface and regions of the
relatively high pile of the second pile surface.
[0009] Implementations of this aspect of the disclosure may include
one or more of the following additional features. One or more of
the regions of relatively low pile comprises regions of fleece or
velour. The insulating-filler fabric layer comprises a terry sinker
loop fabric with the terry loop left un-napped. The terry sinker
loop fabric has a reverse plaited construction. The
insulating-filler fabric layer has a weight of about 1 ounce per
square yard to about 12 ounces per square yard, and a thickness
(bulk) of about 0.1 inch to about 4 inches; and wherein the
insulating-filler fabric layer provides insulation of 0.2
clo/oz.sup.2 to 1.6 clo/oz.sup.2. The insulating-filler fabric
layer is quilted to one or both of the inner fabric layer and the
outer fabric layer. The insulating-filler fabric layer is stitched
to one or both of the inner fabric layer and the outer fabric layer
along a periphery of the insulated composite fabric. The inner
fabric layer has an air permeability that is different from an air
permeability of the outer fabric layer, and wherein the inner
fabric layer has an air permeability that is relatively greater
than an air permeability of the outer fabric layer, or wherein the
inner fabric layer has an air permeability that is relatively less
than an air permeability of the outer fabric layer. The insulated
composite fabric has an air permeability of about 1.0
ft.sup.3/ft.sup.2/min to about 300 ft.sup.3/ft.sup.2/min, tested
according to ASTM D-737 under a pressure difference of 1/2 inch of
water across the insulated composite fabric, and wherein the
insulated composite fabric provides insulation of 0.2 clo/oz.sup.2
to 3.0 clo/oz.sup.2. The insulated composite fabric further
comprises a waterproof membrane laminated to an inner surface of
the outer fabric layer, and disposed between the outer fabric layer
and the insulating-filler fabric layer, and wherein the waterproof
membrane is a vapor permeable membrane, or wherein the waterproof
membrane is selected from a porous hydrophobic membrane, a
hydrophilic non-porous membrane, and an electrospun membrane. The
insulating-filler fabric layer has a terry sinker loop surface
including a plurality of discrete regions of no terry sinker loop
interspersed among regions of terry sinker loop. The
insulating-filler fabric layer has a pile surface including a
plurality of first discrete regions having a first pile height
interspersed among a plurality of other discrete regions having
contrasting pile height relatively greater than the first pile
height. Yarns forming the first discrete regions are relatively
finer than yarns forming the other discrete regions, and wherein
yarns forming the first discrete regions have a denier per filament
(dpf) of less than 1.0. The insulating-filler fabric layer is
constructed to include face yarn that is positioned perpendicular
to stitching yarn or backing yarn.
[0010] Another aspect of the disclosure is directed to a method
comprising forming an insulated composite fabric including:
enclosing an insulating-filler fabric layer between an inner fabric
layer and an outer fabric layer, wherein the insulating-filler
fabric layer is a textile fabric with at least one raised surface
on the fabric; one side of the insulating filler fabric layer
comprising a first relatively high pile surface, the other side of
the insulating filler fabric layer comprising a second relatively
high pile surface, the first relatively high pile surface and the
second relatively high pile surface including regions of no pile
interspersed between the regions of relatively high pile; and
forming an insulated composite fabric including fleece/velour in
regions of relatively low pile lower than the relatively high pile
of the first relatively high pile surface and lower than the
relatively high pile of the second relatively high pile surface on
at least one region of no pile on the first and second pile
surfaces.
[0011] Implementations of this aspect of the disclosure may include
one or more of the following additional features. Enclosing the
insulating-filler fabric layer comprises sewing the
insulating-filler fabric layer to one or both of the inner fabric
layer and the outer fabric layer. Enclosing the insulating-filler
fabric layer comprises laminating the insulating-filler fabric
layer to one or both of the inner fabric layer and the outer fabric
layer. Enclosing the insulating-filler fabric layer comprises
quilting the insulating-filler fabric layer to one or both of the
inner fabric layer and the outer fabric layer. Enclosing the
insulating-filler fabric layer comprises stitching the
insulating-filler fabric layer to one or both of the inner fabric
layer and the outer fabric layer along a periphery of the insulated
composite fabric. Forming the insulating-filler fabric layer
comprises including face yarn positioned perpendicular to stitching
yarn or backing yarn.
[0012] Another aspect of the disclosure provides an insulated
composite fabric that includes an inner fabric layer, an outer
fabric layer, and an insulating-filler fabric layer enclosed
between the inner fabric layer and the outer fabric layer. The
insulating-filler fabric layer is a textile fabric with a raised
surface on at least one side of the fabric.
[0013] Implementations of this aspect of the disclosure may include
one or more of the following additional features. The
insulating-filler fabric layer includes a double face warp knit
fabric. The double face warp knit fabric has a technical back
having a plush velvet surface, and a technical face having a velour
surface. The insulating-filler fabric layer includes a double face
knit fabric having reverse plaited terry sinker loop knit
construction. The double face knit fabric has a technical face with
a raised or napped surface, and a technical back with a cut loop or
velour surface. The insulating-filler fabric layer includes a knit
fabric having sliver knit construction. The insulating-filler
fabric layer includes a terry sinker loop fabric in which the terry
loop is left un-raised. The terry sinker loop fabric has a reverse
plaited construction. A technical face of the terry sinker loop
fabric has a napped finish and a technical back is left as
un-napped, terry loop. A technical face of the terry sinker loop
fabric is left un-napped and a technical back is left as un-napped,
terry loop. The terry sinker loop fabric has a regular plaited
construction. The insulating-filler fabric layer has a terry sinker
loop surface including a plurality of discrete regions of no terry
sinker loop interspersed among regions of terry sinker loop. The
insulating-filler fabric layer includes a double face knit fabric
having sliver knit construction. The insulating fabric layer has a
weight of about 1 ounce per square yard to about 12 ounces per
square yard (e.g., about 1 ounce per square yard to about 4 ounces
per square yard, about 3 ounces per square yard to about 8 ounces
per square yard, or about 4 ounces per square yard to about 12
ounces per square yard). The insulating-filler fabric layer is
quilted to one or both of the inner fabric layer and the outer
fabric layer. The insulating-filler fabric layer is stitched to one
or both of the inner fabric layer and the outer fabric layer along
a periphery of the insulated composite fabric. The
insulating-filler fabric layer is laminated to one or both of the
inner fabric layer and the outer fabric layer. The
insulating-filler fabric layer has a thickness (bulk) of about 0.1
inch to about 4.0 inches (e.g., about 0.1 inch to about 0.2 inch,
about 0.15 inch to about 0.4 inch, about 0.2 inch to about 1.0
inch, or about 3 inches to about 4 inches). The insulating-filler
fabric layer has a pile surface including a plurality of discrete
regions of no pile interspersed among regions of pile. The
insulating-filler fabric layer has a pile surface that includes a
plurality of first discrete regions having a first pile height
interspersed among a plurality of other discrete regions having
contrasting pile height relatively greater than the first pile
height. In some cases, yarns forming the first discrete regions are
relatively finer that yarns forming the other discrete regions. In
some examples, yarns forming the first discrete regions have a
denier per filament (dpf) of less than 1.0. The insulating-filler
fabric layer provides insulation of about 0.2 clo/oz.sup.2 to about
1.6 clo/oz.sup.2. The insulating-filler fabric layer includes a
hydrophobic fabric. The inner fabric layer includes a woven fabric.
The inner fabric layer includes a knit fabric having a single
jersey construction, a double knit construction, a warp knit
construction, or a mesh construction. The inner fabric layer may
have an air permeability that is different from an air permeability
of the outer fabric layer. The inner fabric layer has an air
permeability that is relatively greater than an air permeability of
the outer fabric layer. The inner fabric layer has an air
permeability that is relatively less than an air permeability of
the outer fabric layer. In some cases, the inner fabric layer has
an air permeability that is the same as the air permeability of the
outer fabric layer. The inner fabric layer has an air permeability
of about 5 ft.sup.3/ft.sup.2/min to about 300
ft.sup.3/ft.sup.2/min, tested according to ASTM D-737 under a
pressure difference of 1/2 inch of water across the inner fabric
layer. The outer fabric layer has an air permeability of about 1
ft.sup.3/ft.sup.2/min to about 100 ft.sup.3/ft.sup.2/min, (e.g.,
about 1 ft.sup.3/ft.sup.2/min to about 100 ft.sup.3/ft.sup.2/min),
tested according to ASTM D-737 under a pressure difference of 1/2
inch of water across the outer fabric layer. In some cases, both
the inner fabric layer and the outer fabric layer have very high
air permeability (e.g., at least 200 ft.sup.3/ft.sup.2/min, tested
according to ASTM D-737 under a pressure difference of 1/2 inch of
water across the respective fabric layer). The outer fabric layer
includes a woven fabric. The insulated composite fabric has stretch
in at least one direction. At least one of the outer fabric layer,
the inner fabric layer, and the insulating-filler fabric layer
includes fibers of stretch and/or elastomeric material. The stretch
material includes elastomeric yarns and/or fibers (e.g., spandex
yarns and/or fibers). The outer fabric layer is treated with
durable water repellent, an abrasion resistant coating, camouflage,
or infrared radiation reduction. The insulated composite fabric has
an air permeability of about 1.0 ft.sup.3/ft.sup.2/min to about 300
ft.sup.3/ft.sup.2/min, tested according to ASTM D-737 under a
pressure difference of 1/2 inch of water across the insulated
composite fabric (e.g., about 100 ft.sup.3/ft.sup.2/min to about
300 ft.sup.3/ft.sup.2/min, tested according to ASTM D-737 under a
pressure difference of 1/2 inch of water across the insulated
composite fabric, or about 1.0 ft.sup.3/ft.sup.2/min to about 80.0
ft.sup.3/ft.sup.2/min, tested according to ASTM D-737 under a
pressure difference of 1/2 inch of water across the insulated
composite fabric). The insulating-filler fabric layer is
constructed to include face yarn that is positioned generally
perpendicular to stitching or backing yarn. The insulated composite
fabric provides insulation of about 0.2 clo/oz.sup.2 to about 3.0
clo/oz.sup.2 (e.g., about 0.8 clo/oz.sup.2 to about 1.6
clo/oz.sup.2, about 1.0 clo/oz.sup.2 to about 1.8 clo/oz.sup.2, or
about 1.0 clo/oz.sup.2 to about 3.0 clo/oz.sup.2). At least one of
the inner fabric layer, the outer fabric layer, and the
insulating-filler fabric layer includes flame-retardant material or
is treated to provide flame-retardance. The insulated composite
fabric may also include a waterproof membrane that is laminated to
an inner surface of the outer fabric layer, and which is disposed
between the outer fabric layer and the insulating-filler fabric
layer. The waterproof membrane may be a vapor permeable membrane.
The waterproof membrane may be a porous hydrophobic membrane, a
hydrophilic non-porous membrane, or an electrospun material.
[0014] Another aspect of the disclosure features a fabric garment
that includes a first fabric portion formed of a first insulated
composite fabric. The first insulated composite fabric includes a
first inner fabric layer, a first outer fabric layer, and a first
insulating-filler fabric layer enclosed between the first inner
fabric layer and the first outer fabric layer. The first
insulating-filler fabric layer is a textile fabric with a raised
surface on at least one side of the fabric.
[0015] Implementations of this aspect of the disclosure may include
one or more of the following additional features. The first
insulating-filler fabric layer includes a double face warp knit
fabric. The double face warp knit fabric has a technical back
having plush velvet surface, and a technical face having a velour
surface. The first insulating-filler fabric layer includes a double
face knit fabric having reverse plaited terry sinker loop knit
construction. The double face knit fabric has a technical face with
a raised or napped surface, and a technical back with a cut loop or
velour surface. The first insulating-filler fabric layer includes a
knit fabric having sliver knit construction. The first
insulating-filler fabric layer includes a double face knit fabric
having sliver knit construction. The first insulating-filler fabric
layer includes a terry sinker loop fabric in which the terry loop
is left un-raised. The terry sinker loop fabric has a reverse
plaited construction. A technical face of the terry sinker loop
fabric has a napped finish and a technical back is left as
un-napped, terry loop. In some cases, a technical face of the terry
sinker loop fabric is left un-napped and a technical back is left
as un-napped, terry loop. The terry sinker loop fabric has a
regular plaited construction. The first insulating-filler fabric
layer has a terry sinker loop surface including a plurality of
discrete regions of no terry sinker loop interspersed among regions
of terry sinker loop. The first insulating-filler fabric layer has
a weight of about 1 ounce per square yard to about 12 ounces per
square yard (e.g., about 1 ounce per square yard to about 4 ounces
per square yard, about 3 ounces per square yard to about 8 ounces
per square yard, or about 4 ounces per square yard to about 12
ounces per square yard). The first insulating-filler fabric layer
is quilted to one or both of the first inner fabric layer and the
first outer fabric layer. The first insulating-filler fabric layer
is anchored at seams connecting the first inner fabric layer and
the first outer fabric layer. The first insulating-filler fabric
layer is laminated to one or both of the first inner fabric layer
and the first outer fabric layer. The first insulating-filler
fabric layer has a pile surface including a plurality of discrete
regions of no pile interspersed among regions of pile. In some
cases, the first insulating-filler fabric layer has a pile surface
that includes a plurality of first discrete regions having a first
pile height interspersed among a plurality of other discrete
regions having contrasting pile height relatively greater than the
first pile height. In some examples, yarns forming the first
discrete regions are relatively finer that yarns forming the other
discrete regions. In some cases, yarns forming the first discrete
regions have a denier per filament (dpf) of less than 1.0. The
first insulating-filler fabric layer provides insulation of about
0.2 clo/oz.sup.2 to about 1.6 clo/oz.sup.2. The first
insulating-filler fabric layer includes a hydrophobic fabric. The
first inner fabric layer includes a woven fabric. The first inner
fabric layer includes a knit fabric having a single jersey
construction, a double knit construction, a warp knit construction,
or a mesh construction. The first inner fabric layer may have an
air permeability that is different from an air permeability of the
first outer fabric layer. The first inner fabric layer has an air
permeability that is relatively greater than an air permeability of
the first outer fabric layer. The first inner fabric layer has an
air permeability that is relatively less than an air permeability
of the first outer fabric layer. In some cases, the first inner
fabric layer has an air permeability that is the same as the air
permeability of the first outer fabric layer. The first inner
fabric layer has an air permeability of about 5
ft.sup.3/ft.sup.2/min to about 300 ft.sup.3/ft.sup.2/min, tested
according to ASTM D-737 under a pressure difference of 1/2 inch of
water across the inner fabric layer. The first outer fabric layer
has an air permeability of about 1 ft.sup.3/ft.sup.2/min to about
100 ft.sup.3/ft.sup.2/min, (e.g., about 1 ft.sup.3/ft.sup.2/min to
about 100 ft.sup.3/ft.sup.2/min) tested according to ASTM D-737
under a pressure difference of 1/2 inch of water across the first
outer fabric layer. The first outer fabric layer includes a woven
fabric. The first insulated composite fabric has stretch in at
least one direction. At least one of the first outer fabric layer,
the first inner fabric layer, and the first insulating-filler
fabric layer includes fibers of stretch and/or elastomeric material
(e.g., elastomeric yarns and/or fibers, e.g., spandex yarns and/or
fibers). The first outer fabric layer is treated with durable water
repellent, an abrasion resistant coating, camouflage, or infrared
radiation reduction. The first insulated composite fabric has an
air permeability of about 1.0 ft.sup.3/ft.sup.2/min to about 80.0
ft.sup.3/ft.sup.2/min, tested according to ASTM D-737 under a
pressure difference of 1/2 inch of water across the first insulated
composite fabric (e.g., about 4.0 ft.sup.3/ft.sup.2/min to about
20.0 ft.sup.3/ft.sup.2/min, tested according to ASTM D-737 under a
pressure difference of 1/2 inch of water across the first insulated
composite fabric). The fabric garment also includes a second fabric
portion, and the first and second fabric portions have one or more
contrasting properties selected from contrasting stretch,
contrasting water resistance, contrasting insulative properties,
and contrasting air permeability. The second fabric portion is
formed of a second insulated composite fabric. The second insulated
composite fabric includes a second inner fabric layer, a second
outer fabric layer, and a second insulating-filler fabric layer
enclosed between the second inner fabric layer and the second outer
fabric layer. The second insulated composite fabric has an air
permeability that is different from, and greater than, an air
permeability of the first insulated composite fabric. The second
insulating-filler fabric layer is a textile fabric with a raised
surface on at least one side of the fabric. The second
insulating-filler fabric layer includes a double face warp knit
fabric. The double face warp knit fabric has a technical back
having plush velvet surface, and a technical face having a velour
surface. The second insulating-filler fabric layer includes a
double face knit fabric having reverse plaited terry sinker loop
knit construction. The double face knit fabric has a technical face
with a raised or napped surface, and a technical back with a cut
loop or velour surface. The second insulating-filler fabric layer
includes a knit fabric having sliver knit construction. The second
insulating-filler fabric layer includes a double face knit fabric
having sliver knit construction. The second insulating-filler
fabric layer includes a terry sinker loop fabric in which the terry
loop is left un-raised. The terry sinker loop fabric has a reverse
plaited construction. A technical face of the terry sinker loop
fabric has a napped finish and a technical back is left as
un-napped, terry loop. A technical face of the terry sinker loop
fabric is left un-napped and a technical back is left as un-napped,
terry loop. The terry sinker loop fabric has a regular plaited
construction. The second insulating-filler fabric layer has a terry
sinker loop surface including a plurality of discrete regions of no
terry sinker loop interspersed among regions of terry sinker loop.
The second insulating fabric layer has a weight of about 1 ounce
per square yard to about 12 ounces per square yard (e.g., about 1
ounce per square yard to about 4 ounces per square yard, about 3
ounces per square yard to about 8 ounces per square yard, or about
4 ounces per square yard to about 12 ounces per square yard). The
second insulating-filler fabric layer is quilted to one or both of
the second inner fabric layer and the second outer fabric layer.
The second insulating-filler fabric layer is anchored at seams
connecting the second inner fabric layer and the second outer
fabric layer. The second insulating-filler fabric layer is
laminated to one or both of the second inner fabric layer and the
second outer fabric layer. The second insulating-filler fabric
layer has a pile surface including a plurality of discrete regions
of no pile interspersed among regions of pile. In some cases, the
second insulating-filler fabric layer has a pile surface that
includes a plurality of first discrete regions having a first pile
height interspersed among a plurality of other discrete regions
having contrasting pile height relatively greater than the first
pile height. In some examples, yarns forming the first discrete
regions are relatively finer that yarns forming the other discrete
regions. In some cases, yarns forming the first discrete regions
have a denier per filament (dpf) of less than 1.0. The second
insulating-filler fabric layer provides insulation of about 0.2
clo/oz.sup.2 to about 1.6 clo/oz.sup.2. The second
insulating-filler fabric layer comprises a hydrophobic fabric. The
second inner fabric layer includes a woven fabric. The second inner
fabric layer includes a knit fabric having a single jersey
construction, a double knit construction, a warp knit construction,
or a mesh construction. The second outer fabric layer includes a
woven fabric. The second insulated composite fabric has stretch in
at least one direction. At least one of the second outer fabric
layer, the second inner fabric layer, and the second
insulating-filler fabric layer includes fibers of stretch and/or
elastomeric material. The elastomeric material includes elastomeric
yarns and/or fibers (e.g., spandex yarns and/or fibers). The second
outer fabric layer is treated with durable water repellent, an
abrasion resistant coating, camouflage, or infrared radiation
reduction. The second insulated composite fabric has an air
permeability of about 5 ft.sup.3/ft.sup.2/min to about 300
ft.sup.3/ft.sup.2/min, tested according to ASTM D-737, under a
pressure difference of 1/2 inch of water across the second
insulated composite fabric. The second fabric portion is formed of
a knit fabric having a single jersey construction, a double knit
construction, or a rib knit construction. The second fabric portion
is formed of a single layer fabric or a laminate composite fabric.
The single layer fabric has a single jersey construction, a double
knit construction, a rib knit construction, or a woven
construction. The second fabric portion includes a woven fabric.
The second fabric portion has an air permeability that is different
from an air permeability of the first fabric portion. The second
fabric portion has an air permeability that is relatively greater
than an air permeability of the first fabric portion. The second
fabric portion has an air permeability that is relatively less than
an air permeability of the first fabric portion. The second fabric
portion has an air permeability of about 5 ft.sup.3/ft.sup.2/min to
about 300 ft.sup.3/ft.sup.2/min, tested according to ASTM D-737,
under a pressure difference of 1/2 inch of water across fabric
forming the second fabric portion. The second fabric portion has
greater stretch than the first fabric portion in at least one
direction. At least one of the first inner fabric layer, the first
outer fabric layer, the first insulating-filler fabric layer, the
second inner fabric layer, the second outer fabric layer, and the
second insulating-filler fabric layer includes flame-retardant
material or is treated to provide flame-retardance. The fabric
garment may also include a waterproof membrane that is laminated to
an inner surface of the first outer fabric layer, and which is
disposed between the first outer fabric layer and the first
insulating-filler fabric layer. The waterproof membrane is a vapor
permeable membrane. The waterproof membrane is a porous hydrophobic
membrane, a hydrophilic non-porous membrane, or an electrospun
material. The fabric garment is reversible, and the first inner
fabric layer and the first outer fabric layer have contrasting
appearance and/or surface texture.
[0016] Another aspect of the disclosure provides a method that
includes forming an insulated composite fabric by enclosing an
insulating-filler fabric layer between an inner fabric layer and an
outer fabric layer. The insulating-filler fabric layer is a textile
fabric with a raised surface on at least one side of the
fabric.
[0017] Implementations of this aspect of the disclosure may include
one or more of the following additional features. Enclosing the
insulating-filler fabric layer includes sewing the
insulating-filler fabric layer to one or both of the inner fabric
layer and the outer fabric layer. Enclosing the insulating-filler
fabric layer includes laminating the insulating-filler fabric layer
to one or both of the inner fabric layer and the outer fabric
layer. The method also includes treating the outer fabric layer
with durable water repellent (DWR), an abrasion resistant coating,
camouflage, and/or infrared radiation reduction. The method also
includes forming one or more fabric elements out of the insulated
composite fabric, and incorporating the fabric elements into a
fabric garment. The method also includes forming one or more other
fabric elements out of another fabric, and incorporating the one or
more other fabric elements into the fabric garment. The other
fabric has an air permeability that is different from an air
permeability of the insulated composite fabric. The other fabric
has an air permeability that is relatively greater than an air
permeability of the insulated composite fabric. In some cases, the
other fabric has an air permeability that is relatively less than
an air permeability of the insulated composite fabric. The other
fabric has greater stretch than the insulated composite fabric in
at least one direction. The other fabric is a single layer fabric
or a laminate fabric.
[0018] Another aspect of the disclosure features a method of
forming a hybrid composite fabric garment. The method includes
forming a first fabric portion out of a first insulated composite
fabric and forming a second fabric portion out of another fabric
having an air permeability that is different from, and greater
than, an air permeability of the first insulated composite fabric.
The method also includes joining together the first and second
fabric portions to form the hybrid composite fabric garment. The
first insulated composite fabric includes a first inner fabric
layer, a first outer fabric layer, and a first insulating-filler
fabric layer enclosed between the first inner fabric layer and the
first outer fabric layer,. The first insulating-filler fabric layer
is a textile fabric with a raised surface on at least one side of
the fabric;
[0019] Implementations of this aspect of the disclosure may include
one or more of the following additional features. The other fabric
is a second insulated composite fabric. The second insulated
composite fabric includes a second inner fabric layer, a second
outer fabric layer, and a second insulating-filler fabric layer
enclosed between the second inner fabric layer and the second outer
fabric layer. The second insulating-filler fabric layer is a
textile fabric with a raised surface on at least one side of the
fabric. The second insulated composite fabric has an air
permeability that is different from, and greater than, an air
permeability of the first insulated composite fabric. The method
also includes forming the second insulated composite fabric by
enclosing the second insulating-filler fabric layer between the
second inner fabric layer and the second outer fabric layer.
Enclosing the second insulating-filler fabric layer includes
quilting the second insulating-filler fabric layer to one or both
of the second inner fabric layer and the second outer fabric layer.
Enclosing the second insulating-filler fabric layer includes
laminating the second insulating-filler fabric layer to one or both
of the second inner fabric layer and the second outer fabric layer.
The method also includes forming the first insulated composite
fabric by enclosing the first insulating-filler fabric layer
between the first inner fabric layer and the first outer fabric
layer. Enclosing the first insulating-filler fabric layer includes
quilting the first insulating-filler fabric layer to one or both of
the first inner fabric layer and the first outer fabric layer.
Enclosing the first insulating-filler fabric layer includes
laminating the first insulating-filler fabric layer to one or both
of the first inner fabric layer and the first outer fabric
layer.
[0020] Another aspect of the disclosure provides an insulated
composite fabric that includes an outer fabric layer, and an
insulating fabric layer attached the outer fabric layer. The
insulating fabric layer is a textile fabric having a raised surface
facing towards the outer fabric layer.
[0021] Implementations of this aspect of the disclosure may include
one or more of the following additional features. The insulating
fabric layer includes a warp knit fabric. The warp knit fabric has
a technical back having plush velvet, and a technical face defining
a smooth surface. The insulating fabric layer includes a knit
fabric having reverse plaited terry sinker loop construction. The
knit fabric has a technical back with a raised or napped surface,
and a technical face defining a smooth surface. The insulating
fabric layer comprises a terry sinker loop fabric in which the
terry loop is left un-raised. The terry sinker loop fabric has a
reverse plaited construction. A technical face of the terry sinker
loop fabric has a napped finish and a technical back is left as
un-napped, terry loop. A technical face of the terry sinker loop
fabric is left un-napped and a technical back is left as un-napped,
terry loop. The terry sinker loop fabric has a regular plaited
construction. The insulating fabric layer has a terry sinker loop
surface including a plurality of discrete regions of no terry
sinker loop interspersed among regions of terry sinker loop. The
insulating fabric layer has a pile surface including a plurality of
discrete regions of no pile interspersed among regions of pile. In
some cases, the insulating fabric layer has a pile surface that
includes a plurality of first discrete regions having a first pile
height interspersed among a plurality of other discrete regions
having contrasting pile height relatively greater than the first
pile height. In some examples, yarns forming the first discrete
regions are relatively finer that yarns forming the other discrete
regions. In some cases, yarns forming the first discrete regions
have a denier per filament (dpf) of less than 1.0. The insulating
fabric layer provides insulation of about 0.2 clo/oz.sup.2 to about
1.6 clo/oz.sup.2. The insulating fabric layer includes a double
face warp knit or circular knit fabric. The insulating fabric layer
is laminated to the outer fabric layer. The insulating fabric layer
is connected to the outer fabric layer by quilting, sewing,
tucking, and/or ultrasound bonding. The insulating fabric layer is
double face fabric, or a single face textile fabric having the
raised surface facing towards the outer fabric layer, and an
opposite, smooth surface. The outer fabric layer comprises a woven
fabric. The outer fabric layer comprises a knit fabric having a
single jersey construction, a warp knit construction, or a mesh
construction. The insulated composite fabric has stretch in at
least one direction. At least one of the outer fabric layer and the
insulating fabric layer includes fibers of stretch and/or
elastomeric material (e.g., elastomeric yarn and/or fibers). The
outer fabric layer is treated with durable water repellent, an
abrasion resistant coating, camouflage, or infrared radiation
reduction. The insulated composite fabric has an air permeability
of about 1.0 ft.sup.3/ft.sup.2/min to about 300
ft.sup.3/ft.sup.2/min, tested according to ASTM D-737 under a
pressure difference of 1/2 inch of water across the insulated
composite fabric. The insulating fabric layer and/or the outer
fabric layer includes flame-retardant material or is treated to
provide flame-retardance. The insulated composite fabric may also
include a waterproof membrane that is laminated to an inner surface
of the outer fabric layer, and which is disposed between the outer
fabric layer and the insulating fabric layer. The waterproof
membrane may be a vapor permeable membrane. The waterproof membrane
may be a porous hydrophobic membrane, a hydrophilic non-porous
membrane, or an electrospun material.
[0022] In another aspect of the disclosure features an insulated
composite fabric comprising an inner fabric layer, an outer fabric
layer, and an insulating-filler fabric layer enclosed between the
inner fabric layer and the outer fabric layer. The
insulating-filler fabric layer is a textile fabric with a raised
surface on at least one side of the fabric. The insulating-filler
fabric layer comprises fibers having an axial core surrounded by a
multiplicity of radially extending, axially-elongated whiskers,
separated by axially-extending grooves.
[0023] In another aspect, the disclosure features a fabric garment
comprising a first fabric portion formed of a first insulated
composite fabric. The first insulated composite fabric comprising a
first inner fabric layer, a first outer fabric layer, and a first
insulating-filler fabric layer enclosed between the first inner
fabric layer and the first outer fabric layer. The first
insulating-filler fabric layer is a textile fabric with a raised
surface on at least one side of the fabric. The insulating-filler
fabric layer comprises fibers having an axial core surrounded by a
multiplicity of radially extending, axially-elongated whiskers,
separated by axially-extending grooves.
[0024] In another aspect, the disclosure features a method
comprising forming an insulated composite fabric. The method
comprises enclosing an insulating-filler fabric layer between an
inner fabric layer and an outer fabric layer. The insulating-filler
fabric layer is a textile fabric with a raised surface on at least
one side of the fabric. The insulating-filler fabric layer
comprises fibers having an axial core surrounded by a multiplicity
of radially extending, axially-elongated whiskers, separated by
axially-extending grooves.
[0025] Implementations of one or more of the above aspects may
include one or more following features. The fibers have denier of
about 0.3 dpf to about 10.0 dpf or about 1.5 dpf to about 10.0 dpf.
The whiskers have an average length of up to about 200% of a
diameter of the core. The raised surface comprises the fibers
having the axial core surrounded by the multiplicity of radially
extending, axially-elongated whiskers, separated by
axially-extending grooves. The core comprises a polymer and the
whiskers comprise another polymer. The polymer of the core and/or
the polymer of the whiskers comprises polyethylene terephthalate
(PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the
combinations. The fibers have about 3 to about 200 whiskers within
a cross-sectional surface of the fibers. The axially-extending
grooves are nanogrooves or microgrooves. The whiskers have an
average radial length of about 2 nm to about 10 microns. The
insulating-filler fabric layer comprises a double face warp knit
fabric, a double face knit fabric having reverse plaited terry
sinker loop knit construction, sliver knit construction, a double
face knit fabric having sliver knit construction, or a terry sinker
loop fabric in which the terry loop is left un-raised. The double
face warp knit fabric has a technical back having plush velvet
surface, and a technical face having a velour surface. The double
face knit fabric has a technical face with a raised or napped
surface, and a technical back with a cut loop or velour surface.
The terry sinker loop fabric has a reverse plaited construction. A
technical face of the terry sinker loop fabric has a napped finish
and a technical back is left as un-napped, terry loop. A technical
face of the terry sinker loop fabric is left un-napped and a
technical back is left as un-napped, terry loop. The terry sinker
loop fabric has a regular plaited construction. The
insulating-filler fabric layer has a pile surface including a
plurality of first discrete regions having a first pile height
interspersed among a plurality of other discrete regions having
contrasting pile height relatively greater than the first pile
height.
[0026] Implementations of one or more of the above aspects may
include one or more following features. Enclosing the
insulating-filler fabric layer comprises sewing the
insulating-filler fabric layer to one or both of the inner fabric
layer and the outer fabric layer. Enclosing the insulating-filler
fabric layer comprises laminating the insulating-filler fabric
layer to one or both of the inner fabric layer and the outer fabric
layer.
[0027] Implementations of the disclosure can include one or more of
the following advantages.
[0028] In some implementations of the disclosure, the use of a
textile fabric as an insulating filler material in an insulated
composite fabric can help to avoid the use of loose fibers, which
may have a tendency to migrate. This can also allow various fabrics
with various openness to be used as shell layers with reduced
concern over fiber migration and penetration of loose fibers
through the shell fabric and without having to seal or otherwise
limited the air permeability of the shell fabric.
[0029] In some implementations of the disclosure, an insulating
filler material is made of pile (velvet) and/or velour/fleece,
which includes face yarn positioned generally perpendicular to
backing or stitching yarn. This type of construction can provide
high thickness (bulk) with good resiliency to help maintain thermal
insulation even following compression.
[0030] Other aspects, features, and advantages of the disclosure
are in the description, drawings, and claims.
DESCRIPTION OF DRAWINGS
[0031] FIG. 1 is a front perspective view of an insulated fabric
garment.
[0032] FIG. 2 is an end section view of an insulated composite
fabric.
[0033] FIG. 3 is an end section view of an insulating-filler fabric
in the form of a double face warp knit fabric.
[0034] FIG. 4 is an end section view of an insulating-filler fabric
in the form of a double face knit fabric with reverse plaited terry
sinker loop knit construction.
[0035] FIG. 5 is an end section view of an insulating-filler fabric
in the form of a single face fabric.
[0036] FIG. 6 is end section view of insulated composite having a
light-duty construction.
[0037] FIG. 7 is end section view of insulated composite having a
medium-duty construction.
[0038] FIG. 8 is end section view of insulated composite having a
heavy-duty construction.
[0039] FIG. 9 is a front perspective view of a hybrid insulated
fabric garment.
[0040] FIG. 10 is an end section view of an example of an insulated
composite fabric for use in a first fabric portion of the hybrid
insulated fabric garment of FIG. 9.
[0041] FIG. 11 is an end section view of an example of an insulated
composite fabric for use in a second fabric portion of the hybrid
insulated fabric garment of FIG. 9.
[0042] FIG. 12 is a plan view of an insulating-filler fabric having
a pile surface that includes no pile regions interspersed among
regions of pile.
[0043] FIGS. 13A-13E are end section views illustrating
insulating-filler fabrics having void regions (i.e., regions of
relatively lower pile or no pile).
[0044] FIGS. 14A-14C are end section views of alternative
embodiments of an insulated composite fabric laminate.
[0045] FIG. 15A is an end section view of a two layer insulated
composite fabric.
[0046] FIG. 15B is an end section view of a two layer insulated
composite fabric laminate.
[0047] FIG. 16 is an end section view of an insulated composite
fabric having a waterproof membrane.
[0048] FIG. 17 is a front perspective view of a hybrid insulated
fabric garment having regions of contrasting water resistance.
[0049] FIGS. 18A and 18B are end section and perspective side
views, respectively, of a multi-groove fiber, and FIG. 18C is an
end perspective view of a multi-groove fiber as seen through a
scanning electron microscope.
[0050] FIGS. 18D and 18E are end section views of other
implementations of multi-groove fibers having relative shorter
whiskers and having relatively longer whiskers, respectively.
[0051] FIG. 19 is a schematic cross-sectional representation of a
process for conversion of a precursor into a multi-groove fiber,
and FIG. 19A is an end section view of an intermediate product
including a removable sheath during the process of making
multi-groove fibers.
[0052] FIG. 20 is a schematic view of a fabric construction of this
disclosure implementing incorporation of multi-groove fibers.
[0053] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0054] Referring to FIG. 1, an insulated fabric garment 10 is
formed from a plurality of fabric elements that are joined
together, e.g. by stitching at seams 11. The fabric elements
include left and right front elements 12, 13, a rear element 14, a
collar element 16, and left and right arm elements 17, 18. Each of
these fabric elements consists of an insulated composite fabric
("technical down"). FIG. 2 illustrates an insulated composite
fabric 20 that is suitable for forming the fabric elements. The
insulated composite fabric 20 consists of an inner "shell-liner"
fabric layer 21, which forms an inner surface of the fabric garment
10 worn towards a user's body; an outer "shell" fabric layer 22,
which forms an outer surface of the fabric garment 10; and an
insulating-filler fabric layer 23 enclosed therebetween. The
insulating-filler fabric layer 23 can be sewn (e.g., quilted (as
illustrated in FIG. 2) and/or connected with tack stitches) to one
or both of the inner and outer fabric layers 21, 22, or, in some
cases, a loose insulating-filler fabric layer 23 is anchored in the
seams 11 of the fabric garment 10 and/or along the periphery of the
individual fabric elements. Alternatively or additionally, the
insulating-filler fabric layer 23 can be attached to one or both of
the inner and outer fabric layers 21, 22 by other physical
anchoring, e.g., via snapping, tucking, jumping and tucking,
ultrasound bonding, lamination, etc.
[0055] The insulating-filler fabric layer 23 is a textile fabric
with raised surface on one side or both sides. The textile fabric
of the insulating-filler fabric layer 23 is constructed to include
face yarn (pile) that is positioned generally perpendicular to
stitching or backing yarn. The term "pile," as used herein,
includes pile surfaces formed by any desired method, including but
not limited to cut loops, loops cut on the knitting machine, loops
cut off the knitting machine, and raised fibers. This type of
construction can provide high bulk with good resiliency to maintain
the thermal insulation of the insulating-filler fabric layer 23
even under compression.
[0056] Referring to FIG. 3, the insulating-filler fabric layer 23
may be formed from a double face warp knit fabric 30 that includes
a technical back 32 formed of pile yarns that are brushed to
provide a plush velvet surface 33, and a technical face 34 formed
of backing yarns and stitching yarns. The backing yarns or the
stitching yarns of the technical face 34 may be napped to form a
fleece/velour 35. Alternatively, in some cases, some of the pile
yarns overlay the stitch yarn at the technical face 35 and may
brushed or napped to form a fleece/velour 35 surface at the
technical face 35. Additional details regarding the construction of
a suitable double face warp knit fabric may be found in U.S. Pat.
No. 6,196,032, issued Mar. 6, 2001, U.S. Pat. No. 6,199,410, issued
Mar. 13, 2001, U.S. Pat. No. 6,832,497, issued Dec. 21, 2004, U.S.
Pat. No. 6,837,078, issued Jan. 4, 2005, and U.S. Pat. No.
5,855,125, issued Jan. 5, 1999, the complete disclosures of all of
which are incorporated herein by reference. Suitable double face
warp knit fabrics are commercially available, e.g., from Polartec,
LLC, of Lawrence, Mass., under the trademark BOUNDARY.RTM..
[0057] Alternatively or additionally, the insulating-filler fabric
layer 23 may be formed from a double face knit fabric having
reverse plaited terry sinker loop knit construction. Referring to
FIG. 4, the double face knit fabric with reverse plaited terry
sinker loop knit construction 40 has a technical face 42 with a
raised or napped surface 43, and a technical back 44 in which
sinker loops are sheared to form a cut loop velvet surface 45.
Additional details regarding the construction of a suitable double
face knit fabric with reverse plaited terry sinker loop knit
construction may be found in U.S. Pat. No. 6,131,419, issued Oct.
17, 2000, the complete disclosure of which is incorporated herein
by reference.
[0058] Referring to FIG. 5, the insulating-filler fabric layer 23
may also be formed from a single face fabric 50 that is constructed
to include a technical face 52 with face yarn that is positioned
generally perpendicular to stitching or backing yarn 54.
[0059] Alternatively or additionally, the insulating-filler fabric
layer 23 may be formed from a fabric having a sliver knit
construction. The sliver knit construction can be formed by
circular knitting coupled with the drawing-in of sliver of fibers
to produce a pile like fabric. The sliver knit construction allows
for the use of relatively coarse fiber (e.g., 5 dpf to 15 dpf).
This relatively coarse fiber can provide for good resiliency and
resistance to compression, and can generate very high pile (e.g.,
pile height of 3 inches to 4 inches). The sliver fabric of the
insulating-filler fabric layer can be finished as a single face
fabric with a raised surface at the technical back, or as a double
face fabric with raised surfaces on both the technical back and the
technical face. Generally, the sliver knit construction is prone to
"shedding" and may exhibit undesirable aesthetic appearance (e.g.,
poor finish) when raised on the technical face. However, when
incorporated as a filler layer, the aesthetic appearance of the
raised technical face is less critical since the fabric is enclosed
between the outer "shell" fabric layer 22 and the inner
"shell-liner" fabric layer 21.
[0060] In some cases, the insulating-filler fabric layer 23 may
include elastomeric material for enhanced stretch and recovery. For
example, the insulating-filler fabric layer 23 may include
elastomeric yarns and/or fibers, e.g., incorporated in the backing
or stitching yarns. In some examples, the insulating-filler fabric
layer 23 has stretch without including elastomeric material.
[0061] The insulating-filler fabric layer 23 has a weight of about
1 ounce per square yard to about 12 ounces per square yard, has
relatively high thickness (bulk) (e.g., a thickness of at least
about 0.1 inch, e.g., about 0.1 inch to about 1.0 inch), and has
high insulation per weight unit (e.g., about 0.2 clo/oz.sup.2 to
about 1.6 clo/oz.sup.2).
[0062] The insulating-filler fabric layer 23 may consist of a
hydrophobic fabric, which, in case of water penetration through the
outer fabric layer 22 (FIG. 2) will not be held or absorbed, and
will be able to dry fast.
[0063] The inner and outer fabric layers 21, 22 (FIG. 2) can both
be made of woven fabric. Alternatively, in some cases, the inner
"shell-liner" fabric layer 21 and/or the outer "shell" fabric layer
22 may instead consist of a knit fabric, such as a knit fabric
having a single jersey construction, a double knit construction, a
warp knit construction, or a mesh construction. The respective
fabrics of the inner and outer fabric layers 21, 22 may be formed
of synthetic yarns and/or fibers, regenerated yarns and/or fibers,
natural yarns and/or fiber, and combinations thereof.
[0064] In some cases, the inner fabric layer 21 and/or the outer
fabric layer 22 can also include elastomeric material, such as
elastomeric yarns and/or fibers incorporated in the construction of
the respective fabrics, for enhanced stretch and recovery. The
incorporation of elastomeric material in the inner and outer fabric
layers 21,22 can be particularly beneficial where the
insulating-filler fabric layer 23 also has stretch, such that the
inner fabric layer 21 and the outer fabric layer 22 can stretch and
move with the insulating filler layer 23 for enhanced user
comfort.
[0065] The moisture vapor transmission rate and the air
permeability of the insulated composite fabric 20 can be controlled
by the void or openness of the fabrics of the inner and/or outer
fabric layers 21, 22. In some cases, for example, the control of
the air permeability of the insulated composite fabric 20 can be
achieved by controlling one or more parameters (e.g., yarn size,
yarn count, and/or weave density (pick/fill)) of the fabric forming
the inner "shell-liner" fabric layer 21 and/or the outer "shell"
fabric layer 22. Alternatively or additionally, the control of the
air permeability of the insulated composite fabric 20 can be
achieved by applying coating or film lamination 24 (FIG. 2) to one
or more surfaces of the inner fabric layer 21 and/or the outer
fabric layer 22.
[0066] The respective fabrics of the inner and outer fabric layers
21, 22 can be selected to provide the insulated composite fabric 20
with an air permeability within a range of about 1.0
ft.sup.3/ft.sup.2/min to about 300 ft.sup.3/ft.sup.2/min according
to ASTM D-737, under a pressure difference of 1/2 inch of water
across the insulated composite fabric 20. Depending on the
particular construction, the composite fabric 20 may be tailored
toward different end uses. For example, the insulated composite
fabric 20 can be constructed to provide cold weather insulation
with relatively high air permeability for use in conditions of
relatively high physical activity. In this case, the respective
fabrics of the inner and outer fabric layers 21, 22 can be selected
to provide the insulated composite fabric 20 with an air
permeability of about 100 ft.sup.3/ft.sup.2/min to about 300
ft.sup.3/ft.sup.2/min according to ASTM D-737, under a pressure
difference of 1/2 inch of water across the insulated composite
fabric 20.
[0067] Alternatively, the insulated composite fabric 20 can be
constructed to provide cold weather insulation with relatively low
air permeability for use in conditions of relatively little
physical activity. In this case, the respective fabrics of the
inner and outer fabric layers 21, 22 can be selected to provide the
insulated composite fabric 20 with an air permeability of about 1
ft.sup.3/ft.sup.2/min to about 80 ft.sup.3/ft.sup.2/min according
to ASTM D-737, under a pressure difference of 1/2 inch of water
across the insulated composite fabric 20. The complete disclosures
of the test method ASTM D-737 is incorporated herein by
reference.
[0068] In some cases, the inner fabric layer 21 can have a
relatively higher air permeability than the fabric of the outer
fabric layer 22. Utilizing fabric with higher air permeability for
the inner fabric layer 21, which is worn towards the user's body,
can help to enhance vapor movement and vapor transmission away from
the user's body during periods of high activity to help prevent
overheating. For example, the inner fabric layer 21 may have an air
permeability of about 5 ft.sup.3/ft.sup.2/min to about 300
ft.sup.3/ft.sup.2/min, tested according to ASTM D-737, under a
pressure difference of 1/2 inch of water across the inner fabric
layer 21, and the outer fabric layer 22 may have an air
permeability of about 1 ft.sup.3/ft.sup.2/min to about 100
ft.sup.3/ft.sup.2/min (e.g., about 1 ft.sup.3/ft.sup.2/min to about
30 ft.sup.3/ft.sup.2/min), tested according to ASTM D-737, under a
pressure difference of 1/2 inch of water across the outer fabric
layer 22.
[0069] Further description is provided by the following examples,
which do not limit the scope of the claims
EXAMPLES
Example 1
[0070] FIG. 6 illustrates one example of an insulated composite
fabric 20' with a light-duty construction. The fabric includes an
inner fabric layer 21', an outer fabric layer 22', and an
insulating-filler fabric layer 23' enclosed therebetween. Both the
inner fabric layer 21' and the outer fabric layer 22' consist of a
knit fabric with mesh construction. The mesh construction of the
inner and outer fabric layers 21', 22' has a plurality of openings
25. The insulating-filler fabric layer 23' consists of a double
face knit fabric (e.g., double face warp knit, double face knit
with raised sinker terry loop construction, or double face sliver
knit) having a weight of about 1 ounce per square yard to about 4
ounces per square yard, and a bulk (thickness) of about 0.1 inch to
about 0.2 inch. The insulating-filler fabric layer 23' is sewn
(e.g., quilted) to one or both of the inner and outer fabric layers
21', 22'. The light-duty insulated composite fabric 20' provides
insulation of about 0.8 clo/oz.sup.2 to about 1.6 clo/oz.sup.2.
Example 2
[0071] FIG. 7 illustrates an insulated composite fabric 20'' with a
medium-duty construction. The medium-duty insulated composite
fabric 20'' includes an inner fabric layer 21'' consisting of a
knit fabric with mesh construction, an outer fabric layer 22''
consisting of a woven fabric, and an insulating-filler fabric layer
23'' enclosed there between. The insulating-filler fabric layer
23'' consists of a double face knit fabric (e.g., double face warp
knit, double face knit with raised sinker terry loop construction,
or double face sliver knit) having a weight of about 3 ounces per
square yard to about 8 ounces per square yard, and a bulk
(thickness) of about 0.15 inch to about 0.4 inch. The
insulating-filler fabric layer 23'' is sewn (e.g., quilted) to one
or both of the inner and outer fabric layers 21'', 22''. The
medium-duty insulated composite fabric 20'' provides insulation of
about 1.0 clo/oz.sup.2 to about 1.8 clo/oz.sup.2.
Example 3
[0072] FIG. 8 illustrates an insulated composite fabric 20''' with
a heavy-duty construction. The heavy weight insulated composite
fabric 20''' includes an inner fabric layer 21''', an outer fabric
layer 22''', and an insulating-filler fabric layer 23''' enclosed
there between. In this heavy-duty construction, both the inner
fabric layer 21''' and the outer fabric layer 22''' consist of a
woven fabric. The insulating-filler fabric layer 23''' consists of
a double face knit fabric (e.g., double face warp knit, double face
knit with raised sinker terry loop construction, or double face
sliver knit) having a weight of about 4 ounces per square yard to
about 12 ounces per square yard, and a bulk (thickness) of about
0.2 inch to about 1.0 inch. The insulating-filler fabric layer
23''' is sewn (e.g., quilted) to one or both of the inner and outer
fabric layers 21''', 22'''. The heavy-duty insulated composite
fabric 20''' provides insulation of about 1.0 clo/oz.sup.2 to about
3.0 clo/oz.sup.2
Other Implementations
[0073] While certain implementations have been described above,
other implementations are possible.
[0074] For example, an entire fabric garment may be constructed
from the insulted composite fabric, or, in some cases, a fabric
garment may be formed which includes the insulated composite fabric
only in sections.
[0075] FIG. 9 illustrates a hybrid insulated fabric garment 110 in
the form of a jacket that includes a first fabric portion 120 and a
second fabric portion 140. The first fabric portion 120 covers the
user's shoulder regions and extends below the elbows down towards
the user's wrists. The first fabric portion 120 is formed of a
plurality of first fabric elements 122 that are joined together by
stitching at seams 111. The first fabric elements 122 are formed
from a first insulated composite fabric 130, which may have a
construction as described above with regard to FIG. 2. Referring to
FIG. 10, the first insulated composite fabric 130 includes a first
inner fabric layer 131 that forms an inner surface of the fabric
garment 110 worn towards the user's body, a first outer fabric
layer 132 that forms an outer surface of the fabric garment 110,
and a first insulating-filler fabric layer 134 consisting of a
textile fabric with a raised surface on at least one side of the
fabric (a double face fabric is shown in FIG. 10). The first
insulating-filler fabric layer 134 is enclosed between the first
inner fabric layer 131 and the first outer fabric layer 132. The
first insulated composite fabric 130 has an air permeability of
about 1.0 ft.sup.3/ft.sup.2/min to about 80.0 ft.sup.3/ft.sup.2/min
(e.g., about 4.0 ft.sup.3/ft.sup.2/min to about 20.0
ft.sup.3/ft.sup.2/min) tested according to ASTM D-737, under a
pressure difference of 1/2 inch of water across the first insulated
composite fabric 130.
[0076] The second fabric portion 140 covers a lower torso region of
the user's body and is formed of a plurality of second fabric
elements 142, which are joined together and with the first fabric
elements 122 by stitching at seams 111. The second fabric elements
142 are formed from a second insulated composite fabric 150, which,
like the first insulated composite fabric 130, may also have a
construction as described above with regard to FIG. 2. With
reference to FIG. 11, the second insulated composite fabric 150
includes a second inner fabric layer 151, which forms an inner
surface of the fabric garment 110; a second outer fabric layer 152,
which forms an outer surface of the fabric garment 110; and a
second insulating-filler fabric layer 154 consisting of a textile
fabric with a raised surface on at least one side of the fabric. A
single face fabric is shown in FIG. 11; however, the second
insulating-filler fabric layer 154 may, alternatively or
additionally, include a double face fabric, e.g., a double face
fabric with relatively lower thickness than the fabric of the first
insulating-filler fabric layer 134. The second insulating-filler
fabric layer 154 is enclosed between the second inner fabric layer
151 and the second outer fabric layer 152. The second insulated
composite fabric 150 is constructed to have an air permeability
that is different from, and relatively greater than, the air
permeability of the first insulated composite fabric 130. The
second insulated composite fabric 150 has an air permeability of
about 5 ft.sup.3/ft.sup.2/min to about 300 ft.sup.3/ft.sup.2/min
tested according to ASTM D-737, under a pressure difference of 1/2
inch of water across the second insulated composite fabric 150.
[0077] Alternatively or additionally, the first and second fabric
portions 120, 140 can have contrasting stretch. For example, the
first fabric portion 120 may have greater stretch (e.g., in the
outer shell, the inner shell layer, and the insulting-filler) than
the second fabric layer 140. Providing greater stretch in the
shoulder regions, for example, may enhance wearer comfort and
reduce resistance while moving the arms, while other parts, e.g.,
the second fabric portion, may be non-stretch.
[0078] In some cases, the second fabric elements 142 may, instead,
consist of a plain textile fabric, e.g., a circular knit like
single jersey (plaited or non-plaited), double knit, rib, warp
knit, or woven with and/or without stretch. Or, as another
alternative, the second fabric elements 142 may consist of a double
face knit fabric having reverse plaited terry sinker loop knit
construction. Suitable fabrics for forming the second fabric
elements 142 are commercially, available, e.g., from Polartec, LLC,
of Lawrence, Mass., under the trademarks POWER STRETCH.RTM. and
BOUNDARY.RTM..
[0079] In some cases, the second fabric elements 142 may be formed
of a laminate composite fabric with outer and inner fabric layers;
and a barrier resistant to wind and liquid water while providing
water vapor transport through absorption-diffusion-desorption,
including a hydrophilic barrier and/or adhesive layer adhered to
the inner and/or outer fabric layer. Suitable laminate composite
fabrics are commercially available, e.g., from Polartec, LLC, of
Lawrence, Mass., under the trademarks WINDBLOC.RTM. and POWER
SHIELD.RTM..
[0080] In some cases, enhancing the packability or compression
(i.e., reducing the total volume of the insulated composite fabric)
can be achieved by having voids or pile out (i.e., regions of no
pile) in a predetermined pattern in the insulating-filler fabric
layer. For example, FIG. 12 shows a raised surface knit fabric 60
having a first pile surface 62 that includes regions of no pile 64
interspersed among regions of pile 66 (e.g., pile having a height
of at least about 2.0 mm. About 5% to about 70% of the surface area
of the insulating-filler fabric can be covered by no pile
regions.
[0081] As mentioned above, the raised surface knit fabric of the
insulating filler layer may have a construction made on a warp
knitting double needle bar raschel machine, where the pile yarns
are grouped in a predetermined pattern and some predetermined
sections have voids (no pile yarn). For example, FIG. 13A
illustrates an embodiment of such a raised surface knit fabric 200
having a first pile surface 210 on the technical back that includes
void regions 212a (e.g., regions of no pile) interspersed between
regions of pile 214a. The fabric 200 also includes a second pile
surface 220 (after raising) on the technical face. As shown in FIG.
13A, the second pile surface 220 also includes void regions 212b
(e.g., regions of no pile) interspersed between regions of pile
214b. When incorporated into an insulated composite fabric, such as
described above, the pile yarn on the technical back and on the
technical face (after raising) will keep the outer "shell" and the
inner "shell-liner" fabric layers spaced apart, entrapping stagnant
air, maximizing thermal insulation of the insulated composite
fabric. The air entrapped between the shell and the shell-liner in
the regions of no pile, will provide good thermal in static
condition at very low air movement or wind.
[0082] In dynamic conditions (air flow or wind blowing onto the
shell material having controlled air permeability), the thermal
insulation in the void region may be reduced. However, the loss of
thermal insulation can be reduced by providing relative low
fleece/velour (lower than the interconnecting pile) in the void
regions 212a, 212b. This can be done by adding additional pile yarn
230 (preferably in fine dpf like micro fiber under 1.0 denier)
without generating interconnecting pile, but which is held by the
stitch and backing yarn along the technical face (FIG. 13B) and/or
along the technical back (FIG. 13D), and generating fleece/velour
on the technical face upon raising the additional pile yarn 230 by
napping (FIG. 13C) and/or generating fleece on the technical back
upon raising the additional pile yarn 230 by napping (FIG. 13E).
This low fleece/velour (much lower than that formed by the
interconnecting pile) in the void region with improved tortuousity
and reduced air movement (keeping entrapped air stagnate) to reduce
thermal heat loss by convection.
[0083] While implementations of insulating-filler fabrics have been
described which include one or more raised surfaces, in some
implementations, e.g., where less insulation is needed, the
insulating-filler fabric may instead have a regular knit
construction (single or double face) which is finished on one or
both sides by brushing.
[0084] In some cases, the outer "shell" fabric layer, the inner
"shell-liner" fabric layer, and/or the insulating-filler fabric
layer may be formed of, and/or incorporate, flame-retardant
materials (e.g., flame retardant fibers), or may be treated (e.g.,
chemically treated) to provide flame-retardance. In some
implementations, the outer "shell" fabric layer is treated with
durable water repellent (DWR), an abrasion resistant coating,
camouflage, and/or infrared radiation reduction.
[0085] Although embodiments of insulated composite fabrics have
been described in which an insulating-filler fabric layer is
attached to one or both of a inner fabric layer and an outer fabric
layer by sewing, in some cases, the insulating-filler fabric layer
may be laminated to one or both of the inner fabric layer and the
outer fabric layer. FIG. 14A illustrates an insulated composite
fabric laminate 320. The insulated composite fabric laminate 320
includes an inner fabric layer 321, an outer fabric layer 322, and
an insulating-filler fabric layer 323 enclosed therebetween. The
insulating-filler fabric layer 323 consists of a double face knit
fabric that is bonded to the inner fabric layer 321 and the outer
fabric layer 322 with an adhesive 326. The adhesive can applied in
a manner to substantially avoid further limiting the air
permeability of the insulated composite fabric laminate 320. The
adhesive can be applied, for example, in a dot coating pattern.
[0086] FIG. 14B illustrates an alternative embodiment in which the
insulating-filler fabric layer 323 is laminated only to the inner
fabric layer 321, and FIG. 14C illustrates an alternative
embodiment in which the insulating filler fabric layer 323 is
laminated only to the outer fabric layer 322.
[0087] FIG. 15A illustrates yet another example of an insulated
composite fabric 420. The insulated composite fabric 420 of FIG.
15A includes an outer "shell" fabric layer 422 and an inner,
insulating fabric layer 421. The outer fabric layer 422 consists of
a woven fabric. The insulating fabric layer 421 consists of a
single face knit fabric (e.g., single face warp knit, single face
knit with raised sinker terry loop construction, or single face
sliver knit) having a raised surface 423 (pile or velour) and an
opposite, smooth surface 424. The insulating fabric layer 421 is
attached to the outer fabric layer 422 (e.g., by sewing (e.g.,
quilting at any pattern, sewing, tucking, ultrasound bonding, or
tack stitching), lamination, anchored by stitching along seams, or
other physical anchoring like snapping, etc.) such that the raised
surface 423 faces toward the outer fabric layer 422. The smooth
surface 424 of the insulating fabric layer 421 forms an exposed
surface of the insulated composite fabric 420. The insulated
composite fabric 420 can be incorporated in a fabric garment such
as any of the garments described above. For example, the insulated
composite fabric 420 of FIG. 14 could be used in the first fabric
portion or the second fabric portion of the jacket of FIG. 9. When
incorporated in a fabric garment, the smooth surface 424 of the
insulating fabric layer 421 can be arranged to form an inner
surface of the garment worn towards the user's body.
[0088] Either or both of the insulating fabric layer 421 and the
outer fabric layer 422 can have stretch in at least one direction.
In some cases, for example, either or both of the insulating fabric
layer 421 and the outer fabric layer 422 can include elastomeric
material (e.g., spandex yarns and/or fibers) for enhanced stretch
and shape recovery.
[0089] Referring still to FIG. 15A, the moisture vapor transmission
rate and the air permeability of the insulated composite fabric 420
can be controlled by the void or openness of the fabric of the
outer fabric layer 422. In some cases, for example, the control of
the air permeability of the insulated composite fabric 420 can be
achieved by controlling one or more parameters (e.g., yarn size,
yarn count, and/or weave density (pick/fill)) of the fabric forming
the outer fabric layer 422. Alternatively or additionally, the
control of the air permeability of the insulated composite fabric
420 can be achieved by applying coating or film lamination to one
or both surfaces of the outer fabric layer 422.
[0090] FIG. 15B illustrates yet another example of an insulated
composite fabric 420'. The insulated composite fabric 420' of FIG.
15B includes an outer "shell" fabric layer 422 and an inner,
insulating fabric layer 421'. As illustrated in FIG. 15B, the
insulating fabric layer 421' consists of a double face knit fabric
that is bonded to the outer fabric layer 422 with an adhesive 426
to form a fabric laminate. Alternatively or additionally, the
insulating fabric layer 421' may be connected to the outer fabric
layer by quilting (in any pattern), tucking, ultrasound bonding,
etc.
[0091] Either or both of the insulating fabric layer 421', and the
outer fabric layer 422 can have stretch in at least one direction.
The moisture vapor transmission rate and the air permeability of
the insulated composite fabric 420' can be controlled as discussed
above with regard to FIG. 15A.
[0092] In some cases, the insulated composite fabric may be
provided with water resistant properties. For example, the outer
"shell" fabric layer may have a very tight construction (e.g., a
tight woven construction) and may be treated with durable water
repellent (DWR). Alternatively or additionally, the insulated
composite fabric may be provided with a waterproof membrane (e.g.,
a breathable waterproof membrane). For example, FIG. 16 illustrates
an embodiment of an insulated composite fabric 500 that consists of
an inner "shell-liner" fabric layer 510, and an outer "shell"
fabric layer 520 and an insulating-filler fabric layer 530 enclosed
therebetween. In this example, a waterproof membrane 540 is
laminated to an inner surface 522 of the outer "shell" fabric layer
520. The water barrier can be made of porous hydrophobic membrane,
hydrophilic non-porous membrane, or electrospun material.
Preferably, the insulating-filler fabric layer 530 is hydrophobic
(e.g., formed of hydrophobic yarns/fibers), which, in case of water
penetration through the outer fabric layer 520 will not be held or
absorbed, and will be able to dry fast.
[0093] The water proof insulated composite fabric 500 can be used
to form an entire fabric garment, or in some cases may only form a
portion or portions of the silhouette. For example, FIG. 17
illustrates a hybrid insulated fabric garment 610 that includes a
first fabric portion 620 and a second fabric portion 640. The first
fabric portion 620 is disposed in one or more upper regions (e.g.,
arranged to cover a wearer's upper torso, shoulders and extending
down the arms) of the fabric garment (i.e., those region more
likely in use to be exposed to rain). The first fabric portion 620
is formed of first fabric elements 622. The first fabric elements
622 are formed from a water repellent insulated composite fabric,
which may have a construction as described above with regard to
FIG. 16.
[0094] The second fabric portion 640 is disposed in a lower region
(e.g., arranged to cover lower torso and lower back regions of the
user's body), which are less likely during use to be exposed to
rain. The second fabric portion 640 is formed of second fabric
elements 642, which are joined together and with the first fabric
elements 622 by stitching at seams 611. The second fabric elements
642 are formed from a second insulated composite fabric, which may
have a construction as described above with regard to FIG. 2.
[0095] In some implementations, a reversible insulated composite
fabric garment may also be provided. For example, the insulated
composite fabric garment can be formed of an insulated composite
fabric, similar to that described above with reference to FIG. 2,
consisting of a first fabric layer, a fabric layer, and an
insulating-filler fabric layer enclosed therebetween. The fabric
garment may be reversible such that both the first fabric layer and
the second fabric layer can optionally serve as either an outer
"shell" fabric layer or an inner "shell-liner" fabric layer, which
will allow the wearer to have a reversible insulated composite
fabric ("technical down") garment. The first and second fabric
layers may be made of different color fabrics and/or fabrics with
different patterns (e.g., camouflage) and/or different
textures.
[0096] Although fabric garments in the form of jackets have been
described, it should be noted that the insulated composite fabrics
described herein may also be incorporated in various types of
fabric articles, including, but not limited to, coats, shells,
pull-overs, vests, shirts, pants, blankets (e.g., home textile
blankets or outdoor blankets), etc.
[0097] In some cases, the insulating layer (e.g., the
insulating-filler fabric layer (e.g., of any one of FIG. 2, 6-8,
10, 11, or 14A-14C) or the insulating fabric layer (e.g., of any
one of FIG. 15A or 15B)) may consist of a terry sinker loop (in
reverse plaiting or regular plaiting) in which the terry loop is
left un-raised. A high sinker (e.g., 2 to 9 mm) can be used to form
the terry sinker loop. In this construction, the terry sinker loop
may be provided in a predetermined pattern or design, while having
other section(s) without the terry sinker loop (having void), to
reduce the total weight as well as helping in the pliability and
easy pack ability (easy folding). As mentioned above, the terry
sinker loop can be made in regular plaiting construction as well as
reverse plaiting. In the case of reverse plaiting, the technical
face (jersey side) may be finished, and the technical back may be
left in a terry sinker loop (un napped), or the terry sinker loop
may be left on the technical back, without napping the technical
face-jersey side (similar to regular plaited construction).
[0098] In some implementations, the insulating-filler fabric layer
23, e.g., having features discussed above with reference to FIGS.
2-5, contains multi-groove (nano or micro or other) fibers ("MGF"),
which is described in more detail below. Referring again to FIGS. 3
and 4, one or both of the raised surfaces 32, 34 or the raised
surfaces 42, 44 incorporate the multi-groove fibers. In some
implementations, the multi-groove fibers in the raised surfaces
have relatively longer whiskers to provide good thermal insulation.
Referring again to FIG. 5, backing yarn 54 can form a smooth
surface that includes the multi-groove fibers having relatively
shorter whiskers. The multi-groove fibers having relatively shorter
whiskers can facilitate water management. In some cases, both the
fabric bodies and the raised surfaces of the insulating-filler
fabric layer 23 incorporate the multi-groove fibers. The
multi-groove fibers incorporated in different parts of the layer 23
can have different features, such as denier, whisker lengths,
etc.
[0099] Multi-groove fibers having relatively shorter whiskers, e.g.
as developed by Taiwan Textile Researched Institute ("TTRI"), are
described in Liu et al. U.S. Patent Publication No. 2010/0159241,
published Jun. 24, 2010 (assigned on its face to Taiwan Textile
Research Institute), the complete disclosure of which is
incorporated herein by reference. As will be described, whisker
fibers permit formation of fabric layers, including raised surface
velour and velour/velour fabric layers, with certain advantageous
features, including, but not limited to, soft touch or ultra-suede
touch, while still generating appropriate thickness/bulk of the
raised surface fabric.
[0100] Referring to FIGS. 18A, 18B, and 18C, a multi-groove fiber
720 suitable for use in the insulating-filler fabric layer 23
consists of an axially-elongated core 722 and multiple (e.g.,
3-200) grooves 726 defined and spaced apart by whiskers 724 that
extend generally radially from the core 722. The whiskers 724,
e.g., axially-elongated whiskers, are separated by grooves 726,
e.g., axially-elongated grooves, and can have an average radial
length, l, in the order of microns or nanometers. The core 722 can
have any desired mass density (i.e. denier or mass-per-length),
e.g., a coarse denier of about 1.5 dpf to about 10.0 dpf, or a fine
denier of about 0.3 dpf to about 1.5 dpf. In some implementations,
the total mass density of the fiber 720 is selected to be about 0.3
dpf to about 1.5 dpf. In some implementations, multi-groove fibers
720 are incorporated in the insulating-filler fabric layer 23 have
relatively longer whiskers and are relatively coarse to provide
good thermal insulation properties.
[0101] The core 722 is formed of a synthetic (polymeric) material,
e.g., selected from among, e.g. polyester, nylon, polypropylene,
and others. The whiskers 724 are formed of the same synthetic
material as the core 720. For example, both the core 720 and the
whiskers 724 are formed of polyester. Referring to FIGS. 18D and
18E, other implementations of multi-groove fibers 720', 720'' are
shown, e.g. with whiskers of relatively shorter length and
relatively longer length, respectively. In some implementations, an
average radial length, l, of the whiskers 724' of multi-groove
fibers 720' is smaller than the diameter of the core 722'. An
average radial length, l, of the whiskers 724'' of the multi-groove
fibers 720'' is greater than the diameter of the core 722''. The
whiskers may an average length of up to about 200% of the diameter
of the core, e.g., for relatively longer whiskers, or may have an
average length of down to about 0.01% of a diameter of the core,
e.g. for relatively shorter whiskers. The relatively longer
whiskers may have an average length in the range of about 20% to
about 100% of a diameter of a core, and the relatively shorter
whiskers can have an average length in the range of about 0.1% to
about 1.0% of a diameter of a core, or about 200 nm to about 2
microns.
[0102] The multi-groove fibers can provide the fabric layer with
improved thermal insulation properties. The fabric layer can resist
release or displacement of the entrapped air as compared to raised
surface fabric layers containing conventional fibers, when exposed
to dynamic conditions (movement and/or blowing air). Under static
conditions, the raised surface or surface regions of the disclosure
containing the multi-groove fibers and the raised surface or
surface regions containing conventional fibers, without grooves or
whiskers, can both entrap a similar amount of air to provide
similar thermal insulation properties to the fabric layer. However,
air displacement in the raised surface containing the multi-groove
fibers is reduced as compared to a raised surface formed of
conventional fibers, e.g., because of the tortuosity effect caused
by the multi-groove fibers. In addition, under dynamic conditions,
i.e., when the fabric layers are in motion, e.g. caused by wind or
by movement of the user, movement of multi-groove fibers on a
raised surface of the fabric layer of the disclosure is more
restricted, e.g. as compared to movement of conventional fibers of
a raised surface of a conventional fabric layer, e.g. in particular
in the case of relatively longer whiskers. Accordingly, the fabric
layer of the disclosure provide good thermal insulation to the user
under both static and dynamic conditions.
[0103] Referring also to FIG. 19, the multi-groove fibers may be
formed according to processes described in Liu et al. U.S. Patent
Publication No. 2010/0159241, as referenced above. Multi-groove
fibers may also be available commercially from TTRI. Similar fibers
may also be available from Hills, Inc. (Melbourne, Fla., USA). As
shown in FIG. 19, according to the patent publication of Liu et
al., multi-groove fibers are formed initially as a precursor 740',
extruded from a spinneret die, the fiber precursor consisting of a
core 732 surrounded by an edge region 746. The edge region 746 is
formed of alternating materials 734, 736, e.g., polymeric
materials, respectively. The polymer 734 later forms whiskers over
the core 732, and the polymer 736 forms a removable, e.g.,
dissolvable, sheath separating the polymer 734. In some
implementations, as shown in FIG. 19A, the sheath 736 extends
beyond the whisker material 734 along the radial direction. The
surface of the edge region surrounding the core 732 is formed of
the sheath material 736. Upon removal of the polymer sheath 736,
grooves are formed among the whiskers.
[0104] The polymers 734, 736 can be in the form of alternating
sheets or webs extending along a longitudinal axis of the core 732.
The polymer 734 is the same as the synthetic material forming the
core 732. The polymer 736 is different from the materials forming
the core 732 and the polymer 734, and is dissolvable or otherwise
removable. The polymer 736 and the polymer 734 typically have
surface energy that is quite similar. Referring still to FIG. 19,
the fiber precursor 740' is next subjected to processing (arrow, P)
for removal of the sheath 736, thereby forming multiple grooves 738
disposed about and extending axially along the core 732 of the
multi-groove fiber 740, the grooves 738 being defined by and
between intervening "whiskers" 742 formed of the sheets of the
first set 734.
[0105] Referring again to FIGS. 18A and 18B, and also to FIG. 18C,
fibers 720 have a core 722 and whiskers 724 separated by grooves
726 extending from the surface of the core. The fibers 720 can be
multi-groove nano fibers having a total (including the core and the
whiskers) average mass density of about 0.3 dpf to about 10.0 dpf.
The fibers 720 can also be multi-groove micro fibers. The whiskers
724 and grooves 726 cause the fibers 720 to have relatively low
mass density as compared to a relatively smaller diameter or
thickness for fibers in the indicated range of denier. For example,
for purposes of comparison, a conventional fiber without the
grooves and whiskers and formed of the same material would have a
thickness of about 2% to about 75% of the thickness of the fiber
720, in order to have denier in the range indicated for the
multi-groove fiber 720. In contrast, if a conventional fiber had a
diameter in the range indicated above for multi-groove fiber 720,
and was formed of the same material, such a conventional fiber
would have denier in the range of about 1.3 to about 50 times the
denier of the fiber 720.
[0106] According to the present disclosure, the sizes, thicknesses,
and/or mass densities of the multi-groove fibers 720 can be
selected based on the desired features of the fibers 720, e.g.,
denier, and/or other features of the raised surface(s) 32, 34, 42,
44, or 52 (FIGS. 3-5). The whiskers 724 can have an average radial
length, l, of about 2 nm to about 10 microns, e.g., 200 nm to 2
microns, and an average thickness, t, of about 100 nm to 1 micron,
e.g., 200 nm to 1 micron, or 250 nm. As mention above, the grooves
can be nano-size or micro-size, e.g., having an average width, w,
of about 100 nm to 10 microns, e.g., 250 nm. The ratio of the
average diameter, D, of the core 722 to the average length, l, of
the whiskers 724 and/or the ratio of the average thickness, t, to
the average width, w, can be adjusted to obtain desired fiber
properties, e.g., by changing the materials for and/or processes of
making the multi-groove fibers 720 (discussed further below). In
the example shown in FIG. 3E, the ratio of core diameter to the
average length of the whiskers is 1:1.
[0107] In some implementations, each multi-groove fiber 720 has
about 3 to about 200 whiskers, e.g., about 10-200 whiskers, about
40-200 whiskers, or about 60-80 whiskers, extending generally
radially from the core. The grooves 726 extend the entire length of
the multi-groove fiber 720. In some implementations, the grooves
726 have substantially the same dimensions and/or are substantially
evenly distributed about and/or along a cross-sectional surface of
the multi-groove fiber 720. In other implementations, the grooves
726 may have different dimensions and/or may be distributed
irregularly. Although the core 722 and the multi-groove fibers 720
appearing in the figures are shown as having circular
cross-section, it is to be understood that the core 722 and the
multi-groove fibers 720 may have other cross-sectional shapes. In
some implementations, a fiber can include both relatively longer
whiskers and relatively shorter whiskers along its cross
section.
[0108] In some implementations, the multi-groove fibers 720 are
formed or consist of synthetic (polymeric) material. The core 722
and the whiskers 724 are typically formed of the same polymeric
material. Suitable polymeric materials for use in the core 722 and
the whiskers 724 include, e.g., polyethylene terephthalate (PET),
polypropylene (PP), polyamide 6 (PA 6), PA 66, and/or combinations
thereof.
[0109] Referring again to FIG. 19, multi-groove fibers 740, e.g.,
that are similar to or the same as the multi-groove fibers 720 of
FIGS. 18A and 18B, can be made by forming a polymer extrusion 730
of three or more polymers 732, 734, 736 and removing one of the
polymers 736 to form grooves 738 among whiskers 742 formed of the
polymer 736. The polymeric extrusion 30 includes a core region 744
formed of the polymer 732 and an edge region 746 formed of polymers
734, 736. The polymer 734 is the same as the polymer 732, and the
whiskers are separated by the sheath formed by the removable
polymer 736, e.g., dissolvable polyester, polyvinyl alcohol (PVA),
polybutylene terephthalate (PBT), poly(lactic acid) or polylactide
(PLA), or others. The sheath can be removed by exposing the polymer
extrusion 730 to water or caustic soda (NaOH). The polymer 736 can
be removed by heating or radiating the polymer extrusion 730 and
dissolving the polymer 736. Other removable polymers and removal
mechanisms may also be employed. The polymers 732, 734 can be the
previously discussed polymers for forming the core 722 and the
whiskers 724.
[0110] Referring again to FIGS. 18D and 18E, the thickness, t, and
the length, l, of the whiskers 742 can be adjusted by modifying the
polymers 734, 736 or other related parameters and factors. For
example, the spinneret used for extruding the fibers and/or the
weight ratio of the whisker polymer 734 and the sheath polymer 736
can be controlled or adjusted to modify parameters of resulting
product. The feeding rate of each polymer, the spin head and the
spinning plates in the spinneret can also be modified. For example,
the weight ratio can be in the range of from 9/1 to 1/9. The
dimensional ratio of the core 744 to the edge 742 (FIG. 19) can
also be adjusted, e.g., to provide the desired fiber denier and
thickness. In some implementations, multi-groove fibers 720' (FIG.
18D) with relatively shorter and/or thicker edge segments,
resulting in relatively shorter and/or thinner whiskers 724', may
be desirable, e.g. to produce fabric having a matte appearance or
finish. Conversely, multi-groove fiber 720'' (FIG. 18E) with
relatively longer and/or thinner edge segments, resulting in
relatively longer and/or thicker whiskers 724'', may also be
desirable, e.g. to provide a softer touch to the fibers, and to the
fabric containing or made of the fibers, e.g. resembling
ultra-suede. The ratio of dissolvable and non-dissolvable segments,
as well as the ratio of edge and core dimensions, can also be
adjusted.
[0111] In some implementations, the multi-groove fibers can be
incorporated in the insulating-filler fabric layer 23 to allow the
insulating-filler fabric layer 23 to manage water across the layer.
As an example, referring to FIG. 20, a fabric portion 1100 of the
insulating-filler fabric layer has a plaited construction can move
liquid sweat from the inner side 1104 (facing a user's skin
surface) to the outer side 1106. Relatively coarser denier fibers
are used on inner side 1104 (facing the user's skin) and relatively
finer denier fibers are used on outer side 1106 (away from the
user's skin). Use of the multi-groove fibers (or whisker fibers) as
the relatively finer denier fiber on the outer side 1106 permits
use of very fine fibers on inner side 1104 (0.1 to 1.0 dpf), while
still maintaining, or improving, water management. In some
implementations, whiskers having a relatively shorter length, l,
e.g., 200 nm to 10 microns, can provide good water management by
allowing water to move along the grooves 726 (FIG. 18A), 738 (FIG.
19) among the whiskers. The whiskers 724, 742 and the grooves 726,
738 also increase the total surface area of the fibers 720, 740, so
that the fibers 720, 740 have a relatively larger capacity to hold
liquid and water evaporation can be enhanced. In some
implementations, the fibers 720, 740 can have any size core (i.e.,
any denier) with a desired length of whiskers selected to provide a
desired fiber property, e.g., denier and/or water management. In
some implementations, the insulating-filler fabric layer is used
with the inner and outer layers that also provide water management
properties.
[0112] Other implementations are within the scope of the following
claims.
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