Insulated composite fabric

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.

TECHNICAL FIELD

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

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.

Some known nonwoven filler materials, such as Primaloft®, available from Albany International Corp, and Thinsulate™, 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.

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 ft3/ft2/min and, in many cases, close to zero ft3/ft2/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 ft3/ft2/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.

Nonwoven filler materials also tend to flatten under compression and as a result may exhibit a loss in thermal insulation.

SUMMARY

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.

One aspect of the disclosure, described below with reference, e.g., toFIG. 12andFIGS. 13A-13Eof 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.

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/oz2to 1.6 clo/oz2. 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 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the insulated composite fabric, and wherein the insulated composite fabric provides insulation of 0.2 clo/oz2to 3.0 clo/oz2. 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.

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.

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.

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.

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/oz2to about 1.6 clo/oz2. 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 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the inner fabric layer. The outer fabric layer has an air permeability of about 1 ft3/ft2/min to about 100 ft3/ft2/min, (e.g., about 1 ft3/ft2/min to about 100 ft3/ft2/min), tested according to ASTM D-737 under a pressure difference of ½ 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 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ 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 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the insulated composite fabric (e.g., about 100 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the insulated composite fabric, or about 1.0 ft3/ft2/min to about 80.0 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ 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/oz2to about 3.0 clo/oz2(e.g., about 0.8 clo/oz2to about 1.6 clo/oz2, about 1.0 clo/oz2to about 1.8 clo/oz2, or about 1.0 clo/oz2to about 3.0 clo/oz2). 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.

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.

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/oz2to about 1.6 clo/oz2. 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 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the inner fabric layer. The first outer fabric layer has an air permeability of about 1 ft3/ft2/min to about 100 ft3/ft2/min, (e.g., about 1 ft3/ft2/min to about 100 ft3/ft2/min) tested according to ASTM D-737 under a pressure difference of ½ 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 ft3/ft2/min to about 80.0 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the first insulated composite fabric (e.g., about 4.0 ft3/ft2/min to about 20.0 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ 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/oz2to about 1.6 clo/oz2. 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 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737, under a pressure difference of ½ 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 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737, under a pressure difference of ½ 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.

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.

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.

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;

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.

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.

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/oz2to about 1.6 clo/oz2. 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 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737 under a pressure difference of ½ 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.

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.

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.

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.

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.

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.

Implementations of the disclosure can include one or more of the following advantages.

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.

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.

Other aspects, features, and advantages of the disclosure are in the description, drawings, and claims.

DETAILED DESCRIPTION

Referring toFIG. 1, an insulated fabric garment10is formed from a plurality of fabric elements that are joined together, e.g. by stitching at seams11. The fabric elements include left and right front elements12,13, a rear element14, a collar element16, and left and right arm elements17,18. Each of these fabric elements consists of an insulated composite fabric (“technical down”).FIG. 2illustrates an insulated composite fabric20that is suitable for forming the fabric elements. The insulated composite fabric20consists of an inner “shell-liner” fabric layer21, which forms an inner surface of the fabric garment10worn towards a user's body; an outer “shell” fabric layer22, which forms an outer surface of the fabric garment10; and an insulating-filler fabric layer23enclosed therebetween. The insulating-filler fabric layer23can be sewn (e.g., quilted (as illustrated inFIG. 2) and/or connected with tack stitches) to one or both of the inner and outer fabric layers21,22, or, in some cases, a loose insulating-filler fabric layer23is anchored in the seams11of the fabric garment10and/or along the periphery of the individual fabric elements. Alternatively or additionally, the insulating-filler fabric layer23can be attached to one or both of the inner and outer fabric layers21,22by other physical anchoring, e.g., via snapping, tucking, jumping and tucking, ultrasound bonding, lamination, etc.

The insulating-filler fabric layer23is a textile fabric with raised surface on one side or both sides. The textile fabric of the insulating-filler fabric layer23is 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 layer23even under compression.

Referring toFIG. 3, the insulating-filler fabric layer23may be formed from a double face warp knit fabric30that includes a technical back32formed of pile yarns that are brushed to provide a plush velvet surface33, and a technical face34formed of backing yarns and stitching yarns. The backing yarns or the stitching yarns of the technical face34may be napped to form a fleece/velour35. Alternatively, in some cases, some of the pile yarns overlay the stitch yarn at the technical face35and may brushed or napped to form a fleece/velour35surface at the technical face35. 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®.

Alternatively or additionally, the insulating-filler fabric layer23may be formed from a double face knit fabric having reverse plaited terry sinker loop knit construction. Referring toFIG. 4, the double face knit fabric with reverse plaited terry sinker loop knit construction40has a technical face42with a raised or napped surface43, and a technical back44in which sinker loops are sheared to form a cut loop velvet surface45. 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.

Referring toFIG. 5, the insulating-filler fabric layer23may also be formed from a single face fabric50that is constructed to include a technical face52with face yarn that is positioned generally perpendicular to stitching or backing yarn54.

Alternatively or additionally, the insulating-filler fabric layer23may 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 layer22and the inner “shell-liner” fabric layer21.

In some cases, the insulating-filler fabric layer23may include elastomeric material for enhanced stretch and recovery. For example, the insulating-filler fabric layer23may include elastomeric yarns and/or fibers, e.g., incorporated in the backing or stitching yarns. In some examples, the insulating-filler fabric layer23has stretch without including elastomeric material.

The insulating-filler fabric layer23has 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/oz2to about 1.6 clo/oz2).

The insulating-filler fabric layer23may consist of a hydrophobic fabric, which, in case of water penetration through the outer fabric layer22(FIG. 2) will not be held or absorbed, and will be able to dry fast.

The inner and outer fabric layers21,22(FIG. 2) can both be made of woven fabric. Alternatively, in some cases, the inner “shell-liner” fabric layer21and/or the outer “shell” fabric layer22may 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 layers21,22may be formed of synthetic yarns and/or fibers, regenerated yarns and/or fibers, natural yarns and/or fiber, and combinations thereof.

In some cases, the inner fabric layer21and/or the outer fabric layer22can 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 layers21,22can be particularly beneficial where the insulating-filler fabric layer23also has stretch, such that the inner fabric layer21and the outer fabric layer22can stretch and move with the insulating filler layer23for enhanced user comfort.

The moisture vapor transmission rate and the air permeability of the insulated composite fabric20can be controlled by the void or openness of the fabrics of the inner and/or outer fabric layers21,22. In some cases, for example, the control of the air permeability of the insulated composite fabric20can 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 layer21and/or the outer “shell” fabric layer22. Alternatively or additionally, the control of the air permeability of the insulated composite fabric20can be achieved by applying coating or film lamination24(FIG. 2) to one or more surfaces of the inner fabric layer21and/or the outer fabric layer22.

The respective fabrics of the inner and outer fabric layers21,22can be selected to provide the insulated composite fabric20with an air permeability within a range of about 1.0 ft3/ft2/min to about 300 ft3/ft2/min according to ASTM D-737, under a pressure difference of ½ inch of water across the insulated composite fabric20. Depending on the particular construction, the composite fabric20may be tailored toward different end uses. For example, the insulated composite fabric20can 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 layers21,22can be selected to provide the insulated composite fabric20with an air permeability of about 100 ft3/ft2/min to about 300 ft3/ft2/min according to ASTM D-737, under a pressure difference of ½ inch of water across the insulated composite fabric20.

Alternatively, the insulated composite fabric20can 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 layers21,22can be selected to provide the insulated composite fabric20with an air permeability of about 1 ft3/ft2/min to about 80 ft3/ft2/min according to ASTM D-737, under a pressure difference of ½ inch of water across the insulated composite fabric20. The complete disclosures of the test method ASTM D-737 is incorporated herein by reference.

In some cases, the inner fabric layer21can have a relatively higher air permeability than the fabric of the outer fabric layer22. Utilizing fabric with higher air permeability for the inner fabric layer21, 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 layer21may have an air permeability of about 5 ft3/ft2/min to about 300 ft3/ft2/min, tested according to ASTM D-737, under a pressure difference of ½ inch of water across the inner fabric layer21, and the outer fabric layer22may have an air permeability of about 1 ft3/ft2/min to about 100 ft3/ft2/min (e.g., about 1 ft3/ft2/min to about 30 ft3/ft2/min), tested according to ASTM D-737, under a pressure difference of ½ inch of water across the outer fabric layer22.

Further description is provided by the following examples, which do not limit the scope of the claims

EXAMPLES

FIG. 6illustrates one example of an insulated composite fabric20′ with a light-duty construction. The fabric includes an inner fabric layer21′, an outer fabric layer22′, and an insulating-filler fabric layer23′ enclosed therebetween. Both the inner fabric layer21′ and the outer fabric layer22′ consist of a knit fabric with mesh construction. The mesh construction of the inner and outer fabric layers21′,22′ has a plurality of openings25. The insulating-filler fabric layer23′ 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 layer23′ is sewn (e.g., quilted) to one or both of the inner and outer fabric layers21′,22′. The light-duty insulated composite fabric20′ provides insulation of about 0.8 clo/oz2to about 1.6 clo/oz2.

FIG. 7illustrates an insulated composite fabric20″ with a medium-duty construction. The medium-duty insulated composite fabric20″ includes an inner fabric layer21″ consisting of a knit fabric with mesh construction, an outer fabric layer22″ consisting of a woven fabric, and an insulating-filler fabric layer23″ enclosed there between. The insulating-filler fabric layer23″ 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 layer23″ is sewn (e.g., quilted) to one or both of the inner and outer fabric layers21″,22″. The medium-duty insulated composite fabric20″ provides insulation of about 1.0 clo/oz2to about 1.8 clo/oz2.

FIG. 8illustrates an insulated composite fabric20″′ with a heavy-duty construction. The heavy weight insulated composite fabric20″′ includes an inner fabric layer21″′, an outer fabric layer22″′, and an insulating-filler fabric layer23″′ enclosed there between. In this heavy-duty construction, both the inner fabric layer21″′ and the outer fabric layer22″′ consist of a woven fabric. The insulating-filler fabric layer23″′ 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 layer23″′ is sewn (e.g., quilted) to one or both of the inner and outer fabric layers21″′,22″′. The heavy-duty insulated composite fabric20″′ provides insulation of about 1.0 clo/oz2to about 3.0 clo/oz2

Other Implementations

While certain implementations have been described above, other implementations are possible.

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.

FIG. 9illustrates a hybrid insulated fabric garment110in the form of a jacket that includes a first fabric portion120and a second fabric portion140. The first fabric portion120covers the user's shoulder regions and extends below the elbows down towards the user's wrists. The first fabric portion120is formed of a plurality of first fabric elements122that are joined together by stitching at seams111. The first fabric elements122are formed from a first insulated composite fabric130, which may have a construction as described above with regard toFIG. 2. Referring toFIG. 10, the first insulated composite fabric130includes a first inner fabric layer131that forms an inner surface of the fabric garment110worn towards the user's body, a first outer fabric layer132that forms an outer surface of the fabric garment110, and a first insulating-filler fabric layer134consisting of a textile fabric with a raised surface on at least one side of the fabric (a double face fabric is shown inFIG. 10). The first insulating-filler fabric layer134is enclosed between the first inner fabric layer131and the first outer fabric layer132. The first insulated composite fabric130has an air permeability of about 1.0 ft3/ft2/min to about 80.0 ft3/ft2/min (e.g., about 4.0 ft3/ft2/min to about 20.0 ft3/ft2/min) tested according to ASTM D-737, under a pressure difference of ½ inch of water across the first insulated composite fabric130.

The second fabric portion140covers a lower torso region of the user's body and is formed of a plurality of second fabric elements142, which are joined together and with the first fabric elements122by stitching at seams111. The second fabric elements142are formed from a second insulated composite fabric150, which, like the first insulated composite fabric130, may also have a construction as described above with regard toFIG. 2. With reference toFIG. 11, the second insulated composite fabric150includes a second inner fabric layer151, which forms an inner surface of the fabric garment110; a second outer fabric layer152, which forms an outer surface of the fabric garment110; and a second insulating-filler fabric layer154consisting of a textile fabric with a raised surface on at least one side of the fabric. A single face fabric is shown inFIG. 11; however, the second insulating-filler fabric layer154may, 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 layer134. The second insulating-filler fabric layer154is enclosed between the second inner fabric layer151and the second outer fabric layer152. The second insulated composite fabric150is constructed to have an air permeability that is different from, and relatively greater than, the air permeability of the first insulated composite fabric130. The second insulated composite fabric150has an air permeability of about 5 ft3/ft2/min to about 300 ft3/ft2/min tested according to ASTM D-737, under a pressure difference of ½ inch of water across the second insulated composite fabric150.

Alternatively or additionally, the first and second fabric portions120,140can have contrasting stretch. For example, the first fabric portion120may have greater stretch (e.g., in the outer shell, the inner shell layer, and the insulting-filler) than the second fabric layer140. 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.

In some cases, the second fabric elements142may, 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 elements142may consist of a double face knit fabric having reverse plaited terry sinker loop knit construction. Suitable fabrics for forming the second fabric elements142are commercially, available, e.g., from Polartec, LLC, of Lawrence, Mass., under the trademarks POWER STRETCH® and BOUNDARY®.

In some cases, the second fabric elements142may 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® and POWER SHIELD®.

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. 12shows a raised surface knit fabric60having a first pile surface62that includes regions of no pile64interspersed among regions of pile66(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.

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. 13Aillustrates an embodiment of such a raised surface knit fabric200having a first pile surface210on the technical back that includes void regions212a(e.g., regions of no pile) interspersed between regions of pile214a. The fabric200also includes a second pile surface220(after raising) on the technical face. As shown inFIG. 13A, the second pile surface220also includes void regions212b(e.g., regions of no pile) interspersed between regions of pile214b. 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.

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 regions212a,212b. This can be done by adding additional pile yarn230(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 yarn230by napping (FIG. 13C) and/or generating fleece on the technical back upon raising the additional pile yarn230by 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.

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.

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.

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. 14Aillustrates an insulated composite fabric laminate320. The insulated composite fabric laminate320includes an inner fabric layer321, an outer fabric layer322, and an insulating-filler fabric layer323enclosed therebetween. The insulating-filler fabric layer323consists of a double face knit fabric that is bonded to the inner fabric layer321and the outer fabric layer322with an adhesive326. The adhesive can applied in a manner to substantially avoid further limiting the air permeability of the insulated composite fabric laminate320. The adhesive can be applied, for example, in a dot coating pattern.

FIG. 14Billustrates an alternative embodiment in which the insulating-filler fabric layer323is laminated only to the inner fabric layer321, andFIG. 14Cillustrates an alternative embodiment in which the insulating filler fabric layer323is laminated only to the outer fabric layer322.

FIG. 15Aillustrates yet another example of an insulated composite fabric420. The insulated composite fabric420ofFIG. 15Aincludes an outer “shell” fabric layer422and an inner, insulating fabric layer421. The outer fabric layer422consists of a woven fabric. The insulating fabric layer421consists 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 surface423(pile or velour) and an opposite, smooth surface424. The insulating fabric layer421is attached to the outer fabric layer422(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 surface423faces toward the outer fabric layer422. The smooth surface424of the insulating fabric layer421forms an exposed surface of the insulated composite fabric420. The insulated composite fabric420can be incorporated in a fabric garment such as any of the garments described above. For example, the insulated composite fabric420ofFIG. 14could be used in the first fabric portion or the second fabric portion of the jacket ofFIG. 9. When incorporated in a fabric garment, the smooth surface424of the insulating fabric layer421can be arranged to form an inner surface of the garment worn towards the user's body.

Either or both of the insulating fabric layer421and the outer fabric layer422can have stretch in at least one direction. In some cases, for example, either or both of the insulating fabric layer421and the outer fabric layer422can include elastomeric material (e.g., spandex yarns and/or fibers) for enhanced stretch and shape recovery.

Referring still toFIG. 15A, the moisture vapor transmission rate and the air permeability of the insulated composite fabric420can be controlled by the void or openness of the fabric of the outer fabric layer422. In some cases, for example, the control of the air permeability of the insulated composite fabric420can 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 layer422. Alternatively or additionally, the control of the air permeability of the insulated composite fabric420can be achieved by applying coating or film lamination to one or both surfaces of the outer fabric layer422.

FIG. 15Billustrates yet another example of an insulated composite fabric420′. The insulated composite fabric420′ ofFIG. 15Bincludes an outer “shell” fabric layer422and an inner, insulating fabric layer421′. As illustrated inFIG. 15B, the insulating fabric layer421′ consists of a double face knit fabric that is bonded to the outer fabric layer422with an adhesive426to form a fabric laminate. Alternatively or additionally, the insulating fabric layer421′ may be connected to the outer fabric layer by quilting (in any pattern), tucking, ultrasound bonding, etc.

Either or both of the insulating fabric layer421′, and the outer fabric layer422can have stretch in at least one direction. The moisture vapor transmission rate and the air permeability of the insulated composite fabric420′ can be controlled as discussed above with regard toFIG. 15A.

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. 16illustrates an embodiment of an insulated composite fabric500that consists of an inner “shell-liner” fabric layer510, and an outer “shell” fabric layer520and an insulating-filler fabric layer530enclosed therebetween. In this example, a waterproof membrane540is laminated to an inner surface522of the outer “shell” fabric layer520. The water barrier can be made of porous hydrophobic membrane, hydrophilic non-porous membrane, or electrospun material. Preferably, the insulating-filler fabric layer530is hydrophobic (e.g., formed of hydrophobic yarns/fibers), which, in case of water penetration through the outer fabric layer520will not be held or absorbed, and will be able to dry fast.

The water proof insulated composite fabric500can 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. 17illustrates a hybrid insulated fabric garment610that includes a first fabric portion620and a second fabric portion640. The first fabric portion620is 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 portion620is formed of first fabric elements622. The first fabric elements622are formed from a water repellent insulated composite fabric, which may have a construction as described above with regard toFIG. 16.

The second fabric portion640is 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 portion640is formed of second fabric elements642, which are joined together and with the first fabric elements622by stitching at seams611. The second fabric elements642are formed from a second insulated composite fabric, which may have a construction as described above with regard toFIG. 2.

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 toFIG. 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.

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.

In some cases, the insulating layer (e.g., the insulating-filler fabric layer (e.g., of any one ofFIG. 2, 6-8, 10, 11, or14A-14C) or the insulating fabric layer (e.g., of any one ofFIG. 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).

In some implementations, the insulating-filler fabric layer23, e.g., having features discussed above with reference toFIGS. 2-5, contains multi-groove (nano or micro or other) fibers (“MGF”), which is described in more detail below. Referring again toFIGS. 3 and 4, one or both of the raised surfaces32,34or the raised surfaces42,44incorporate 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 toFIG. 5, backing yarn54can 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 layer23incorporate the multi-groove fibers. The multi-groove fibers incorporated in different parts of the layer23can have different features, such as denier, whisker lengths, etc.

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.

Referring toFIGS. 18A, 18B, and 18C, a multi-groove fiber720suitable for use in the insulating-filler fabric layer23consists of an axially-elongated core722and multiple (e.g., 3-200) grooves726defined and spaced apart by whiskers724that extend generally radially from the core722. The whiskers724, e.g., axially-elongated whiskers, are separated by grooves726, e.g., axially-elongated grooves, and can have an average radial length, l, in the order of microns or nanometers. The core722can 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 fiber720is selected to be about 0.3 dpf to about 1.5 dpf. In some implementations, multi-groove fibers720are incorporated in the insulating-filler fabric layer23have relatively longer whiskers and are relatively coarse to provide good thermal insulation properties.

The core722is formed of a synthetic (polymeric) material, e.g., selected from among, e.g. polyester, nylon, polypropylene, and others. The whiskers724are formed of the same synthetic material as the core720. For example, both the core720and the whiskers724are formed of polyester. Referring toFIGS. 18D and 18E, other implementations of multi-groove fibers720′,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 whiskers724′ of multi-groove fibers720′ is smaller than the diameter of the core722′. An average radial length, l, of the whiskers724″ of the multi-groove fibers720″ is greater than the diameter of the core722″. 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.

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.

Referring also toFIG. 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 inFIG. 19, according to the patent publication of Liu et al., multi-groove fibers are formed initially as a precursor740′, extruded from a spinneret die, the fiber precursor consisting of a core732surrounded by an edge region746. The edge region746is formed of alternating materials734,736, e.g., polymeric materials, respectively. The polymer734later forms whiskers over the core732, and the polymer736forms a removable, e.g., dissolvable, sheath separating the polymer734. In some implementations, as shown inFIG. 19A, the sheath736extends beyond the whisker material734along the radial direction. The surface of the edge region surrounding the core732is formed of the sheath material736. Upon removal of the polymer sheath736, grooves are formed among the whiskers.

The polymers734,736can be in the form of alternating sheets or webs extending along a longitudinal axis of the core732. The polymer734is the same as the synthetic material forming the core732. The polymer736is different from the materials forming the core732and the polymer734, and is dissolvable or otherwise removable. The polymer736and the polymer734typically have surface energy that is quite similar. Referring still toFIG. 19, the fiber precursor740′ is next subjected to processing (arrow, P) for removal of the sheath736, thereby forming multiple grooves738disposed about and extending axially along the core732of the multi-groove fiber740, the grooves738being defined by and between intervening “whiskers”742formed of the sheets of the first set734.

Referring again toFIGS. 18A and 18B, and also toFIG. 18C, fibers720have a core722and whiskers724separated by grooves726extending from the surface of the core. The fibers720can 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 fibers720can also be multi-groove micro fibers. The whiskers724and grooves726cause the fibers720to 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 fiber720, in order to have denier in the range indicated for the multi-groove fiber720. In contrast, if a conventional fiber had a diameter in the range indicated above for multi-groove fiber720, 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 fiber720.

According to the present disclosure, the sizes, thicknesses, and/or mass densities of the multi-groove fibers720can be selected based on the desired features of the fibers720, e.g., denier, and/or other features of the raised surface(s)32,34,42,44, or52(FIGS. 3-5). The whiskers724can 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 core722to the average length, l, of the whiskers724and/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 fibers720(discussed further below). In the example shown inFIG. 3E, the ratio of core diameter to the average length of the whiskers is 1:1.

In some implementations, each multi-groove fiber720has 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 grooves726extend the entire length of the multi-groove fiber720. In some implementations, the grooves726have substantially the same dimensions and/or are substantially evenly distributed about and/or along a cross-sectional surface of the multi-groove fiber720. In other implementations, the grooves726may have different dimensions and/or may be distributed irregularly. Although the core722and the multi-groove fibers720appearing in the figures are shown as having circular cross-section, it is to be understood that the core722and the multi-groove fibers720may have other cross-sectional shapes. In some implementations, a fiber can include both relatively longer whiskers and relatively shorter whiskers along its cross section.

In some implementations, the multi-groove fibers720are formed or consist of synthetic (polymeric) material. The core722and the whiskers724are typically formed of the same polymeric material. Suitable polymeric materials for use in the core722and the whiskers724include, e.g., polyethylene terephthalate (PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, and/or combinations thereof.

Referring again toFIG. 19, multi-groove fibers740, e.g., that are similar to or the same as the multi-groove fibers720ofFIGS. 18A and 18B, can be made by forming a polymer extrusion730of three or more polymers732,734,736and removing one of the polymers736to form grooves738among whiskers742formed of the polymer736. The polymeric extrusion30includes a core region744formed of the polymer732and an edge region746formed of polymers734,736. The polymer734is the same as the polymer732, and the whiskers are separated by the sheath formed by the removable polymer736, 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 extrusion730to water or caustic soda (NaOH). The polymer736can be removed by heating or radiating the polymer extrusion730and dissolving the polymer736. Other removable polymers and removal mechanisms may also be employed. The polymers732,734can be the previously discussed polymers for forming the core722and the whiskers724.

Referring again toFIGS. 18D and 18E, the thickness, t, and the length, l, of the whiskers742can be adjusted by modifying the polymers734,736or other related parameters and factors. For example, the spinneret used for extruding the fibers and/or the weight ratio of the whisker polymer734and the sheath polymer736can 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 core744to the edge742(FIG. 19) can also be adjusted, e.g., to provide the desired fiber denier and thickness. In some implementations, multi-groove fibers720′ (FIG. 18D) with relatively shorter and/or thicker edge segments, resulting in relatively shorter and/or thinner whiskers724′, may be desirable, e.g. to produce fabric having a matte appearance or finish. Conversely, multi-groove fiber720″ (FIG. 18E) with relatively longer and/or thinner edge segments, resulting in relatively longer and/or thicker whiskers724″, 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.

In some implementations, the multi-groove fibers can be incorporated in the insulating-filler fabric layer23to allow the insulating-filler fabric layer23to manage water across the layer. As an example, referring toFIG. 20, a fabric portion1100of the insulating-filler fabric layer has a plaited construction can move liquid sweat from the inner side1104(facing a user's skin surface) to the outer side1106. Relatively coarser denier fibers are used on inner side1104(facing the user's skin) and relatively finer denier fibers are used on outer side1106(away from the user's skin). Use of the multi-groove fibers (or whisker fibers) as the relatively finer denier fiber on the outer side1106permits use of very fine fibers on inner side1104(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 grooves726(FIG. 18A),738(FIG. 19) among the whiskers. The whiskers724,742and the grooves726,738also increase the total surface area of the fibers720,740, so that the fibers720,740have a relatively larger capacity to hold liquid and water evaporation can be enhanced. In some implementations, the fibers720,740can 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.