Windproof and water resistant composite fabric with barrier layer

Abstract: A stretchable, drapable, windproof, water resistant and water vapor permeable composite fabric (12) including an inner layer of fabric (16), a polyurethane barrier (18, 20) and an outer layer of fabric (22). The barrier (18, 20) is constructed to allow water vapor molecules to travel therethrough but restricts the passage of wind and liquid water. The water vapor is transported to and travels through the barrier (18, 20) to the outer fabric layer (22) where it is removed to the environment.

Description: This invention relates generally to a clothing material and, in particular, to a drapable, stretchable, windproof and water resistant, water vapour permeable, composite fabric that can be used as outerwear. Treatments to render fabrics wind and water resistant have been known for many years. However, it has been difficult to create fabrics which are suitable for apparel use and which are windproof, water resistant and water vapour permeable. It has also been difficult to create fabrics that are both water vapour permeable and wind resistant. In particular, it has been difficult to create a soft, stretchable, drapable, breathable, wind and water resistant fabric. Conventional double-faced raised knit fabrics are porous and thus not effective in sheltering the wearer from wind. In the past, a rubber layer has been adhered to a fabric substrate to impart wind and waterproof qualities and the exposed surface of the rubber layer was flocked. Foamed adhesives have been used to adhere layers of flock in upholstery fabrics. These fabrics, however, have generally been formed using an open weave fabric, such as Osnaburg, as a fabric substrate and do not have the degree of stretchability and drapability required for apparel fabrics. U.S. Patents Nos. 4,308,303 to Mastroianni and 4,353,945 to Sampson teach flocked, foam coated, fibrous reinforced, water vapour permeable bacterial barriers for forming surgical drapes and gowns and similar articles. The barriers include a microporous polyelefin film coated with a foam latex polymer upon which a layer of fibers is flocked. The barriers, however, are not suitable for apparel since the flock is adhered to a polyolefin film, not a fabric. Such materials are also not fully suitable for most outerwear applications. US-A-4194041 relates to a waterproof article for use in protective clothing. The article comprises a micro-porous hydrophobic outer layer and a hydrophilic inner layer. Textile material may be applied to the article to increase strength and appearance. US-A-4761324 relates to an elastic, laminated, water-proof, moisture permeable fabric. The fabric comprises a layer of elastic material, such as spandex and a polymer film layer. Previously, a drapable, windproof, water resistant and water vapor permeable composite fabric has been formed by dispersing a thin layer of foamed adhesive between a fabric substrate and a layer of flocked fibers. The pores of the foamed adhesive are formed to be large enough to allow water vapor molecules to pass through but are too small to allow air or liquid water molecules to pass through, except under pressure. This construction can render the fabric wind and water resistant but it is neither sufficiently stretchable or drapable for apparel use. In addition, as the wind and water resistance is improved, the water vapor permeability decreases. Thus, it has proved not possible to achieve the desired level of water vapor permeability using this fabric construction technique. Further, for some applications, a flocked outer surface is not satisfactory. Accordingly, it is desirable to provide an improved windproof, water resistant and water vapor permeable fabric which eliminates the problems associated with prior art fabrics and to provide a novel, soft, stretchable, drapable water vapor permeable, windproof and water resistant composite fabric. Generally speaking, in accordance with the invention, a stretchable, drapable, water vapour permeable, windproof and water resistant composite fabric for use in a garment comprising an outer layer of fabric, barrier means for providing resistance to wind and liquid water while providing for water vapour transport through absorption-diffusion-desorption including a hydrophillic barrier layer of hydrophillic polyurethane disposed on said outer layer of fabric and an inner layer of fabric disposed on said barrier layer at least one of said outer layer of fabric and said inner layer of fabric being a raised surface weft knit fabric. The barrier is constructed to prevent air and water droplets from passing through the fabric layers while allowing water vapour to travel therethrough. This renders the fabric windproof yet breathable and water resistant. The inner fabric layer may be rendered hydrophillic to provide moisture transport by wicking moisture away from the body and a plain surface is attached to the barrier. The outer fabric should be suitable for apparel use. It, like the inner layer, has a knit construction and may be rendered hydrophillic. The composite fabric according to the invention can be manufactured by forming the barrier on a carrier and then transferring the barrier from the carrier to either or both of the fabric layers and adhering the two fabric layers together. Accordingly, it is an object of the invention to provide a windproof fabric which is water resistant. A further object of the invention is to provide a composite fabric which is insulative against wind chill. A still further object of the invention is to provide a fabric which is water resistant. Another object of the invention is to provide a water resistant composite fabric having stretchability and drapability suitable for apparel. Yet another object of the invention is to provide a fabric which is liquid water resistant and water vapor permeable. Still another object of the invention is to provide an improved composite fabric which is windproof. Still another object of the invention is to provide improved outerwear material. Still other objects and advantages of the invention will, in part, be obvious and will in part, be apparent from the specification. The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others and the article possessing the features, properties, and the relation of elements, which are exemplified in the following detailed disclosure and the scope of the invention will be indicated in the claims. For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which: Fig. 1 is a perspective view of a garment made from a composite fabric constructed in accordance with the invention; Fig. 2 is an enlarged partial cross-sectional view taken along line 2-2 of the garment of Fig. 1; Fig. 3 is a cross-sectional view of a composite fabric constructed in accordance with another embodiment of the invention; and Fig. 4 is a cross-sectional view of a composite fabric constructed in accordance with another embodiment of the invention. Composite fabric material constructed in accordance with the invention is formed with a first layer of outer fabric material, a windproof and water resistant barrier thereon and a second layer of inner fabric material applied to the barrier. The barrier is preferably formed of water resistant material such as polyurethane and should be made to be breathable and to act as an air barrier. The breathability can be imparted by forming the layer to have sufficient thinness to permit water vapor to pass through the layer, as by an absorption-diffusion-desorption process or by providing the material with micro-pores for the passage of said water vapor. The inner fabric layer may be formed of 100% polyester having a plain surface and a raised surface, such as brushed polyester fabric or polyester fleece material. The 100% polyester inner fabric layer may be rendered hydrophilic to promote moisture transport, so that the inner fabric will transport moisture from the body to the plain surface. The barrier is disposed on the inner fabric. When the inner fabric is constructed with a plain surface having raised portions extending therefrom, the barrier is preferably disposed on the plain surface. A particularly well suited barrier is formed from a hydrophilic polyurethane and may be derived from a solvent based system. The hydrophilic polyurethane is formed so that moisture will pass therethrough by an absorption-diffusion-desorption process. Such a polyurethane barrier is non-porous and formed so that body moisture will be transported therethrough, while being sufficiently resistant to the passage of water droplets. The thickness of the barrier or polyurethane layer can be selected to balance the breathability and degree of water resistance. In addition, the barrier could be partially hydrophobic, in that there are fewer pores/mm 2 than in a true hydrophobic barrier. Therefore, the moisture will pass through the hydrophilic portion of the barrier by an absorption-diffusion-desorption process and through the micro-pores of the hydrophobic portion. The barrier layer may be an aromatic or an aliphatic polyurethane and can contain: a polyfunctional isocyanate to promote cross-linking, melamine to promote adhesion, aliphatic polyamine to catalyze curing and a fluorocarbon resin for water repellency. A microporous film, permeable to water vapor but impervious to liquid water can also be used. Such a film would be hydrophobic. The barrier layer should be formed to be soft and to have the ability to stretch and recover. It should also preferably be formed to have the ability to adhere to fabric layers without the application of an intervening adhesive. A preferred polyurethane material is available from UCB Chemical Corp., located in Drogenbos, Belgium. The outer fabric is disposed on the remaining side of the barrier. The outer fabric will be hydrophobic or rendered hydrophilic. The outer fabric can be formed of 100% polyester, such as polyester fleece having terry loop construction and can have a plain surface with a raised fabric surface extending therefrom. The outer fabric can also be a stretch material. The outer fabric can also be made from acrylic, cotton, nylon, wool, rayon or a combination thereof. In another embodiment of the invention, a sub-barrier layer is disposed on the desired surface of both the inner fabric and the outer fabric. The sub-barrier layers are disposed on and adhered to each other to form the desired barrier layer. In such a case, the sub-barrier layers are preferably joined by heat and/or pressure. The barrier layer or sub-barrier layers can also be adhered with adhesive. Reference is made to Figs. 1 and 2 wherein a garment, indicated generally at 10 is depicted. Garment 10 (ie a jacket) is made from a composite fabric in accordance with an embodiment of the invention, indicated generally at 12. Composite fabric 12 includes an inner fabric layer 16, a first sub-barrier layer 18 thereon, a second sub-barrier layer 20 thereon and an outer fabric layer 22 on second barrier layer 20. Inner fabric layer 16 includes a raised surface 2 and a plain surface 28. Sub-barriers 18 and 20 are made of polyurethane and are windproof and water resistant. Outer fabric layer 22 includes a plain surface 29 and a raised surface 21. In one method of constructing the fabric, sub-barrier layers 18 and 20 are laid on a carrier such as paper (not shown). Sub-barrier layer 18 is transferred from its carrier to inner fabric layer 16 and second sub-barrier layer 20 is transferred from its carrier to outer fabric layer 22. This method, referred to as transfer coating, is advantageous because it allows for the precise control of barrier weight and thickness and allows the use of thinner and lighter barrier layers. Sub-barrier layers 18 and 20 are then adhered to each other to form composite fabric 12. Inner fabric layer 16 can also be made from acrylic, cotton, nylon, polyester, wool, rayon or a combination thereof. It can be treated to provide moisture transport to wick the moisture from the wearer and raised surface 26 facing the wearer to plain surface 28. Then, by a process of absorption-diffusion-desorption, moisture is transferred through sub-barrier layers 18 and 20 to outer fabric layer 22. In one embodiment, outer fabric layer 22 is a circular weft knit polyester terry loop fabric. The loop and stitch yarn may be filament or spun. If the loop yarn is filament, it is from about 70 to about 150 denier, preferably about 100 denier. If the stitch yarn is filament, it is between from about 70 to about 200 denier, preferably about 100 denier. The fabric layer is from 0,076 to 0,76 cm (0.030 to 0.30 inches) thick, preferably 0,18 cm (0.070 inches) thick. However, this fabric layer is described by way of example and not by way of limitation. Outer fabric layer 22 can be a stretch material, nylon shell material and many other types of fabrics. Outer fabric layer 22 may be dyed conventionally with, for example, disperse dyes and it can be treated to be water repellant. Referring to Fig. 3, in another embodiment of the invention, adhesive is applied to the unraised (plain) side of fabric layers 22 and 16 by gravure printing or by another suitable application process to further secure barrier layer 18 to inner fabric layer 16 and outer fabric layer 22. The adhesive must be discontinuous so as not to interfere with the moisture vapor transport properties of the fabric. Adhesive 15 can be a foamed or unfoamed adhesive and may be water resistant. Generally, the adhesive is preferably a solvent based polyurethane, such as Ucecoat TD9607, manufactured by UCB Chemical Corp. A composite fabric 40 constructed in accordance with another embodiment of the invention is shown in Fig. 4. Fabric 40 is formed with a first fabric layer 41 disposed on barrier layer 42 which is disposed on a second fabric layer 43. Barrier layer 42 should be formed to permit moisture to pass through by an absorption-diffusion-desorption process or by passage through micro-pores. The materials for forming fabric 40 can be the same as those described above, except that fabric 40 includes a single barrier layer. When composite fabric 12 is used for outerwear, it can provide a breathable fabric which enables water vapor from the wearer to pass through the fabric which therefore, will not trap body moisture. However, it will substantially prevent rain water droplets from reaching the wearer. The result is great comfort. The composite fabric of the invention can provide water resistance so that the garment can be used in rainy weather or in snow. Fabric in accordance with the invention can maximise this characteristic without undue sacrifice of the breathability or wind resistance of the garment. While breathable, composite fabric 12 is impervious to moving air. Therefore, whether the wearer is exposed to windy conditions or creates a windy condition by moving rapidly through still air, the wearer is insulated from the effects of wind chill.

Claims: A stretchable, drapable, water vapour permeable, windproof and water resistant composite fabric for use in a garment comprising an outer layer of fabric (22,41) barrier means (18,20,;44) for providing resistance to wind and liquid water while providing for water vapour transport through absorption-diffusion-desorption including a hydrophillic barrier layer of hydrophillic polyurethane disposed on said outer layer of fabric and an inner layer of fabric (16,43) disposed on said barrier layer at least one of said outer layer of fabric (22,41) and said inner layer of fabric (16,43) being a raised surface weft knit fabric. The composite fabric of claim 1, wherein said outer layer (22,41) of fabric is polyester. The composite fabric of claim 1, wherein at least one of said outer layer of fabric (22,41) and said inner layer of fabric (16,43) is selected from polyester, acrylic, cotton, nylon, wool, rayon or a combination thereof. The composite fabric of any preceding claim, wherein said outer layer of fabric (22,41) and said inner layer of fabric (16,43) are both a stretchable material. The composite fabric of any preceding claim, wherein said outer layer of fabric (22,41) and said inner layer of fabric are both raised surface knit fabrics. The composite fabric of any of claims 1 to 4, wherein the other of said outer layer of fabric (23,41) and said inner layer of fabric (16,43) is a circular weft knit fabric. The composite fabric of any preceding claim, wherein said barrier layer (18,20;44) includes two sub-barriers (15). The composite fabric of any preceding claim, further including an adhesive layer (15) interposed between said outer layer of fabric (16) and said barrier layer (18) and between said inner layer (23) and said barrier layer (18). The composite fabric of any preceding claim, wherein said barrier layer (18,20,;44) also includes hydrophobic material The composite fabric of any preceding claim, wherein said outer layer of fabric (22,41) is hydrophobic. The composite fabric of any preceding claim, wherein said inner layer of fabric (16,43) is hydrophobic. The composite fabric of any of claims 1-10, wherein said inner layer of fabric (16,43) is hydrophillic. A method of forming a stretchable, drapable, water vapour permeable, windproof and water resistant composite fabric comprising the steps of applying a barrier layer on one side of an outer or inner layer of fabric by transfer coating, said barrier layer being selected from hydrophillic material, a hydrophobic material or a combination thereof and applying the other of the inner or outer layer to form said composite fabric. The method of claim 13, further including the step of applying an inner barrier layer on one side of said inner layer of fabric. The method of claim 13 or claim 14, further including the step of applying adhesive between said inner fabric layer and said barrier layer. The method of any of claims 13 to 15, further including applying a water resistant coating to said composite fabric. The method of any of claims 13 to 16, wherein said inner layer of fabric is rendered hydrophobic. The method of any of claims 13 to 16, wherein said outer layer of fabric is rendered hydrophillic. The method of any of claims 13 to 16, wherein said outer layer of fabric is rendered hydrophobic. The method of any of claims 13 to 19, wherein said outer layer of fabric is rendered hydrophillic.

Inventors: LUMB DOUGLAS, ROCK MOSHE, LUMB, DOUGLAS, ROCK, MOSHE
Applicants: MALDEN MILLS IND INC, MALDEN MILLS INDUSTRIES, INC.
Application year: 1992
Main classification: B32B27
IPC codes: B32B27, D06N7, A41D31, A41D27