Patent Publication Number: US-2023160119-A1

Title: Fabric with Flow Restricting Core

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 16/713,923 filed on Dec. 13, 2019, by Dustin English, et al., entitled “Fabric with Flow Restricting Core,” which claims priority to U.S. Provisional Application No. 62/779,824 filed Dec. 14, 2018 by Dustin English, et al., entitled “Fabric with Flow Restricting Core,” each of which is incorporated herein by reference as if reproduced in its entirety. 
    
    
     BACKGROUND 
     Controlling the depth to which foaming chemicals or coating materials penetrate a fabric is difficult due to the nature of the foaming process. Indeed, foaming chemicals or coating materials often expand or flow in a non-uniform manner. As such, a fabric incorporating these foaming chemicals or coating materials may suffer from irregularities such as, for example, changing thickness, an uneven look or feel, and so on. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: 
         FIG.  1    is a cross section of an embodiment of an initial stage of a stitched fabric having a barrier layer stitched through by a yarn. 
         FIG.  2    is a cross section of an embodiment of a stitched fabric having a foam core disposed over a barrier layer. 
         FIG.  3    is a cross section of an embodiment of a stitched fabric having a foam core formed from a foaming agent. 
         FIG.  4    is a cross section of an embodiment of a stitched fabric having a second foam core formed from a second foaming agent. 
         FIG.  5    is a cross section of an embodiment of a composite barrier layer suitable for use in the fabrics of  FIGS.  1 - 4   . 
         FIG.  6    is an embodiment of a method of forming the stitched fabric of  FIG.  2   . 
         FIG.  7 A  illustrates yarn stitched through, and forming stitch holes in, a barrier layer. 
         FIG.  7 B  illustrates a melted portion of the barrier layer filling at least a portion of the stich holes. 
         FIG.  7 C  illustrates an embodiment of a coating filling interstitial spaces between individual strands of the yarn to prevent a liquid from passing from one side of the stitched fabric to another side of the stitched fabric via the yarn. 
         FIG.  7 D  illustrates an embodiment of a coating filling interstitial spaces between individual strands of the yarn to prevent a liquid from passing from one side of the stitched fabric to another side of the stitched fabric via the yarn. 
         FIG.  8    illustrates a method of forming a stitched fabric according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     The making and using of the presently preferred embodiments are discussed in detail below. It should be appreciated, however, that the present disclosure provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative and do not limit the scope of the disclosure. 
     Disclosed herein is a fabric or article incorporating or benefiting from a foam core. By constructing a soft, stretchable, lightweight knit with a foam core (e.g., closed cell aerogel foam core), an improved garment or article (e.g., coats, jackets, hats, gloves, footwear, watch bands, bicycle frames, beverage coolers, etc.) with enhanced properties may be produced. 
     Referring to  FIG.  1   , an embodiment fabric  100  in an initial stage is illustrated. The fabric  100  may have a variety of beneficial properties. For example, in an embodiment the fabric  100  is soft, stretchable, able to wick away moisture, and so on. As shown in  FIG.  1   , in an embodiment the fabric  100  in this initial stage includes a barrier layer  102  and a yarn  104 . 
     In an embodiment, the barrier layer  102  is configured to inhibit fluid flow. In other words, the barrier layer  102  is generally liquid resistant or waterproof. Therefore, the barrier layer  102  functions to discourage fluid flow through the fabric  100 . In addition, in an embodiment the barrier layer  102  is also windproof, yet still permits the fabric  100  to be breathable. In other words, the barrier layer  102  is able to block wind from undesirably passing through the fabric  100  while still permitting moisture vapor generated by, for example, body heat to be dissipated. 
     Still referring to  FIG.  1   , the yarn  104  is stitched through the barrier layer  102 . In an embodiment the yarn  104  is a polyester or polyester-blend yarn, a nylon or nylon-containing yarn, a carbon fiber yarn, or other type of yarn. The yarn  104  may be chemically or otherwise treated to resist stains, repel moisture, resist flames, or provide other beneficial properties. 
     As shown, in an embodiment the yarn  104  is stitched through more than a majority (e.g., greater than 50%) of the barrier layer  102 . In other words, the yarn  104  is stitched over a substantial portion of the length and width of barrier layer  102 . Depending on how tightly the stitching is performed, the yarn  104  may permit portions of the underlying barrier layer  102  to be visible or may obscure all or a portion of the underlying barrier layer  102 . 
     In an embodiment, the fabric  100  of  FIG.  1    is constructed by stitching a polyester yarn  104  through the barrier layer  102  such that the majority of the surface area of the barrier layer  102  is covered. During the stitching process, the yarn  104  forms stitch holes  106  through the barrier layer  102  as shown in  FIG.  1   . In some circumstances, it is desirable to seal off or plug these stitch holes  106 . As will be more fully explained below, some or all of the stitch holes  106  formed by the yarn  104  are partially or fully filled when the barrier layer  102  is sufficiently heated. For example, the barrier layer  102  may be heated to a thermoplastic state, which allows a portion of the barrier layer  102  to flow and plug a portion of the stitch holes  106  in the barrier layer  102 . 
     Referring now to  FIG.  2   , a fabric  200  including a barrier layer  202 , a yarn  204 , and a foam core  208  is illustrated. Similar to the fabric  100  of  FIG.  1   , the fabric  200  includes stitch holes  206  that have been partially or fully filled after the barrier layer  202  is heated. However, the fabric  200  also incorporates the foam core  208  on one side of the barrier layer  202 . As shown, the barrier layer  202  controls the depth to which the foam core  208  penetrates into the fabric  200 . For example, the barrier layer  202  prevents the foam core  208  from progressing further downwardly into the fabric  200  as oriented in  FIG.  2   . Indeed, by putting the barrier layer  202  (or other membrane) in the fabric  200  at the desired depth, the depth to which the foam core  208  penetrates the fabric can be precisely controlled. 
     In an embodiment, the barrier layer  202  may support or include a radiant reflective film. That is, a radiant reflective film may be disposed upon a surface of the barrier layer  202  or incorporated into the barrier layer  202 . In an embodiment, the radiant reflective film on or in the barrier layer  202  prevents or inhibits radiant energy from entering an article (e.g., a beverage cooler). In an embodiment, the radiant reflective film prevents or inhibits radiant energy from exiting the interior of an article (e.g., a beverage cooler). 
     In an embodiment, the barrier layer  202  is a non-woven fabric. In such an embodiment, the yarn  204  is stitched through the barrier layer  202 . However, the stitch holes  206  that are formed are not plugged by melting a portion on of the barrier layer  202  as described elsewhere herein. 
     In an embodiment, a beverage cooler may be formed using a fabric  200  containing a barrier layer  202  benefitting from a radiant reflective film (e.g., a soft side beverage cooler). In an embodiment, the barrier layer  202  is moisture vapor permeable. Therefore, any steam generated by hot items placed in the beverage cooler is allowed to escape. As such, the steam does not condense inside the beverage cooler, which helps keeps the items therein both hot and dry. 
     In an embodiment, the foam core  208  comprises any structure having pockets of gas trapped in a liquid or solid. In an embodiment, the foam core  208  comprises a closed cell aerogel foam, a polyurethane foam (i.e., foam rubber), a polystyrene foam, a polyvinyl chloride (PVC) foam, and so on. In an embodiment, the foam core  208  has either hydrophobic or hydrophilic surfaces. In an embodiment, the foam core  208  comprises a non-foaming coating (e.g., polyurethane). 
     In an embodiment, a stitched fabric (e.g., fabric  200 ) includes a barrier layer (e.g., barrier layer  202 ), a yarn (e.g., yarn  204 ) stitched through and forming stitch holes (e.g., stitch holes  206 ) in the barrier layer, where a melted portion of the barrier layer fills at least a portion of the stitch holes, and a coating (e.g., foam core  208 , non-foaming coating, etc.) formed over the barrier layer. In an embodiment, the coating is prevented from progressing further into the stitched fabric by the barrier layer. In an embodiment, the coating comprises a polyurethane, another suitable polymer (e.g., Polycarbonate, Polyether-Polycarbonate, Polyether-Polyester, etc.), or a coating containing or formed from a polymer resin. In an embodiment, the coating is non-foaming. In an embodiment, the barrier layer supports or includes a radiant reflective film. 
     In an embodiment, a stitched fabric (e.g., fabric  200 ) includes a non-woven barrier layer (e.g., barrier layer  202 ), a yarn (e.g., yarn  204 ) stitched through and forming stitch holes (e.g., stitch holes  206 ) in the non-woven barrier layer, and a foam core (e.g., foam core  208 ) formed over the non-woven barrier layer. In an embodiment, the non-woven barrier layer includes or supports a radiant reflective film. In an embodiment, the foam core is prevented from progressing further into the stitched fabric by the non-woven barrier layer. In an embodiment, the non-woven barrier layer is configured to control a depth to which the foam core penetrates into the stitched fabric. 
     In an embodiment, a stitched fabric (e.g., fabric  200 ) includes a non-woven barrier layer (e.g., barrier layer  202 ), a yarn (e.g., yarn  204 ) stitched through and forming stitch holes (e.g., stitch holes  206 ) in the barrier layer, and a coating (e.g., foam core  208 , non-foaming coating, etc.) formed over the non-woven barrier layer. In an embodiment, the coating is prevented from progressing further into the stitched fabric by the barrier layer. In an embodiment, the coating comprises a polyurethane, another suitable polymer (e.g., Polycarbonate, Polyether-Polycarbonate, Polyether-Polyester, etc.), or a coating containing or formed from a polymer resin. 
     Referring now to  FIG.  3   , in an embodiment the foam core  308  begins as a foaming agent  308 ′. As shown, the foam agent  308 ′ is applied over the barrier layer  302 , which has already been heated to close off the stitch holes  306 . The foam agent  308 ′ is subjected to heat or some other catalyst until it fully or sufficiently expands. As shown in  FIG.  3   , the foam core  308  formed from the foam agent  308 ′ may completely cover the yarn  304  on one side of the fabric  300 . 
     Referring now to  FIG.  4   , in an embodiment a second foam core  410  is formed on a side of the fabric  400  opposite the initially formed foam core  408 . The second foam core  410  begins as a foaming agent  410 ′. The second foam core  410  may be the same as or different than the first foam core  408 . As shown, the foam agent  410 ′ is applied over the barrier layer  402  on a side opposite the foam core  408 . The barrier layer  402  has already been heated to close off the stitch holes  406 . The foam agent  410 ′ is subjected to heat or some other catalyst until it fully or sufficiently expands. As shown in  FIG.  4   , the foam core  410  formed from the foam agent  410 ′ may completely cover the yarn  404  on one side of the fabric  400 . Thus, the fabric  400  may have two precisely controlled foam cores  408 ,  410 . 
     In  FIG.  5   , a composite barrier layer  512  that may be used in the fabrics  100 - 400  is illustrated. In an embodiment, the barrier layer  512  comprises an adhesive  520  and an intermediate material  522  (e.g., a porous membrane or a non-porous film) as shown in  FIG.  5   . In an embodiment, the barrier layer  512  may include several adhesive  520  layers and/or several intermediate layers  522 . 
     A melting point of the adhesive  520  is generally lower than a melting point of the intermediate material  522 . Therefore, the adhesive  520  may be melted without also melting the intermediate material  522 . In other words, the adhesive  520  may be forced to flow through the application of sufficient heat without flowing, or compromising the integrity of, the intermediate material  522 . 
     In an embodiment, the melting point of the adhesive  520  may be between about 140° C. to about 180° C. (about 284° F. to about 356° F.) while the melting point of the intermediate material  522  exceeds about 180° C. (about 356° F.). Where the adhesive  520  and the intermediate material  522  have different distinct melting points as noted above, the barrier layer  512  may be referred to as having an “A-B” type format. In an embodiment, the adhesive  520  is approximately two thousandths of an inch (i.e., 2 mils) and the intermediate material  522  is approximately one thousandth of an inch (i.e., 1 mil). 
     In general, the adhesive  520  is a thermoplastic, copolyamide, or other suitably meltable type of material capable of bonding two layers of fabric together. A variety of different adhesives  520  may be used in the barrier layer  512 . By way of example, the adhesive  520  may be a high-quality textile adhesive such a polyurethane adhesive film, an ethylene-vinyl acetate, and the like. In an embodiment, the adhesive  520  may be heat sensitive, pressure sensitive, or both. 
     The intermediate material  522  of the barrier layer  512  may be either a membrane or a film formed from a variety of different materials. In an embodiment, the intermediate material  522  is formed from polyurethane, polyester, urethane, polyether, polytetrafluoroethylene (PTFE), or another polymer-based material. The intermediate material  522  may be manufactured using, for example, an extrusion, a melt blowing, or an electrospinning process. 
     As shown in  FIGS.  1 - 4   , the fabric  100 - 400  is free of any other layer (e.g., a face layer or an interior layer) disposed over the foam core  208 ,  308 ,  408 ,  410  or over the exposed barrier layer  202 ,  302  (see  FIGS.  2 - 3   ). As such, the barrier layer  202 - 302 , the yarn  204 - 304 , and/or the foam core  208 ,  308 ,  408 ,  410  are free from contact by another layer on either side of the barrier layer  102 - 302  and/or foam core  208 ,  308 ,  408 ,  410 . In an embodiment, the foam core  308 , the barrier layer  302 , and the yarn  304  are free from contact by another layer as shown in  FIG.  3   . Even so, in an embodiment other layers (e.g., a face layer, an interior layer, etc.) may be added to the fabrics. 
     In an embodiment, a resin or other coating chemistry may be used in place of any of the foam cores disclosed herein. The resins may be used in conjunction with, for example, carbon fibers to form the fabrics. In an embodiment, the composite fabrics  100 - 400  with the foam cores are thermo-moldable. 
     In  FIG.  6   , a method  600  of forming the fabric  200  of  FIG.  2    is illustrated. In step  602 , a barrier layer  202  is provided. In step  604 , a yarn  204  is stitched through the barrier layer and the barrier layer  202  is heated as described herein to at least partially fill the stitch holes  206 . In step  606 , a foam core  208  is formed over the barrier layer  202 . In an embodiment, the barrier layer  202  and the foam core  208  are subjected to heating at the same time. As such, the foam core  208  is produced at the same time as the stitch holes  206  are closed off. In an embodiment, a second foam core (e.g., foam core  410 ) may be formed on an opposing side of the stitched fabric  200  as the barrier layer  202 . 
       FIG.  7 A  illustrates yarn  704  stitched through, and forming stitch holes  706  in, a barrier layer  702 . The yarn  704 , stitch holes  706 , and barrier layer  702  may be similar to the yarns, stitch holes, and barrier layers previously described herein. In an embodiment, the yarn  704  is formed from a plurality of individual strands  723  of fiber. As shown, interstitial spaces are formed between the individual strands  723  of the yarn  704 . That is, the yarn  704  contains small pockets, gaps, channels, and/or voids therein. 
       FIG.  7 B  illustrates a melted portion  715  of the barrier layer  702  filling at least a portion of the stich holes  706 . In an embodiment, the melted portion  715  of the barrier layer  702  engages or abuts against an external surface of the yarn  704 . As such, the melted portion  715  of the barrier layer  702  is able to prevent a liquid (e.g., water) from passing from one side  750  of the barrier layer  702  to another side  752  of the barrier layer  702  via the stitch hole  706 . 
     In an embodiment, the melted portion  715  of the barrier layer  702  may penetrate the yarn  704  and occupy a portion of the interstitial spaces between individual strands of the yarn  704 . If the melted portion  715  of the barrier layer  702  penetrates the yarn  704  sufficiently, the melted portion  715  of the barrier layer  702  may occupy the interstitial spaces between the individual strands  723  of the yarn  704  to prevent liquid from passing from one side  750  of the barrier layer  702  to another side  752  of the barrier layer  702  via the yarn  704 . If, however, the melted portion  715  of the barrier layer  702  does not penetrate the yarn  704  sufficiently and does not occupy the interstitial spaces between the individual strands  723  of the yarn  704 , a liquid may still be able to pass from one side  750  of the barrier layer  702  to another side  752  of the barrier layer  702  via the yarn  704  as shown in  FIG.  7 B . That is, a liquid may be able to flow through the yarn  704  like a liquid flows through a drinking straw due to the interstitial spaces. 
       FIG.  7 C  illustrates an embodiment of a coating  708  filling interstitial spaces between individual strands  723  of the yarn  704  to prevent a liquid from passing from one side  760  of the stitched fabric  700  to another side  762  of the stitched fabric  700  via the yarn  704 . The coating  708  may be similar to the other coatings previously described herein. In an embodiment, the coating  708  comprises a foaming coating. In an embodiment, the coating  708  comprises a non-foaming coating. In an embodiment, the coating comprises a polyurethane, another suitable polymer (e.g., Polycarbonate, Polyether-Polycarbonate, Polyether-Polyester, etc.), or a coating containing or formed from a polymer resin. 
     In an embodiment, the coating  708  abuts against an external surface of the barrier layer  702  on the one side  760  of the stitched fabric  700 . In an embodiment, the coating  708  includes an adhesive to secure the coating  708  to the barrier layer  702 . The coating  708  may be applied to the barrier layer  702  and the yarn  704  in a variety of different ways. For example, the coating  708  may be sprayed, foamed, or poured on the barrier layer  702  and the yarn  704 . In an embodiment, the coating  708  is heated to adhere the coating to the barrier layer  702  and/or the yarn  704 . In an embodiment, the coating  708  is secured to the barrier layer  702  and/or the yarn  704  without the application of heat. In an embodiment, the barrier layer  702  and/or the yarn  704  may be dipped into the coating  708 . 
     In an embodiment, the coating  708  entirely covers the yarn  704  on the one side  760  of the stitched fabric. In an embodiment, another coating (not shown) similar to the coating  708  is formed on or over the barrier layer  702  on the other side  762  of the stitched fabric  700 . In an embodiment, the coating  708  is hydrophobic, waterproof, or water resistant so as to prevent or inhibit a liquid from flowing through the yarn  704 . 
       FIG.  7 D  illustrates an embodiment of a coating  708  filling interstitial spaces between individual strands  723  of the yarn  704  to prevent a liquid from passing from one side  760  of the stitched fabric  700  to another side  762  of the stitched fabric  700  via the yarn  704 . As shown in  FIG.  7 D , the coating  708  does not completely cover or engulf the yarn  704  on one side  760  of the stitched fabric  700 . Instead, the coating  708  extends into the stitch holes  706 . As such, the coating  708  is able to occupy the interstitial spaces in the portions of the yarn  704  disposed within the stitch holes  706 . In an embodiment, the coating  708  is allowed to flow into the stitch holes  706 . In an embodiment, the coating  708  is encouraged to progress into the stitch holes  706  using a force other than gravity such as, for example, air pressure, mechanical pressure, or some other external force. 
       FIG.  8    illustrates a method  800  of forming a stitched fabric according to an embodiment of the present disclosure. In block  802 , the method  800  includes stitching a yarn through, and forming stitch holes in, a barrier layer. In block  804 , the method  800  includes melting a portion of the barrier layer to fill at least a portion of the stitch holes. 
     In block  806 , the method  800  includes filling interstitial spaces between individual strands of the yarn with a coating to prevent a liquid from passing from one side of the stitched fabric to another side of the stitched fabric via the yarn. 
     In an embodiment, the method further includes flowing and/or forcing the coating into the stitch holes. In an embodiment, the method further includes restricting the coating from entirely covering the yarn on the one side of the stitched fabric. 
     While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods might be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented. 
     In addition, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as coupled or directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.