Abstract:
A fabric structure comprising a shell and a lining free of each other. The shell includes an outer closely woven synthetic fabric, an inner connected high tensile strength pattern imprinted on the inner face thereof, and fluorocarbon impregnation thereof. The lining includes an intermediate outer synthetic polymer membrane, and an inner synthetic polymer fabric.

Description:
FIELD OF THE INVENTION 
     The present invention relates to fabric constructions for outerwear, and, more particularly, to fabric constructions for coats, pants, jackets, boots, gloves and other outer clothing that are designed for protection against inclement weather. 
     The Prior Art 
     Clothing for inclement weather typically is constructed from fabrics or combinations of fabrics that strive to achieve seemingly inconsistent objectives. It is desired that such clothing be vapor permeable, water repellent, wind obstructing, stain resistant, dimensionally stable, externally durable, and internally comfortable. Vapor permeable membranes and/or tight weaving have been among the compromises needed to permit simultaneous vapor permeability, water repulsion and wind obstruction. Special fabrics and/or coatings have been among the compromises needed for stain resistance, dimensional stability, external durability and internal comfort. In particular, for example, the interstices within tightly woven fabric, which must remain open to achieve breathing, tend to become blocked by water proofing and wind blocking treatments. There is an ongoing need for the improvement of outerwear for protection against inclement weather. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present invention relates to outerwear comprising an outer shell and an inner lining that combine to achieve vapor permeability, water repellancy, wind obstruction, stain resistance, dimensional stability, external durability and internal comfort. More specifically, the present invention relates to a fabric construction comprising an outer shell and an inner lining that are characterized by particular materials and interrelationships. 
     The shell is composed of a tightly woven synthetic fabric, which initially has imprinted on its inner face a connected high tensile strength pattern, and which thereafter is impregnated with a protective coating. The lining is composed of a waterproof breathable membrane and a soft synthetic fabric support. The membrane has a structure that is characterized by either mechanical micropore diameters or hydrophilic molecular intervals which are infinitesimally smaller in dimension than the interstices in the synthetic fabric of the shell. External durability and stain resistance are provided by the tightly woven synthetic fabric of the shell. Dimensional stability is provided by the imprinted high tensile strength pattern. Water repellancy and wind obstruction are provided to some degree by the tightly woven synthetic fabric of the shell and to a major degree by the membrane of the lining. Vapor transmission is enabled by the breathable membrane of the lining and permitted by the interstices in the support for the breathable membrane, the interstices in the synthetic fabric of the shell and the openings in the pattern imprinted thereon. Comfortable contact with the wearer is provided by the fabric support for the breathable membrane. 
     The invention accordingly comprises the fabric structures, outerwear and processes which are described in the following specification, the scope of which will be indicated in the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a fuller understanding of the nature and objects of the present invention, reference is made to the accompanying drawings, wherein. 
     FIG. 1 is a perspective view of a storm coat and storm pants embodying the present invention; 
     FIG. 2 illustrates the pattern which is imprinted on the inner face of the shell; and 
     FIG. 3 is a grossly exaggerated view of the main fabric construction of the clothing of FIG. 1, cross-sectioned to illustrate fabric, impregnation and molecular or micro structure. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 illustrates an outdoor outfit 10 consisting of a jacket and pants that embody the present invention. All of the major areas, i.e. bodice, arms and legs, comprise an outer shell 12 and an inner lining 14. FIGS. 2 and 3 illustrate details of shell 12 and lining 14, of which the illustrated clothing is constructed. 
     Generally, shell 12 comprises a closely woven, synthetic polymer fabric stratum 15 that is characterized generally by a low level of water absorption, i.e. nylon, acrylic or polyester. After being scoured and dyed, the inner face of fabric stratum 15 is directly imprinted with a connected but open pattern stratum 16 of a relatively high tensile strength, highly flexible elastomer, for example, an acrylic urethane. Preferably, the pattern is characterized by solid portions that cover between 30 and 70% of substrate fabric 15, has from 5 to 15 openings per inch and weigh from 0.1 to 1 oz. per square yard. Following imprinting of pattern stratum 16, the entire fabric, together with pattern stratum 16, is impregnated with a finishing composition 18, particularly a fluorocarbon release agent that will not clog the interstices of the fabric. 
     Generally, lining 14 comprises, at its outer face, a membrane stratum 22 and, at its inner face, a fabric stratum 24. Membrane stratum 22 is composed of a thin polymer which, by virtue of its physico-chemical structure, i.e. its microstructure or molecular structure, is capable of repelling liquid water, but of transmitting water vapor. Fabric stratum 24 is shown as a knitted or woven synthetic that presents a soft, comfortable surface for contact with and drape about a wearer. In a further embodiment of the present invention, the membrane stratum is sandwiched between a pair of such fabric strata. 
     In one form, membrane stratum is an expanded microporous polymer, i.e. a polymer which has been stretched to produce therethrough microscopic pores (micropores) that are sufficiently large to permit the transmission of water vapor, but that are too small to permit the passage of droplets of liquid water. Droplets of liquid water have a sufficiently large surface tension to preclude deformation necessary for passage through the micropores. 
     In another form, membrane stratum is a hydrophilic polymer having molecular chains along which water vapor travels through the thermal gradient established between a relatively high temperature at the surface of a wearer and a relatively low temperature remote from the surface of the wearer. 
     The following are preferred examples of different components of the fabric construction of the present invention. 
     EXAMPLE I 
     Shell Fabric 15 
     Cloth Type: 
     200 Denier nylon (warp), and 3 ply 70 denier taslanized nylon (filling), plain weave. 
     Count: 
     warp: 114, filling: 52 
     Weight (uncoated): 
     5.5 oz. per sq. yd. (+or -0.4 oz.) 
     Break Strength [lbs]: 
     warp: 351 [min.], filling: 156 [min.] 
     Tear Strength [lbs]: 
     warp: 19 [min.], filling: 8 [min.] 
     Shrinkage: 
     warp 2% [max.], filling 2% [max.] 
     Color Fastness and Crocking: 
     Good 
     EXAMPLE II 
     Shell Fabric 15 
     Cloth Type: 
     nylon 70 denier (warp), and 2 ply taslanized 
     nylon 70 denier (filling), plain weave. 
     Count: 
     warp: 158, filling: 68 
     Weight: (uncoated): 
     3.0 oz. per sq. yd. (+or -0.4 oz.) 
     Break Strength [lbs]: 
     warp: 210 [min.], filling: 100 [min.] 
     Tear Strength [lbs]: 
     warp: 4 [min.], filling: 6 [min.] 
     Shrinkage: 
     warp 2% [max.], filling 2% [max.] 
     Color Fastness and Crocking: 
     Good 20/40 hours 
     EXAMPLE III 
     Printed Pattern 16 
     Honeycomb pattern printed, non-ravel coating to ensure breathability, prevent seam slippage, and to maintain shell fabric appearance. The coating consists of an aqueous blend of acrylic, urethane and silicone. The resulting pattern consists of a terpolymer which on drying contains about 12 to 30% urethane, about 1% silicone, and a roughly remainder of acrylic. During printing, the viscosity is adjusted so that it may be applied with a rotary screen printing head onto dyed fabric using a rotary screen having the desired pattern. In the present case, the screen is designed to have a hexagonal pattern with about 50% coverage and 9 cells per linear inch. Preferred coating weight add-on is in the range of 0.3 to 0.5 ounces per square yard. A formulation of this type is sold by Lyons Coatings, Inc., Franklin, Mass., under the trade designation Coating Compound 975-3. 
     EXAMPLE IV 
     Protective Impregnation 18 
     After pattern 16 has been applied and dried, shell 12 is given a water repellent treatment which consists of a protective material being applied onto the surface and dried in a manner which is well understood by those skilled in the art. One such coating is a fluorocarbon solution sold by 3M under the trade designation SCOTCHGARD. It has been found that durability of pattern 16 and its adhesion to fabric 15 is optimum when protective impregnation 18 occurs after pattern 16 has been applied. 
     EXAMPLE V 
     Vapor Permeable Membrane 22 
     Membrane 22 is a porous composite made from two components. One component is pure expanded polytetrafluoroethylene. This portion of the membrane contains about nine billion pores per square inch. The pores are much smaller than a droplet of liquid water but much larger than a molecule of water vapor. Liquid water cannot pass through the membrane but moisture vapor can pass through. The other component is polyalkylene oxide polyurethane-urea, an oleophobic substance that prevents contamination of the membrane from oils, cosmetics, insect repellents, food substances, and other hazards. Porous membranes 22 are manufactured and sold by W. L. Gore &amp; Associates, Inc., Elkton, Md. under the trade designation GORE-TEX. 
     This membrane has the following specifications: Waterproof-Breathable Membrane: 
     Weight (oz/yd 2 ): 
     0.75 oz/yd 2  (+or -0.25) 
     Breathability (MVTR g/m 2  /24 hrs): 
     650 minimum 
     ASTM E-96-80 Procedure B 
     Hydrostatic Resistance (psi): 
     60 minimum 
     Federal Standard 191, Method 
     5512 (Mullen Tester) 
     EXAMPLE VI 
     Vapor Permeable Membrane 22 
     Membrane is a non-porous, hydrophilic polyester ether, the molecular chains of which have a water vapor conductive or capillary effect. Water vapor enters into the closed membrane and moves along the molecular chains. The direction of movement is determined by the water vapor concentration gradient between the front and back of the membrane. In the vicinity of a textile, water vapor is mixed with air. As the temperature of air rises, it can absorb increasing concentrations of water vapor: For example, the warm air between skin and clothing can absorb up to approx. 40 μg/m 3  of water vapor, and outside air at 20° C. up to 17 g/m 3 . Even in rainy weather, the water vapor is higher on the side closest to the skin, than on the outside. This results in transport of water vapor from inside to outside. Non-porous hydrophilic polyesters of this type are sold under the trade designation SYMPATEX by Enka. This membrane has the following specifications. 
     
         ______________________________________Raw material:     hydrophilic polyester             etherStructure:        homogeneous, non-porousDensity:          1.27 g/m.sup.3Thickness:        15 μmWidth:            155 cmVisual properties:             colorless, transparent,             slightly opaqueSoftening point:  above 200° C.Melting point:    above 220° C.Shrinkage in hot air:             slight shrinkage (&lt;1%)             up to 200° C.Strength:         more than 1,5 daN/5 cmStretch before tearing:             approx. 300%Permanent stretch:             approx. 20% after 50%             overall stretchRecovery:         up to approx. 4% overall             stretching no residual             stretchingMoisture absorption:             1.6% at 50% relative             humidity, 20° C.Windproofness:    no air passage (DIN             53887)Water absorption: approx. 5% at 20° C. after             wetting and spin dryingWater vapor       above 2500 g/m2 24 hrpermeability:     ASTM E 96-66 (method B,             modified)Water Tightness:  no water permeation at 1             bar = 10 m water column             (DIN 53886)______________________________________ 
    
     EXAMPLE VII 
     Fabric Laminate 24 
     In one form, the waterproof-breathable membrane is laminated to a nylon tricot weave or weave knit, resulting in a dry-cleanable waterproof material with high moisture vapor transmission. This fabric has the following specifications: 
     Cloth Type: 
     40 denier single ply 100% nylon tricot weave or knit 
     Count: 
     Wales: 39 
     Courses: 40 
     Color: 
     White 
     EXAMPLE VIII 
     Fabric Laminates 24 
     In another form, there are two fabric lamina 24, in the form of woven synthetic polymer, preferably polyester. These lamina sandwich the membrane therebetween and have the following specifications: 
     Cloth Type: 
     100% texturized polyester, 70 denier warp and filling, jet dyed, plain weave 
     Count: 
     warp: 102, filling: 97 
     Weight: 
     2.18 oz. per square yard 
     Color: 
     charcoal grey 
     EXAMPLE IX 
     Preferred Combination 
     Preferred combination of shell and lining comprises the following: 
     Shell fabric 15 
     nylon as specified in Example I 
     Pattern 16 
     copolymer as specified in Example III 
     Protective impregnation 18 
     fluorocarbon as specified in Example IV 
     Membrane 22 
     polytetrafluorethylene, polyalkylene oxide 
     polyurethane urea composite as specified in Example V 
     Single fabric laminate 24 
     nylon tricot weave or knit as specified in EXAMPLE VII. 
     EXAMPLE X 
     Preferred Combination 
     Another preferred combination of shell and lining comprises the following: 
     Shell fabric 15 
     nylon as specified in Example I 
     Pattern 16 
     copolymer as specified in Example III 
     Protective impregnation 18 
     fluorocarbon as specified in Example IV 
     Membrane 22 
     hydrophilic polyester ether as specified in EXAMPLE VI 
     Single fabric laminate 24 
     nylon tricot weave or knit as specified in 
     EXAMPLE VII. 
     OPERATION 
     Shell 12 and lining 14 cooperate in the following manner. Vapor permeability is enabled by the micropores of membrane 22, in cooperation with the openings in printed pattern 16 and the interstices of fabric strata 15, 24. Water repellancy is achieved by treated fabric 15, 18, and by membrane 22 which protects against seepage through fabric 15. Wind obstruction is achieved by fabric 15 and membrane 22. Stain resistance and durability are achieved by fabric 15 and the treatment 18 to which it has been subjected. Fabric 24 has a pleasant hand and feel. The construction ensures a comfortable balance among evaporation, conduction and convection in the space between the shell and the lining.