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Title:
FABRICS WITH IMPROVED MOISTURE MANAGEMENT
Document Type and Number:
WIPO Patent Application WO/2018/144318
Kind Code:
A1
Abstract:
The present disclosure provides articles of manufacture with improved moisture management, as well as methods of making such articles. In some embodiments, provided herein are fabrics with an outer layer comprising a hydrophilic material and an inner layer comprising a first region with a hydrophobic material having a first hydrophobicity and a second region with a hydrophobic material having a second hydrophobicity. Further provided herein are methods of making fabrics with improved moisture management, e.g., by printing or knitting.

Inventors:
XING SIYUAN (US)
FOOTE RACHEL (US)
Application Number:
PCT/US2018/015305
Publication Date:
August 09, 2018
Filing Date:
January 25, 2018
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
ATACAMA INC (US)
International Classes:
A41D27/28; D03D15/00
Domestic Patent References:
WO2006120490A12006-11-16
Foreign References:
US4585449A1986-04-29
CN204273355U2015-04-22
US4501025A1985-02-26
US6183847B12001-02-06
Attorney, Agent or Firm:
JONES, Kevin et al. (US)
Download PDF:
Claims:
CLAIMS

What is claimed is:

1. A fabric, comprising: (a) an outer layer comprising a hydrophilic material; and

(b) an inner layer comprising:

(i) a first region comprising a hydrophobic material having a first hydrophobicity, and

(ii) a second region comprising a hydrophobic material having a second hydrophobicity, wherein the first region is more hydrophobic than the second region, and wherein the second region is in contact with at least a portion of the hydrophilic material of the outer layer.

2. The fabric of claim 1, wherein the hydrophobic materials of the first and second regions are different. 3. The fabric of claim 1, wherein the hydrophobic materials of the first and second regions are the same, wherein the first region comprises the hydrophobic material at a first concentration, wherein the second region comprises the hydrophobic material at a second concentration, and wherein the first concentration is greater than the second concentration.

4. The fabric of claim 1, wherein the hydrophobic materials of the first and second regions are the same, wherein the first region comprises the hydrophobic material at a first cross- sectional depth of the inner layer, wherein the second region comprises the hydrophobic material at a second cross-sectional depth of the inner layer, and wherein the first cross-sectional depth is greater than the second cross-sectional depth.

5. The fabric of any one of claims 1-4, wherein the inner layer further comprises a third region comprising a hydrophobic material having a third hydrophobicity, and wherein the third region is more hydrophobic than the first region.

6. The fabric of any one of claims 1-5, wherein the outer layer further comprises one or more regions comprising a hydrophobic material.

7. The fabric of claim 6, wherein the hydrophobic material of the outer layer resists a hydrostatic pressure of less than or equal to about 150pa.

8. The fabric of claim 6 or claim 7, wherein a portion of the hydrophilic material of the outer layer separates the hydrophobic material of the outer layer from the hydrophobic materials of the inner layer.

9. The fabric of claim 8, wherein the hydrophobic material of the outer layer covers the outer surface of the outer layer.

10. The fabric of any one of claims 1-9, wherein the hydrophobic material of the first region resists a hydrostatic pressure of greater than or equal to about 500pa. 11. The fabric of any one of claims 1-10, wherein the hydrophobic material of the first region resists a hydrostatic pressure of less than or equal to about 3kpa.

12. The fabric of any one of claims 1-11, wherein the hydrophobic material of the second region resists a hydrostatic pressure of less than or equal to about 150pa.

13. The fabric of any one of claims 1-12, wherein the second region comprises less than about 20% of the inner layer by surface area.

14. The fabric of claim 13, wherein the second region comprises less than about 10% of the inner layer by surface area.

15. The fabric of any one of claims 1-12, wherein the first region comprises less than about 20% of the inner layer by surface area. 16. The fabric of any one of claims 1-15, wherein the hydrophilic material comprises a hydrophilic textile.

17. The fabric of claim 16, wherein the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof.

18. The fabric of claim 17, wherein the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof.

19. The fabric of any one of claims 1-18, wherein the hydrophobic material of the first region, the second region, or both comprises polypropylene, polydimethylsiloxane, or a fluoro- polymer.

20. The fabric of any one of claims 1-19, wherein the hydrophobic material of the first region, the second region, or both comprises a porous material with a hydrophobic coating.

21. The fabric of claim 20, wherein the hydrophobic coating comprises fluoropolymer, silicone, or wax.

22. The fabric of claim 20 or claim 21, wherein the porous material is a textile.

23. The fabric of claim 22, wherein the textile is a natural fiber, a synthetic fiber, or a blend thereof.

24. The fabric of claim 23, wherein the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and any blend thereof.

25. The fabric of any one of claims 1-24, wherein the fabric comprises one or more holes extending through both the outer and inner layers.

26. The fabric of claim 25, wherein the one or more holes are greater than or equal to about lmm in diameter and less than or equal to about 5mm in diameter.

27. The fabric of any one of claims 1-26, wherein the fabric is a component of a garment, and wherein the inner layer is configured to face the skin of a wearer of the garment.

28. The fabric of any one of claims 1-27, wherein the fabric is a component of a garment, outerwear, footwear, outdoor gear, pack, backpack, outerwear accessory, car seat sweat cover, diaper, pad, wound dressing, or bed sheet.

29. A method of making a fabric, the method comprising:

(a) providing a hydrophilic material comprising an outer and an inner surface;

(b) screen printing a hydrophobic material onto a first region of the inner surface of the hydrophilic material to produce a first hydrophobicity; and

(c) screen printing a hydrophobic material onto a second region of the inner surface of the hydrophilic material to produce a second hydrophobicity, wherein the first region is more hydrophobic than the second region, thereby making a fabric comprising an outer layer comprising a hydrophilic material and an inner layer comprising the first region and the second region, wherein the second region is in contact with at least a portion of the hydrophilic material of the outer layer.

30. The method of claim 29, wherein the hydrophobic materials of the first and second regions are different.

31. The method of claim 29, wherein the hydrophobic materials of the first and second regions are the same, wherein the first region comprises the hydrophobic material at a first concentration, wherein the second region comprises the hydrophobic material at a second concentration, and wherein the first concentration is greater than the second concentration.

32. The method of claim 29, wherein the hydrophobic materials of the first and second regions are the same, wherein the first region is screen printed to a first cross-sectional depth of the inner surface of the hydrophilic material, wherein the second region is screen printed to a second cross- sectional depth of the inner surface of the hydrophilic material, and wherein the first cross-sectional depth is greater than the second cross-sectional depth.

33. The method of claim 29, further comprising:

(d) screen printing a hydrophobic material having a third hydrophobicity onto a third region of the inner surface of the hydrophilic material, wherein the third region is more hydrophobic than the first region.

34. The method of any one of claims 29-33, further comprising, after screen printing the hydrophobic material onto the second and/or third second region of the inner surface:

(e) screen printing a hydrophobic material onto one or more regions of the outer surface of the hydrophilic material.

35. The method of claim 34, wherein, after step (e), the hydrophobic material printed onto the outer surface resists a hydrostatic pressure of less than or equal to about 150pa.

36. The method of claim 34 or claim 35, wherein the hydrophobic material is printed onto the outer surface in the one or more regions at a cross-sectional depth such that a portion of the hydrophilic material separates the hydrophobic material of the outer surface from the

hydrophobic materials of the inner surface.

37. The method of claim 36, wherein the hydrophobic material is printed onto the outer surface such that it covers the outer surface of the outer layer.

38. The method of any one of claims 29-37, wherein after step (b), the hydrophobic material of the first region resists a hydrostatic pressure of less than or equal to about 3kpa.

39. The method of any one of claims 29-38, wherein after step (c), the hydrophobic material of the second region resists a hydrostatic pressure of less than or equal to about 150pa.

40. The method of any one of claims 29-39, wherein the second region comprises less than about 20% of the inner layer by surface area.

41. The method of claim 40, wherein the second region comprises less than about 10% of the inner layer by surface area.

42. The method of any one of claims 29-39, wherein the first region comprises less than about 20% of the inner layer by surface area.

43. The method of any one of claims 29-42, wherein the hydrophilic material comprises a hydrophilic textile.

44. The method of claim 43, wherein the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof.

45. The method of claim 44, wherein the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof.

46. The method of any one of claims 29-45, wherein the hydrophobic material of the first region, the second region, or both comprises polypropylene, polydimethylsiloxane, or a fluoro- polymer.

47. The method of any one of claims 29-46, wherein the hydrophobic material of the first region, the second region, or both comprises a porous material with a hydrophobic coating.

48. The method of claim 47, wherein the hydrophobic coating comprises fluoropolymer, silicone, or wax.

49. The method of claim 47 or claim 48, wherein the porous material is a textile.

50. The method of claim 49, wherein the textile is a natural fiber, a synthetic fiber, or a blend thereof.

51. The method of claim 50, wherein the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and any blend thereof.

52. The method of any one of claims 29-51, wherein the fabric comprises one or more holes extending through both the outer and inner layers.

53. The method of claim 52, wherein the one or more holes are greater than or equal to about lmm in diameter and less than or equal to about 5mm in diameter. 54. A method of making a fabric, the method comprising:

(a) knitting an outer layer of the fabric using a hydrophilic yarn;

(b) knitting a first region of an inner layer of the fabric using a hydrophobic yarn, wherein the first region is knitted with a first hole size, thereby making a first region having a first hydrophobicity; and (c) knitting a second region of the inner layer of the fabric using the hydrophobic yarn, wherein the second region is knitted with a second hole size, thereby making a second region having a second hydrophobicity, wherein the first region is more hydrophobic than the second region, and wherein the second region is in contact with at least a portion of the hydrophilic yarn of the outer layer. 55. The method of claim 54, wherein the second hole size is less than or equal to about 8mm.

56. The method of claim 54 or claim 55, wherein the first hole size is between about ΙΟμιη and about 300μιη.

57. A method of making a fabric, the method comprising:

(a) knitting an outer layer of the fabric using a hydrophilic yarn; (b) knitting a first region of an inner layer of the fabric using a hydrophobic yarn, thereby making a first region having a first hydrophobicity; and (c) knitting a second region of the inner layer of the fabric using the hydrophobic yarn, wherein the hydrophilic yarn is stitched from the outer layer into the second region of the inner layer to produce a second hydrophobicity, wherein the first region is more hydrophobic than the second region.

58. The method of any one of claims 54-57, wherein the hydrophilic yarn comprises a hydrophilic textile.

59. The method of claim 58, wherein the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof.

60. The method of claim 59, wherein the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof.

61. The method of any one of claims 54-60, wherein the hydrophobic yarn comprises polypropylene, polydimethylsiloxane, or a fluoro-polymer.

62. The method of any one of claims 54-60, wherein the hydrophobic yarn comprises a porous material with a hydrophobic coating.

63. The method of claim 62, wherein the hydrophobic coating comprises fluoropolymer, silicone, or wax.

64. The method of claim 62 or claim 63, wherein the porous material is a textile.

65. The method of claim 64, wherein the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and any blend thereof.

66. The method of any one of claims 54-65, wherein the outer layer, first region, and second region are knitted using a double needle bed jacquard machine.

67. The method of any one of claims 29-66, wherein the fabric is part of a garment, and wherein the inner layer is configured to face the skin of a wearer of the garment.

68. The method of any one of claims 29-67, wherein the fabric is a component of a garment, outerwear, footwear, outdoor gear, pack, backpack, outerwear accessory, car seat sweat cover, diaper, pad, wound dressing, or bed sheet.

69. A fabric made by the method of any one of claims 29-68.

Description:
FABRICS WITH IMPROVED MOISTURE MANAGEMENT

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the priority benefit of U.S. Provisional Application Serial No. 62/454,001, filed February 2, 2017, which is hereby incorporated by reference in its entirety. STATEMENT OF GOVERNMENT SUPPORT

[0002] This invention was made with Government support under Small Business Innovation Research (SBIR) Grant No. 1556133 awarded by the National Science Foundation. The

Government has certain rights in this invention.

FIELD [0003] The present disclosure relates to articles of manufacture with improved moisture management, as well as methods related thereto.

BACKGROUND

[0004] Perspiration is the primary means of thermoregulation for the human body, during which sweat (mainly composed of water) is secreted through the skin and evaporation of the fluid removes the heat from the surface underneath. Without efficient sweat removal during intensive activity, accumulated sweat can drastically increase the humidity level surrounding the skin, resulting in a very uncomfortable feeling. Active wear, which uses highly-wicking fabric, has been the current standard solution for removing sweat from the body. However, after absorbing the moisture on skin, the inside and the outside of the fabric become equally wet. After taking in a certain amount of moisture, the fabric will start to stick to skin due to the capillary action between the wet surface and skin.

[0005] A variety of structures have been proposed to improve the moisture management capacity of fabric. The general idea of these structures is to create the inside of the fabric such that it is more hydrophobic than the outside surface so that, during sweating, moisture can be transferred to the outside surface while the inside surface remains dry. Two main solutions exist currently. One solution is to pattern a certain area inside the fabric to be hydrophobic while leave the other regions hydrophilic {see, e.g., U.S. Pat. No. 7,008,887 and U.S. PG Pub. Nos. US2014/0230121, US2016/0090669, US2014/0106138, and US2014/0109282). Another is to completely treat the inside of the fabric to be "net hydrophobic" by mixing a hydrophobic coating with a percentage of hydrophilic chemicals {e.g., U.S. Pat. No. 7,842,625). Both solutions have problems when dealing with sweat in practical application. For the first solution, there are still hydrophilic/wet spots on the inside of the fabric even when there is limited amount of sweat. For the second, the hydrophilic component in the coating will attenuate the repellency of the hydrophobic region; as a result, the hydrophobic region will become wet when the external hydrophilic surface is saturated.

[0006] Therefore, a need exists for articles with improved moisture management capacity. Such articles would be able to conduct moisture (e.g. , a bodily fluid, such as sweat) from the inside to the outside while keeping the inside dry. These articles may find use, e.g. , in fabrics for garments, sheets, and other accessories. BRIEF SUMMARY

[0007] To meet these and other demands, the present disclosure provides articles with improved moisture management, as well as methods related thereto. The articles have a unique structure with an outer hydrophilic layer and an inner layer with different regions having a distinct level of hydrophobicity. Advantageously, this structure conducts sweat or other fluids to the outer hydrophilic layer while keeping at least a large portion of the inner layer completely dry regardless of how much liquid is absorbed or removed, thereby solving the problems of existing fabrics.

[0008] In certain aspects, the present disclosure provides a fabric comprising: (a) an outer layer comprising a hydrophilic material; and (b) an inner layer comprising: (i) a first region comprising a hydrophobic material having a first hydrophobicity, and (ii) a second region comprising a hydrophobic material having a second hydrophobicity, wherein the first region is more hydrophobic than the second region, and wherein the second region is in contact with at least a portion of the hydrophilic material of the outer layer. In some embodiments, the hydrophobic materials of the first and second regions are different. In some embodiments, the hydrophobic materials of the first and second regions are the same, wherein the first region comprises the hydrophobic material at a first concentration, wherein the second region comprises the hydrophobic material at a second concentration, and wherein the first concentration is greater than the second concentration. In some embodiments, the hydrophobic materials of the first and second regions are the same, wherein the first region comprises the hydrophobic material at a first cross-sectional depth of the inner layer, wherein the second region comprises the

hydrophobic material at a second cross-sectional depth of the inner layer, and wherein the first cross-sectional depth is greater than the second cross-sectional depth. In some embodiments, the inner layer further comprises a third region comprising a hydrophobic material having a third hydrophobicity, and wherein the third region is more hydrophobic than the first region. In some embodiments, the outer layer further comprises one or more regions comprising a hydrophobic material. In some embodiments, the hydrophobic material of the outer layer covers the outer surface of the outer layer. In some embodiments, the hydrophobic material of the outer layer resists a hydrostatic pressure of less than or equal to about 150pa. In some embodiments, a portion of the hydrophilic material of the outer layer separates the hydrophobic material of the outer layer from the hydrophobic materials of the inner layer. In some embodiments, the hydrophobic material of the first region resists a hydrostatic pressure of greater than or equal to about 500pa. In some embodiments, the hydrophobic material of the first region resists a hydrostatic pressure of less than or equal to about 3kpa. In some embodiments, the hydrophobic material of the second region resists a hydrostatic pressure of less than or equal to about 150pa. In some embodiments, the second region comprises less than about 20% of the inner layer by surface area. In some embodiments, the second region comprises less than about 10% of the inner layer by surface area. In some embodiments, the first region comprises less than about 20% of the inner layer by surface area. In some embodiments, the first region comprises less than about 10% of the inner layer by surface area. In some embodiments, the hydrophilic material comprises a hydrophilic textile. In some embodiments, the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof. In some embodiments, the hydrophobic material of the first region, the second region, or both comprises polypropylene, polydimethylsiloxane, or a fluoro-polymer. In some embodiments, the hydrophobic material of the first region, the second region, or both comprises a porous material with a hydrophobic coating. In some embodiments, the

hydrophobic coating comprises fluoropolymer, silicone, or wax. In some embodiments, the porous material is a textile. In some embodiments, the textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and any blend thereof. In some embodiments, the fabric comprises one or more holes extending through both the outer and inner layers. In some embodiments, the one or more holes are greater than or equal to about 1mm in diameter and less than or equal to about 5mm in diameter. In some embodiments, the fabric is a component of a garment, and wherein the inner layer is configured to face the skin of a wearer of the garment. In some embodiments, the fabric is a component of a garment, outerwear, footwear, outdoor gear, pack, backpack, outerwear accessory, car seat sweat cover, diaper, pad, wound dressing, or bed sheet. [0009] In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a hydrophilic material comprising an outer and an inner surface; (b) screen printing a hydrophobic material onto a first region of the inner surface of the hydrophilic material to produce a first hydrophobicity; and (c) screen printing a hydrophobic material onto a second region of the inner surface of the hydrophilic material to produce a second hydrophobicity, wherein the first region is more hydrophobic than the second region, thereby making a fabric comprising an outer layer comprising a hydrophilic material and an inner layer comprising the first region and the second region, wherein the second region is in contact with at least a portion of the hydrophilic material of the outer layer. In some

embodiments, the hydrophobic materials of the first and second regions are different. In some embodiments, the hydrophobic materials of the first and second regions are the same, wherein the first region comprises the hydrophobic material at a first concentration, wherein the second region comprises the hydrophobic material at a second concentration, and wherein the first concentration is greater than the second concentration. In some embodiments, the hydrophobic materials of the first and second regions are the same, wherein the first region is screen printed to a first cross-sectional depth of the inner surface of the hydrophilic material, wherein the second region is screen printed to a second cross-sectional depth of the inner surface of the hydrophilic material, and wherein the first cross-sectional depth is greater than the second cross-sectional depth. In some embodiments, the method further comprises (d) screen printing a hydrophobic material having a third hydrophobicity onto a third region of the inner surface of the hydrophilic material, wherein the third region is more hydrophobic than the first region. In some

embodiments, the method further comprises, after screen printing the hydrophobic material onto the second and/or third second region of the inner surface: (e) screen printing a hydrophobic material onto one or more regions of the outer surface of the hydrophilic material. In some embodiments, after step (e), the hydrophobic material printed onto the outer surface resists a hydrostatic pressure of less than or equal to about 150pa. In some embodiments, the

hydrophobic material is printed onto the outer surface in the one or more regions at a cross- sectional depth such that a portion of the hydrophilic material separates the hydrophobic material of the outer surface from the hydrophobic materials of the inner surface. In some embodiments, the hydrophobic material is printed onto the outer surface such that it covers the outer surface of the outer layer. In some embodiments, after step (b), the hydrophobic material of the first region resists a hydrostatic pressure of less than or equal to about 3kpa. In some embodiments, after step (c), the hydrophobic material of the second region resists a hydrostatic pressure of less than or equal to about 150pa. In some embodiments, the second region comprises less than about 20% of the inner layer by surface area. In some embodiments, the second region comprises less than about 10% of the inner layer by surface area. In some embodiments, the first region comprises less than about 20% of the inner layer by surface area. In some embodiments, the first region comprises less than about 10% of the inner layer by surface area. In some embodiments, the hydrophilic material comprises a hydrophilic textile. In some embodiments, the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof. In some embodiments, the hydrophobic material of the first region, the second region, or both comprises polypropylene, polydimethylsiloxane, or a fluoro-polymer. In some embodiments, the hydrophobic material of the first region, the second region, or both comprises a porous material with a hydrophobic coating. In some embodiments, the hydrophobic coating comprises fluoropolymer, silicone, or wax. In some embodiments, the porous material is a textile. In some embodiments, the textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and any blend thereof. In some embodiments, the fabric comprises one or more holes extending through both the outer and inner layers. In some embodiments, the one or more holes are greater than or equal to about 1mm in diameter and less than or equal to about 5mm in diameter.

[0010] In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) knitting an outer layer of the fabric using a hydrophilic yarn; (b) knitting a first region of an inner layer of the fabric using a hydrophobic yarn, wherein the first region is knitted with a first hole size, thereby making a first region having a first hydrophobicity; and (c) knitting a second region of the inner layer of the fabric using the hydrophobic yarn, wherein the second region is knitted with a second hole size, thereby making a second region having a second hydrophobicity, wherein the first region is more hydrophobic than the second region, and wherein the second region is in contact with at least a portion of the hydrophilic yarn of the outer layer. In some embodiments, the second hole size is less than or equal to about 8mm. In some embodiments, the first hole size is between about ΙΟμιη and about 300μιη. In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) knitting an outer layer of the fabric using a hydrophilic yarn; (b) knitting a first region of an inner layer of the fabric using a hydrophobic yarn, thereby making a first region having a first hydrophobicity; and (c) knitting a second region of the inner layer of the fabric using the hydrophobic yarn, wherein the hydrophilic yarn is stitched from the outer layer into the second region of the inner layer to produce a second hydrophobicity, wherein the first region is more hydrophobic than the second region. In some embodiments, the hydrophilic yarn comprises a hydrophilic textile. In some embodiments, the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof. In some embodiments, the hydrophobic yarn comprises polypropylene, polydimethylsiloxane, or a fluoro-polymer. In some embodiments, the hydrophobic yarn comprises a porous material with a hydrophobic coating. In some embodiments, the hydrophobic coating comprises fluoropolymer, silicone, or wax. In some embodiments, the porous material is a textile. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and any blend thereof. In some embodiments, the outer layer, first region, and second region are knitted using a double needle bed jacquard machine. In some embodiments of any of the above embodiments, the fabric is part of a garment, and wherein the inner layer is configured to face the skin of a wearer of the garment. In some embodiments of any of the above embodiments, the fabric is a component of a garment, outerwear, footwear, outdoor gear, pack, backpack, outerwear accessory, car seat sweat cover, diaper, pad, wound dressing, or bed sheet.

[0011] In other aspects, the present disclosure provides a fabric made by the method according to any one of the above embodiments.

[0012] It is to be understood that one, some, or all of the properties of the various

embodiments described above and herein may be combined to form other embodiments of the present invention. These and other aspects of the present disclosure will become apparent to one of skill in the art. These and other embodiments of the present disclosure are further described by the detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1A shows a cross-sectional view of a fabric with improved moisture management, in accordance with some embodiments. FIG. IB shows the fabric adjacent to the skin with perspiration.

[0014] FIGS. 2A & 2B show cross-sectional views of fabrics with improved moisture management, in accordance with some embodiments.

[0015] FIG. 3 shows a cross-sectional view of a fabric with improved moisture management, in accordance with some embodiments.

[0016] FIGS. 4A-4C show cross-sectional views of fabrics with improved moisture management, in accordance with some embodiments. [0017] FIG. 5 shows a cross-sectional view of a fabric with improved moisture management, in accordance with some embodiments.

[0018] FIGS. 6A-6F illustrate an exemplary process for producing fabrics with improved moisture management by printing, in accordance with some embodiments. FIGS. 6A & 6B show top (FIG. 6A) and cross-sectional (FIG. 6B) views of step 600 in the process. FIGS. 6C & 6D show top (FIG. 6C) and cross-sectional (FIG. 6D) views of step 640 in the process.

FIGS. 6E & 6F show top (FIG. 6E) and cross-sectional (FIG. 6F) views of step 660 in the process.

[0019] FIG. 7 illustrates an exemplary process for producing fabrics with improved moisture management by knitting, in accordance with some embodiments.

[0020] FIG. 8 illustrates an exemplary process for producing fabrics with improved moisture management by knitting, in accordance with some embodiments.

[0021] FIGS. 9A-9L demonstrate the improved moisture management of an exemplary fabric of the present disclosure (FIGS. 9I-9L), in accordance with some of the embodiments, as compared to "wicking window" (FIGS. 9A-9D) or NanoTex® Dry Inside moisture management coating (FIGS. 9E-9H).

[0022] FIGS. 10A & 10B illustrate an exemplary evaluation of a fabric with improved moisture management, in accordance with some embodiments.

DETAILED DESCRIPTION

I. Articles with Improved Moisture Management

[0023] Certain aspects of the present disclosure relate to articles of manufacture with improved moisture management. In some embodiments, an article of the present disclosure is a fabric with an outer hydrophilic layer and at least two different levels of liquid-repellency (e.g. ,

hydrophobicity) on the inside of the fabric. For example, one level of liquid-repellency may be sufficiently hydrophobic to resist the penetration of moisture through the fabric, whereas the other level is not sufficiently hydrophobic to do so. In some embodiments, a level of liquid- repellency or hydrophobicity may refer to the hydrostatic pressure able to be resisted by the material. Without wishing to be bound to theory, it is thought that such a structure allows for fabrics and other materials able to conduct a fluid (e.g. , sweat or another bodily fluid) from inside of the fabric to the outside of the fabric while keeping a large portion on the inside of the fabric completely dry, no matter how much fluid is absorbed or removed by the fabric. This structure is thought to mitigate and/or eliminate problems with existing materials that rely upon hydrophilic inner layers (e.g. , to wick sweat away from a wearer's skin), such as accumulation of wetness in inner hydrophilic layers and attenuation of liquid repellency in materials with a hydrophilic/hydrophobic gradient. Without wishing to be bound to theory, it is also thought that such a structure helps the wearer to stay drier during wet weather (e.g., rain or snow) because the inside of the fabric has a continuous and completely hydrophobic layer that repels and resists liquid penetration through the fabric.

[0024] In some embodiments, the articles of the present disclosure comprise fabrics with an outer layer comprising a hydrophilic material; and an inner layer comprising: a first region comprising a hydrophobic material having a first hydrophobicity, and a second region comprising a hydrophobic material having a second hydrophobicity. In some embodiments, the first region is more hydrophobic than the second region, and the second region is in contact with at least a portion of the hydrophilic material of the outer layer. The terms "outer" and "inner" as used herein refer to an outer surface facing an external environment (e.g. , rain or sun) and an inner surface facing an element or area to be shielded by the article from the external

environment, such as a wearer's skin, interior space, or dry material. For example, if the article is part of a garment diaper, pad, wound dressing, bed sheet, or the like, the outer direction faces the external environment and the inner direction faces the skin of the wearer. If the article is part of a piece of outdoor gear, the outer direction faces the external environment and the inner direction faces the user while the gear is in use.

[0025] A cross-section of exemplary fabric 100 is shown in FIGS. 1A & IB. Fabric 100 includes outer layer 102 and an inner layer with regions 104 and 106. Outer layer 102 comprises a hydrophilic material that acts as a liquid- absorptive region. Regions 104 and 106, on the other hand, are both hydrophobic and act as liquid-repellent. However, regions 104 and 106 have different degrees of hydrophobicity. For example, in some embodiments, one region of the inner layer is liquid-repellent enough to resist moisture/sweat penetration and stay completely dry during exercise. Another region of the inner layer is not liquid-repellent enough to resist the penetration of moisture/sweat during exercise when the fabric is in close contact and frequent friction with skin. In this example, region 106 is more hydrophobic or liquid-repellent than region 104. Region 104 is also in contact with layer 102.

[0026] FIG. IB shows the performance of the fabric when contacted with skin 110 and moisture 112. When perspiration (e.g. , moisture 112) is present, the sweat droplets emerging on the skin surface are in contact with the inside of the fabric. During the interaction/contact between the skin and the inside of the fabric, the sweat droplets are able to penetrate into the external hydrophilic surface (e.g. , layer 102) through the weak liquid-repellent regions 104 on inner layer of the fabric, as shown by arrow 114. The sweat is repelled by the strong liquid- repellent regions 106, and those regions stay completely dry on the inside of the fabric, even when the external liquid- absorptive region is saturated. The sweat traveling through the weak liquid-repellent region 104 is conducted to the outside liquid- absorptive region (e.g. , layer 102), where it is spread over the hydrophilic regions of layer 102, as shown by arrows 116 and 118. In some embodiments, the moisture is released from the fabric by evaporation.

[0027] A variety of configurations are suitable for varying the hydrophobicity of the regions of the inner layer (e.g. , 104 and 106). In some embodiments, the first and second regions comprise different hydrophobic materials having different degrees of hydrophobicity or liquid-repellency. In other embodiments, the first and second regions comprise the same hydrophobic material, but present in a different concentration, cross-sectional depth, porosity, hydrophobic modification chemistry, or other parameter affecting the overall degree of hydrophobicity or liquid-repellency. Thus, in some embodiments, the first region comprises a hydrophobic material at a first concentration, and the second region comprises the same hydrophobic material at a lesser concentration.

[0028] In some embodiments, the first region comprises a hydrophobic material at a first cross- sectional depth of the inner layer, and the second region comprises the same hydrophobic material at a lesser cross- sectional depth of the inner layer. This concept is illustrated in FIGS. 2A & 2B.

[0029] FIG. 2A shows a cross-section of fabric 200, including outer layer 202 and an inner layer with regions 204a, 204b, 204c, and 204d. Outer layer 202 comprises a hydrophilic material that acts as a liquid- absorptive region. Regions 204a, 204b, 204c, and 204d are all hydrophobic and act as liquid-repellent, but they vary in their degree of hydrophobicity. For example, region 204a completely penetrates fabric 200 and is the most hydrophobic; regions 204b, 204c, and 204d respectively decrease in the degree of penetration and therefore hydrophobicity or liquid- repellency.

[0030] FIG. 2B illustrates a similar concept with fabric 210 having outer layer 212 and an inner layer with regions 214a, 214b, 214c, and 214d. In this example, regions 214a, 214b, 214c, and 214d comprise a hydrophobic material that is less hydrophobic/liquid-repellent than the material of regions 204b, 204c, and 204d. Nonetheless, they still represent varying degrees of hydrophobicity or liquid-repellency.

[0031] FIG. 3 shows a cross-section of fabric 300, including outer layer 302 and an inner layer with regions 304 and 306. In this example, region 304 of the inner layer comprises a

hydrophobic material, while outer layer 302 comprises a hydrophilic material, and region 306 also comprises a hydrophilic material (e.g. , the same material as outer layer 302). In some embodiments, region 306 comprises a material with a hydrostatic pressure resistance that is about Opa.

[0032] In some embodiments, the inner layer further comprises a third region comprising a hydrophobic material. In some embodiments, the third region has a different degree of hydrophobicity/liquid-repellency than the first and/or second region of the inner layer. An exemplary fabric 400 is illustrated in FIG. 4A. Fabric 400 includes outer layer 402 comprising a hydrophilic material and an inner layer with regions 404, 406, and 408. Regions 404, 406, and 408 each comprise a hydrophobic material. The hydrophobic material can be the same or different for each region. In this example, region 408 is the most strongly hydrophobic (e.g. , since it penetrates through the entire cross-section of fabric 400), followed by region 406, and region 404 is the most weakly hydrophobic. In some embodiments, the regions may comprise different hydrophobic materials with different properties (e.g., region 404 has a more weakly hydrophobic material than regions 406 and/or 408). In some embodiments, the regions may comprise hydrophobic materials with different degrees of penetration through the cross-section of fabric 400 (e.g. , 408 has complete penetration, with 406 penetrating less than 408, and 404 penetrating less than 408 and 406).

[0033] In some embodiments, the outer layer further comprises one or more regions comprising a hydrophobic material. Another exemplary fabric 420 is illustrated in FIG. 4B. Fabric 420 includes outer layer 422 comprising a hydrophilic material with region 428 comprising a hydrophobic material. Fabric 420 also includes an inner layer with regions 424 and 426, each comprising a hydrophobic material. The hydrophobic material can be the same or different for each region (i.e., regions 424, 426, and 428). In some embodiments, the regions may comprise different hydrophobic materials with different properties. In some embodiments, the regions may comprise hydrophobic materials with different degrees of penetration through the cross-section of fabric 420.

[0034] In some embodiments, region 428 comprises the hydrophobic material at a cross- sectional depth that is less than the full cross-sectional depth of outer layer 422, e.g. , a portion of the hydrophilic material of outer layer 422 separates the hydrophobic material of region 428 from the hydrophobic materials of the inner layer (e.g. , regions 424 and 426). Stated another way, region 428 does not penetrate through the hydrophilic region of the fabric and therefore does not block the continuity of the hydrophilic regions at the outer layer 422. In the example shown in FIG. 4B, region 428 penetrates slightly, but not fully, into the outer surface of the fabric (e.g. , outer layer 422). Region 428 does not penetrate through or block the connection of the hydrophilic regions of outer layer 422. This structure can be used to display some visual patterns on the outside of the fabric when the fabric becomes wet, without affecting the wicking of moisture on the outside hydrophilic layer. For example, the hydrophobic regions remain dry and retain the original color of the fabric, while the surrounding hydrophilic regions become wet and adopt a darker color, thereby displaying a visual pattern.

[0035] In some embodiments, the hydrophobic material of the outer layer covers the outer surface of the outer layer (e.g. , a majority of the outer surface, or the entire outer surface). An exemplary configuration using this concept is illustrated in FIG. 4C. FIG. 4C shows fabric 430. Fabric 430 includes outer layer 432 comprising a hydrophilic material with region 438 that comprises a hydrophobic material and covers the entire outer surface of outer layer 432. Fabric 430 also includes an inner layer with regions 434 and 436, each comprising a hydrophobic material. The hydrophobic material can be the same or different for each region (i.e., regions 434, 436, and 438). In some embodiments, the regions may comprise different hydrophobic materials with different properties. In some embodiments, the regions may comprise

hydrophobic materials with different degrees of penetration through the cross-section of fabric 430. Region 438 does not penetrate through or block the connection of the hydrophilic regions of outer layer 432. However, by completely covering outer layer 432, region 438 provides a continuous, water-repellent layer that penetrates a portion of outer layer 432. Without wishing to be bound to theory, it is thought that such a structure provides a water-repellent surface on the outside of the fabric.

[0036] In some embodiments, the hydrophobic material of region 428 resists a hydrostatic pressure of less than or equal to about 150pa. For example, in some embodiments, the hydrophobic material of region 428 resists a hydrostatic pressure of less than or equal to about 150pa, less than or equal to about 125pa, less than or equal to about lOOpa, less than or equal to about 75pa, less than or equal to about 50pa, less than or equal to about 25pa, or greater than or equal to Opa. For example, in some embodiments, the hydrophobic material of region 428 resists a hydrostatic pressure of between about 150pa and Opa.

[0037] In some embodiments, a fabric of the present disclosure comprises one or more large openings, such as holes. FIG. 5 illustrates exemplary fabric 500. Fabric 500 includes outer layer 502 comprising a hydrophilic material and an inner layer with regions 504 and 506.

Regions 504 and 506 each comprise a hydrophobic material. Fabric also includes one or more holes (e.g. , hole 508) that traverses the cross-section of fabric 500, e.g., extending through both the outer and inner layers. Without wishing to be bound to theory, it is thought that a hole in a strong liquid-repellent region will not lower the liquid-repellent capacity of the fabric structure around the hole. The value of the hydrostatic pressure of the liquid-repellent region should be measured at the region without the large openings. Otherwise the large opening will lower the hydrostatic pressure value of that region. [0038] In some embodiments, the one or more holes are greater than or equal to about 1mm in diameter and less than or equal to about 5mm in diameter. For example, in some embodiments, a fabric of the present disclosure includes one or more holes greater than or equal to about 1mm in diameter and less than or equal to about 3mm in diameter, greater than or equal to about 2mm in diameter and less than or equal to about 5mm in diameter, greater than or equal to about 1mm in diameter and less than or equal to about 4mm in diameter, greater than or equal to about 2mm in diameter and less than or equal to about 4mm in diameter, greater than or equal to about 3mm in diameter and less than or equal to about 5mm in diameter, about 1mm in diameter, about 2mm in diameter, about 3mm in diameter, about 4mm in diameter, or about 5mm in diameter. It is contemplated that, in embodiments in which the one or more holes are not circular, the exemplary hole diameter sizes described above may instead recite a length and/or width of the one or more holes.

[0039] A variety of hydrophilic materials may suitably be used as described above, e.g. , in an outer layer of a fabric of the present disclosure. In some embodiments, a hydrophilic material of the present disclosure is a textile. In some embodiments, the textile includes without limitation a natural fiber, a synthetic fiber, or a blend thereof. For example, in some embodiments, a textile of the present disclosure may include without limitation cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and/or any blend thereof.

[0040] A variety of hydrophobic materials may suitably be used as described above, e.g. , in one or more regions an inner layer of a fabric of the present disclosure. In some embodiments, a hydrophobic material of the present disclosure comprises polypropylene, polydimethylsiloxane (PDMS), or a fluoro-polymer (including without limitation a polymer made from

tetrafluoroethylene-, vinyl fluoride-, perfluoroether-, vinylidene fluoride-, or

chlorotrifluoroethylene-based monomers, such as polytetrafluoroethylene or PTFE). In some embodiments, hydrophobicity of the hydrophobic material can be achieved through a hydrophobic and/or liquid-repellent coating (e.g., a fluoropolymer, silicone, hydrosilicone, fluoroacrylate, wax, or olefin) or using inherent hydrophobic fibers, including polypropylene, PDMS, PTFE, etc. For example, a hydrophobic material of the present disclosure may comprise a porous material of the present disclosure with a hydrophobic coating on at least a first surface, e.g., as described above. Such porous materials may include, without limitation, a metal mesh, a polymer mesh, or a textile of the present disclosure. In some embodiments, the textile includes without limitation a natural fiber, a synthetic fiber, or a blend thereof. For example, in some embodiments, a textile of the present disclosure may include without limitation cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and/or any blend thereof.

[0041] In some embodiments, and as described in greater detail in section II below, a hydrophobic material of the present disclosure includes a hydrophobic yarn. Materials that can be used for hydrophobic yarns include without limitation inherently hydrophobic fibers (e.g. , contact angle of material is higher than 90 degrees), including polypropylene,

polydimethylsiloxane and fluro-polymer. Suitable materials can also include yarns or textiles modified by water/oil repellent coatings (e.g. fluoropolymer, silicone, wax), including treated natural and synthetic yarns, and blends. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, elastin fiber, and any blend thereof.

[0042] In some embodiments, and as described in greater detail in section II below, a hydrophilic material of the present disclosure includes a hydrophilic yarn. Materials that can be used for hydrophilic yarns include without limitation inherently hydrophilic fibers, including cotton, cellulose, rayon, coconut fiber, silk, bamboo. Suitable materials can also include hydrophilic treated natural and synthetic yarns, including natural and synthetic yarns and blends. In some embodiments, the textile is selected from the group consisting of wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, elastin fiber, and any blend thereof.

[0043] As described above, in some embodiment, a fabric of the present disclosure may comprise an inner layer with a first hydrophobic region and a second hydrophobic region, where the first region is more hydrophobic than the second region. In some embodiments, a hydrophobic material of the present disclosure is able to resist a hydrostatic pressure of greater than or equal to Opa (i.e. , a hydrophilic material can have a negative resistance, since it absorbs moisture). For example, in some embodiments, a hydrophobic material of a first region resists a greater hydrostatic pressure than the hydrophobic material of a second region. Again, as described supra, the materials of the first region and the second region may be different, or they may be the same material in a different configuration, e.g. , cross-sectional depth, concentration, porosity, hydrophobic modification chemistry, etc.

[0044] In some embodiments, the hydrophobic material of the second region resists a hydrostatic pressure of less than or equal to about 150pa, less than or equal to about 125pa, less than or equal to about lOOpa, less than or equal to about 75pa, less than or equal to about 50pa, less than or equal to about 25pa, or greater than or equal to Opa. For example, in some embodiments, the hydrophobic material of the second region resists a hydrostatic pressure of between about 150pa and Opa.

[0045] In some embodiments, the hydrophobic material of the first region resists a hydrostatic pressure of greater than or equal to about 150pa, greater than or equal to about 200pa, greater than or equal to about 250pa, greater than or equal to about 300pa, greater than or equal to about 350pa, greater than or equal to about 400pa, greater than or equal to about 450pa, greater than or equal to about 500pa, greater than or equal to about 600pa, greater than or equal to about 700pa, greater than or equal to about 800pa, greater than or equal to about 900pa, or greater than or equal to about Ikpa. In some embodiments, the hydrophobic material of the first region resists a hydrostatic pressure of less than or equal to about 3kpa, less than or equal to about 2.5kpa, less than or equal to about 2kpa, less than or equal to about 1.5kpa, or less than or equal to about Ikpa. For example, in some embodiments, a hydrophobic material of a first region of the present disclosure resists a hydrostatic pressure less than about any of the following hydrostatic pressures (in pa): 3000, 2500, 2000, 1500, 1000, 900, 800, 700, 600, 500, 400, 300, 250, 200, or 150. In some embodiments, a hydrophobic material of a first region of the present disclosure resists a hydrostatic pressure greater than about any of the following hydrostatic pressures (in pa): 125, 150, 200, 250, 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000, or 2500. That is, the hydrophobic material of a first region of the present disclosure may resist a hydrostatic pressure of any of a range of hydrostatic pressures having an upper limit of 3000, 2500, 2000, 1500, 1000, 900, 800, 700, 600, 500, 400, 300, 250, 200, or 150 pa and an independently selected lower limit of 125, 150, 200, 250, 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000, or 2500pa, wherein the lower limit is less than the upper limit. For example, in some

embodiments, a hydrophobic material of a first region of the present disclosure resists a hydrostatic pressure of between about 500pa and about 3000pa. Techniques for measuring hydrostatic pressure resistance are known in the art. For example, a standard technique is the use of a hydrostatic head tester. The device applies an increasing value of water pressure on a fabric sample, and the maximum hydrostatic pressure is recorded when water penetrates through the sample and leakage happens.

[0046] In some embodiments, the second region of the inner layer comprises less than about 30% of the inner layer, less than about 25% of the inner layer, less than about 20% of the inner layer, or less than about 10% of the inner layer (by surface area). In some embodiments, the first region of the inner layer comprises greater than about 70% of the inner layer, greater than about

75% of the inner layer, greater than about 80% of the inner layer, or greater than about 90% of the inner layer (by surface area). In some embodiments, the first region of the inner layer comprises less than about 30% of the inner layer, less than about 25% of the inner layer, less than about 20% of the inner layer, or less than about 10% of the inner layer (by surface area). In some embodiments, the second region of the inner layer comprises greater than about 70% of the inner layer, greater than about 75% of the inner layer, greater than about 80% of the inner layer, or greater than about 90% of the inner layer (by surface area). In some embodiments, the relevant surface area is the surface area of the inner surface of the inner layer.

[0047] The fabrics described herein may find use in a variety of applications. In some embodiments, a fabric of the present disclosure may be a component of a garment, outerwear, footwear (e.g., a shoe or boot), outdoor gear (e.g., a tent or sleeping bag), a pack or backpack, an outerwear accessory, car seat sweat cover, diaper, pad, wound dressing, or bed sheet. In some embodiments, the garment includes at least a portion of the following items, without limitation: a shirt, shorts, pants, tank-tops, jackets, sports bras, underwear, socks, or gloves.

II. Methods of Making Articles with Improved Moisture Management

[0048] Certain aspects of the present disclosure relate to methods of making an article or fabric having improved moisture management. Exemplary methods of making these articles are set forth below, but the skilled artisan will appreciate that various fabrication methods and materials known in the art may be used to manufacture the articles of the present disclosure, depending upon the specific configuration of the article, without departing from the scope of the present disclosure. Any of the materials described supra may find use in the methods of the present disclosure.

[0049] In some embodiments, a method of making a fabric includes: (a) providing a hydrophilic material comprising an outer and an inner surface; (b) screen printing a hydrophobic material onto a first region of the inner surface of the hydrophilic material to produce a first hydrophobicity; and (c) screen printing a hydrophobic material onto a second region of the inner surface of the hydrophilic material to produce a second hydrophobicity, where the first region is more hydrophobic than the second region. Thus, the fabric includes an outer layer comprising a hydrophilic material and an inner layer comprising the first region and the second region. In some embodiments, the second region is in contact with at least a portion of the hydrophilic material of the outer layer. Any of the outer layers, inner layers and regions thereof, and materials described supra may be used.

[0050] Exemplary process 600 for making a fabric of the present disclosure is illustrated in FIGS. 6A & 6B. As shown in FIGS. 6A, process 600 starts with hydrophilic material 602. Material 602 can be any of the exemplary hydrophilic materials described herein. Screen roller 610 is then used to put down enough hydrophobic material to penetrate material 602. The hydrophobic material may be any of the exemplary materials described herein. This creates an inner surface that includes region 606 comprising the hydrophobic material deposited through roller 610 and region 604 comprising the hydrophilic material 602. A close-up, cross-sectional view of process 600 is provided in FIG. 6B.

[0051] Exemplary process 640 for making a fabric of the present disclosure is illustrated in FIGS. 6C & 6D. Process 640 can be conducted using the material resulting from process 600, in some embodiments. In process 640, a second screen roller 630 is used to apply a hydrophobic material to the inner surface that includes regions 604 and 606. In some embodiments, the hydrophobic material of process 640 is the same as that of process 600. In other embodiments, the hydrophobic material of process 640 is a different material. FIG. 6C shows second screen 630 printing on the substrate with less penetration to form weaker (e.g. , as compared to region 606) liquid-repellent region 612. FIG. 6D shows a cross-sectional view demonstrating that region 606 has a greater cross-sectional depth than region 612.

[0052] Two screens 610 and 630 can be aligned in the printing process so that weak liquid- repellent region 612 and strong liquid repellent region 606 connect. Such alignment is similar to the multi-color printing process. Similar to printing multiple colors with precise registration, the liquid-repellent patterns can be aligned very accurately by one of ordinary skill in the art. Thus, after processes 600 and 640, a material is generated having an outer hydrophilic layer 602 and an inner layer that includes relatively strongly hydrophobic regions 606 and relatively weakly hydrophobic regions 612.

[0053] Some printing methods use various thickeners to keep the ink from migrating and to maintain a clear or well-defined print. In printing in general, there are a number of variables which can be controlled by one of ordinary skill in the art. Some variables such as print paste viscosity, amount of print paste applied, roller/wiper pressure, speeds, mesh size of the screen, etc., can be used to control the depth of penetration of the print paste. One way to control depth of ink penetration is to adjust the printing parameters so that the print paste can penetrate through the fabric without merging together.

[0054] There are currently several different methods of textile printing available, including without limitation flatbed printing, rotary printing, inkjet printing, and so forth. Any liquid- absorptive of the present disclosure, including but not limited to cotton, treated polyester, nylon, silk, bamboo fibers in woven, knitted or non- woven structure, may be used as the material substrate or hydrophilic material (e.g. , 602). Any of the durable liquid-repellent agents described herein, such as fluorochemicals, silicones, waxes or other similar materials, may be used to create liquid-repellent regions (e.g. , 606 and 612).

[0055] In some embodiments, the methods further include screen printing a hydrophobic material having a third hydrophobicity onto a third region of the inner surface of the hydrophilic material. In some embodiments, the third region is more hydrophobic than the first region. For example, the third region may be comprised of a more strongly hydrophobic material, and/or possess a greater concentration, cross-sectional depth, or a lower porosity.

[0056] Exemplary process 660 for making a fabric of the present disclosure is illustrated in FIGS. 6E & 6F. Process 660 can be conducted using the material resulting from process 640, in some embodiments (e.g. , after flipping the material so that the opposite surface faces the roller). In process 660, a third screen roller 650 is used to apply a hydrophobic material to the outer surface that includes region 602. In some embodiments, the hydrophobic material of process 660 is the same as that of process 640 or process 600. In other embodiments, the hydrophobic material of process 640 or process 600 is a different material. FIG. 6E shows third screen 650 printing the substrate with less penetration to form weaker (e.g. , as compared to region 606) liquid-repellent regions 614. FIG. 6F shows a cross-sectional view demonstrating that region 606 has a greater cross-sectional depth than region 614. In some embodiments, region 614 has the same hydrophobicity has region 612. In some embodiments, region 614 can be patterned to show a design (e.g. , a star, logo, or geometric shape), for example when moisture absorption leads to the hydrophobic regions remaining dry and retaining the original color of the fabric, while the surrounding hydrophilic regions become wet and adopt a darker color, thereby displaying a visual pattern (see FIG. 4B). In some embodiments, region 614 comprises the hydrophobic material at a cross-sectional depth that is less than the full cross-sectional depth of the outer layer made of hydrophilic material 602, e.g. , the hydrophobic material is printed onto the outer surface at region 614 at a cross-sectional depth such that a portion of the hydrophilic material separates the hydrophobic material of region 614 from the hydrophobic materials of the inner surface (e.g. , regions 606 and 612). Thus, after processes 600, 640, and 660 a material is generated having an outer layer comprising hydrophilic region 602 and hydrophobic region 614. The material generated also has an inner layer that includes relatively strongly hydrophobic regions 606 and relatively weak hydrophobic regions 612. In some embodiments, this method can also be used to generate the structure described in FIG. 4C. For example, if roller 650 does not have a pattern, it will completely cover the fabric surface with a controlled layer of hydrophobic material.

[0057] Alternatively, a fabric of the present disclosure can be fabricated by knitting. As discussed supra, the hydrophobicity of a material can be modified by varying several different parameters, such as the type of material and/or a property of the material, such as porosity.

[0058] In some embodiments, the structure can be fabricated on a double jersey circular knitting machine. In some embodiments, the fabrication process starts with hydrophobic yarn and hydrophilic yarn. The hydrophilic yarn is used to knit one side of the fabric (e.g. , an outer layer described herein), while on the other side, hydrophobic yarn is knitted to form the other layer (e.g. , an inner layer described herein). In some embodiments, the hydrophobic yarns are knitted with different porosity to form the weak and strong liquid-repellent regions. In some embodiments, the hydrophilic yarn on the front is tucked into selected hydrophobic regions to form a weaker liquid-repellent region.

[0059] In some embodiments, a method of making a fabric includes: (a) knitting an outer layer of the fabric using a hydrophilic yarn; (b) knitting a first region of an inner layer of the fabric using a hydrophobic yarn, wherein the first region is knitted with a first hole size, thereby making a first region having a first hydrophobicity; and (c) knitting a second region of the inner layer of the fabric using the hydrophobic yarn, wherein the second region is knitted with a second hole size, thereby making a second region having a second hydrophobicity. In some embodiments, the first region is more hydrophobic than the second region, and the second region is in contact with at least a portion of the hydrophilic yarn of the outer layer.

[0060] An exemplary knitting diagram for producing a fabric of the present disclosure is provided in FIG. 7. In some embodiments, the fabric is formed on a double jersey circular knitting machine to create different hole sizes as described above. Loops in the drawing indicate a knit stitch, and "v" indicates a tuck stitch (which creates a larger hole in the fabric). The loops on the cylinder needles represent a knit stitch formed on the outer fabric face. Loops on the dial needles represent the backside/inner layer of the fabric surface that comes in contact with the skin when the fabric is worn as part of a fabric or garment of the present disclosure. Loops that go back and forth between the cylinder and dial needles serve as the tie in yarn that keeps the front and backside of the fabric together without an obvious gap in between. In some

embodiments, the yarn on the front is hydrophilic and the yarn visible on the backside is hydrophobic. Designated regions on the backside will have larger holes (bigger distance between yarns) due to the tuck stitch introduced in the specified courses (courses 5, 7 & 9).

[0061] Therefore, the regions without the tucks have a specific knit hole size and the regions with the tucks have a relatively bigger hole size, which will allow water to penetrate the fabric in those areas and go to the outer hydrophilic surface.

[0062] In some embodiments, the maximum hole size can be between about 1mm and about 5mm for the weak hydrophobic region, e.g. , a second region of an inner layer of the present disclosure. For example, in some embodiments, the maximum hole size of the second region of an inner layer of the present disclosure is about 1mm, about 2mm, about 3mm, about 4mm, or about 5mm.

[0063] In some embodiments, the maximum hole size can be between about ΙΟμιη to 300μιη for the strong hydrophobic region, e.g. , a first region of an inner layer of the present disclosure. For example, in some embodiments, the maximum hole size of the first region of an inner layer of the present disclosure is about ΙΟμιη, about 20μιη, about 30μιη, about 40μιη, about 50μιη, about 75μιη, about ΙΟΟμιη, about 150μιη, about 200μιη, about 250μm, or about 300μιη. In some embodiments, the maximum hole size of the first region of an inner layer of the present disclosure is less than about any of the following hole sizes (in μιη): 300, 250, 200, 150, 100, 90, 80, 70, 60, 50, 40, 30, or 20. In some embodiments, the maximum hole size of the first region of an inner layer of the present disclosure is greater than about any of the following hole sizes (in μπι): 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, or 250. That is the maximum hole size of the first region of an inner layer of the present disclosure can be any of a range of hole sizes having an upper limit of 300, 250, 200, 150, 100, 90, 80, 70, 60, 50, 40, 30, or 20 μιη and an independently selected lower limit of 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, or 250 μπι, wherein the lower limit is less than the upper limit.

[0064] In some embodiments, a method of making a fabric includes: (a) knitting an outer layer of the fabric using a hydrophilic yarn; (b) knitting a first region of an inner layer of the fabric using a hydrophobic yarn, thereby making a first region having a first hydrophobicity; and (c) knitting a second region of the inner layer of the fabric using the hydrophobic yarn. In some embodiments, the hydrophilic yarn is stitched from the outer layer into the second region of the inner layer to produce a second hydrophobicity, and the first region is more hydrophobic than the second region.

[0065] In some embodiments, the structure can be fabricated on a double jersey circular knitting machine on a repeat of 9 needles. An exemplary knitting diagram for producing a fabric of the present disclosure is provided in FIG. 8. Loops in the drawing indicate a knit stitch, and "v" indicates a tuck stitch. Loops on the cylinder needles represent what will be knitted on the outer fabric surface, and loops on the dial needles represent what will be knitted on the inner fabric surface. In this example, the tie-in yarn and yarn that is knit exclusively on the front cylinder needles is hydrophilic, and the yarn knit exclusively on the dial needles is hydrophobic. The tie-in yarn will show loops of hydrophilicity on the inside of the fabric in the specified areas according to the knit diagram, thereby making the overall hydrophobicity of that area less than the areas where no tie in yarns are knitted on the backside of the fabric. The tie in yarn serves the purpose of holding the front and back of the fabric together and also provides a conduit for the water to absorb into the fabric and move to the hydrophilic front/outside surface. The proportion of hydrophilic yarns present on the backside is determined by the knit construction. The greater the number of tie-in yarn stitches on the backside, the greater the increase in hydrophilicity of that area. That is to say, if every other needle knits the tie-in yarn to the back surface, that course will have 50% hydrophobic stitches and 50% hydrophilic stitches therefore creating an overall half-hydrophilicity.

EXAMPLES [0066] The present disclosure will be more fully understood by reference to the following example. It should not, however, be construed as limiting the scope of the present disclosure. It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.

Example 1: Moisture management behavior comparison

[0067] FIGS. 9A-9L demonstrate the unique moisture management behavior of an exemplary fabric with improved moisture management as disclosed herein. The tested fabric shows improved moisture management properties (sample: 100% polyester, interlock, treated with strong hydrophobic dot array surrounded by weak hydrophobic regions; FIGS. 9I-9L) as compared to a fabric treated with a wicking window (see, e.g. , U.S. Pat. No. 7,008,887; sample was cut from Fabricast™ booklet prepared by Cotton Incorporated, 93% cotton, 7% spandex, single jersey; FIGS. 9A-9D), or a fabric treated with the NanoTex® Dry Inside moisture management coating (see, e.g., U.S. Pat. No. 7,842,625; sample cut from World Wide

Sportsman™ shirt treated with NanoTex® Dry Inside technology bought from online store, 100% polyester, interlock knit; FIGS. 9E-9H).

[0068] An identical, small amount of water (distilled, ~42.5μΕ) was placed on each of the fabrics on the inner surface, and a picture was taken after initial placement of droplets. As shown in FIG. 9A, the hydrophilic regions of the inside wicking window fabric became wet immediately and quickly wicked the moisture into the fabric. The hydrophilic regions (shown as the pattern) remained wet, and the hydrophobic regions remained dry during the wicking action. In comparison, the droplet remained a sphere on both Dry Inside (FIG. 9E) and the improved moisture management fabric of the present disclosure (FIG. 91), demonstrating the hydrophobic properties of the inside of these samples. After gently rubbing the droplets against the inside surfaces of the samples, both the Dry Inside fabric (FIG. 9F) and the improved moisture management fabric of the present disclosure (FIG. 9J) absorbed the liquid into the fabric structure. However, the improved moisture management fabric of the present disclosure completely absorbed the moisture into the fabric, and the inside of the fabric remained completely dry, unlike the Dry Inside fabric. When the fabrics were flipped over, the moisture was found to be spread on the outside of the fabric samples like a typical moisture wicking fabric (FIGS. 9C, 9G, & 9K).

[0069] Additional moisture was then added to each of the samples with continuous rubbing until the outer surface of the fabric was saturated (FIGS. 9D, 9H, & 9L). Once saturated, the Dry Inside sample became almost equally wet on the outer surface and the inner surface of the fabric (FIG. 9H), while the circular regions (i.e., strong hydrophobic regions) of the fabric of the present disclosure remained mostly dry on the inside of the fabric (FIG. 9L).

[0070] In summary, the results demonstrate the unique properties of the improved moisture management fabric disclosed herein, as compared to existing fabrics. The improved moisture management fabric disclosed herein was able to remain completely dry on the inside before the outside became saturated and remained largely dry even after the outside was completely saturated. Example 2: Wear trial on human body

[0071] A wear trial was conducted by a male athlete wearing a prototype shirt (100% polyester, interlock, fabric weight 165g/m ) that was treated with the improved moisture management fabric of the present disclosure in a 15 by 17 inch rectangular area on the back of the shirt. The pattern on the treated region was a weak hydrophobic dot array surrounded by a strong hydrophobic region (similar to the pattern illustrated in FIGS.6A-D). The athlete performed an indoor cycling test for approximately 30 minutes. Pictures were taken during and after the test. During the test, the shirt performed well, distributing moisture to the outside of the fabric while keeping the inside of the fabric dry (FIG.10A). After the test, the shirt was removed. The inside of the treated rectangular region was found to be dry, while the surrounding untreated regions showed a darker color and was more wet (FIG.10B). These results validate the improved moisture management properties of the fabrics disclosed herein under actual use conditions.

[0072] Although the foregoing descriptions and examples have been described in some detail by way of illustration and example for purposes of clarity of understanding, the descriptions and examples should not be construed as limiting the scope of the present disclosure.