TECHNICAL FIELD

[0001] The present invention relates to multi-layer laminated protective covers for equipment typically stored outdoors such as airplanes, vehicles, munitions, weapons and weapons systems, electrical equipment and the like, and more particularly, to the construction of multi-layer fabrics for such protective covers incorporating one or more Basalt fabric layers.

BACKGROUND INFORMATION

[0002] Protective covers are often used to protect equipment and parts in a wide range of environmental

conditions. Corrosion and oxidation are of particular concern, especially in connection with vehicles, airplanes, munitions, weapons and weapons systems and equipment with metal and/or electronic components and the like.

[0003] Prior protective covers that address the problem of corrosion are described in tJ.S. Patent Nos. 6,833,334,

6,794,317 and 6,444,595. Many of these covers have been found to have fundamental weaknesses that can create a microclimate underneath the cover when in use. The covers have been found to be generally impermeable to or provide good resistance to rain, snow, and offer good water

repellency. They generally use a monolithic impermeable coating on one side of the outer fabric layer to provide water resistance. [0004] In recognition of the microclimates formed

underneath the cover, as a humid environment cools and condensation forms on the protected equipment, some of the covers utilize a center layer made of super absorbent fibers (typically made from super absorbent polymer - SAP) . When the SAP absorbs the condensation it can make the cover extremely heavy when wet and then can freeze in place in a cold environment. The technology also sometimes uses vapor corrosion inhibitors (VCI's that leach out of the cover as moisture passes through the cover and can deposit itself on the equipment leaving a moist residue on the equipment it is trying to protect.

[0005] Additionally, current technologies use UV

stabilizers in the dyes used to color the cover fabrics and although this offers some level of durability, the cover life is still generally in the range of 9-18 months of effective working life.

[0006] There remains a need, however, for more effective covers that provide protection and resistance to penetration of water, wind and sand and that are especially effective with respect to the prevention or at least minimization of oxidation and/or corrosion due to humidity build-up around the covered objects. Additionally, prior art protective covers have been found to be damaged by abrasion and other environmental factors caused by windblown sand, other wind borne particles and UV solar light and therefore, the ideal protective cover should be durable and able to resist abrasion and damage caused by wind, sand and other substances, as well as resist degradation caused by UV energy from the sun.

[0007] It is desirable that covers perform in use without degradation or fall-off in performance for an extended period of time, preferably greater than 4+ years. The primary mode of failure of most covers found in use today is a loss in mechanical strength that can be observed in the formation of holes and tearing of the fabric. This loss in strength and durability is the result of molecular weight loss of the base polymer from which the fabric is made via continued exposure to ultra-violet light.

[0008] Protective covers of the type described above are designed and engineered to protect key assets both military and industrial that are subject to corrosion and or

degradation from exposure to environmental conditions such as rain, fog, snow, wind, relative humidity, ultraviolet light and general pollution such as air borne dust, sand, acid rain etc. Such assets could be military hardware, such as helicopters and armored vehicles, or electronic components such as generators or general ordnance (small to large scale guns) . Overall, cover technology by means of air permeable fabrics are proven to offer suitable protection to the assets described.

[0009] In addition, occasionally applications occur where a cover is needed to protect and cover explosive materials and or sensitive electronic equipment. Usually materials used to manufacture covers use insulative, synthetic materials, such as polyester or nylon or similar textile woven or knitted fabrics. The risk of a static electrical charge build up occurring via the on-off motion from the described material cover or a charge build up from in-use dynamic movement and flexing of the cover could cause catastrophic failure of the cover and the asset being protected.

Moreover, all prior art covers exhibit signs of UV

degradation after a period of time - some sooner than others - but all have this drawback no matter how the prior art fabrics are constructed or treated.

[0010] Previously some concepts used to impart electrical conductivity or static dissipation properties to cover materials have been tried and evaluated. Most include the use of yarns or threads containing a percentage component of either a metallic (stainless steel or copper sulphate) or carbon to render the yarn and thus the woven or knitted fabric made from the yarn, electrically conductive. Fabrics have been made where the conductive fabric uses 100%

electrically conductive yarns or the electrically conductive yarns can be strategically woven or knitted in to the fabric by use of a grid/square pattern or uni-directional design.

[0011] In each case the conductive yarns which are always present on either outer surface of the cover can be exposed to the environments described herein which in turn leads to the risk of long term durability failure based upon UV exposure and abrasion damage. Further, the cost of imparting such yarns in the finished fabric can be expensive and cost prohibitive .

[0012] In many such cover applications described above it is also necessary to provide fire resistance characteristics to the protective covers due to the explosive materials that require protection. This Fire Resistance feature must be provided without impacting the cover's air permeability and Moisture Vapor Transmission Rating (MVTR) characteristics, adding weight or impacting Electro-static discharge.

[0013] Therefore, what is needed is a fabric cover with a multi-layer construction that uses an outer fabric that is designed to be durable, breathable, water-repellant,

conforming, and flexible to be shaped and formed to protect the equipment against corrosion and/or oxidation degradation and potential catastrophic failure caused by its exposure to a wide range of environmental conditions. The cover should provide greater than 2 times the current life of a cover and meet the industry requirements of greater than 4+ years of life. Additionally, the cover should address the problem of corrosion by providing a level of relative humidity (RH) management and control while also providing an effective and durable electrical conductive or electro-static dissipative (BSD) performance characteristics to the cover material. A preferred fabric cover should also include Fire Resistance and UV resistance characteristics.

[0014] It is important to note that the present invention is not intended to be limited to a system or method which must satisfy one or more of any stated objects or features of the invention. It is also important to note that the present invention is not limited to the preferred, exemplary, or primary embodiment (s) described herein. Modifications and substitutions by one of ordinary skill in the art are

considered to be within the scope of the present invention. SUMMARY

[0015] In accordance with an exemplary embodiment of this invention, the present invention includes a hydrophobic but air-permeable cover member including a middle layer which prevents build-up of a micro-climate and stabilizes the pressure under the cover, while still providing the desired water resistance performance needed. An air permeable protective cover is provided that is designed to prevent the ingress of moisture but, at the same time, to allow moisture vapor underneath the cover to readily pass through to the outer environment, thereby preventing humidity buildup and thus helping to prevent or at least minimize oxidation and corrosion of the covered object caused by condensation of any moisture trapped in the air under the cover.

[0016] In the underlying technology, the cover is composed of several laminated layers of different materials. The multiple layers include at least an outer textile layer made of a woven basalt fabric, an intermediate film or membrane of ePTPE or other similar hydrophobic material having good air permeability and moisture-vapor-transmission properties, and an inner textile layer that may or may not be a basalt woven layer that faces toward the object being covered. For specific applications, the intermediate ePTFE membrane may be an air permeable, breathable, treated membrane such as an eVENT* membrane available from BHA Technologies. An optional fourth fabric layer between the outer layer and the film or membrane may incorporate Super Absorbing Polymers (SAPs) to prevent reabsorption of moisture back through the cover. [0017] Corrosion or other inhibitors, such as an antimicrobial to inhibit mold, may also be included in either the inner or outer textile layers or the membrane itself. All of the various embodiments preferably take advantage of

moisture-wicking materials as the laminate layers to help remove moisture vapor from the covered equipment. The various layers or laminations are held together by adhesive or any other acceptable method in order to achieve the required durability of the final product.

[0018] The protective covers described herein preferably have a Moisture Vapor Transmission Rating (MVTR) of at least 4000 g/m ² /day or more and an Air Permeability rating of 0.15 CFM, and wherein the multi-layer fabric system when assembled together or independently, can maintain a relative humidity transmittance rate through the structure at or greater than 0.20%/minute/cu.ft. or 0.05 grains of moisture /minute/cu.ft .

[0019] Basalt is a dark-colored, fine-grained, rock. It most commonly forms as an extrusive rock, such as a lava flow, and is found extensively nearly all around the world. Basalt underlies more of earth's surface than any other rock type. Most areas within Earth's ocean basins are underlain by basalt .

[0020] Basalt fiber is a material made from extremely fine fibers of basalt, which is composed of the minerals

plagloclase, pyroxene, and olivine . It is similar to carbon fiber and fiberglass, having better physicomechanical properties than fiberglass, but being significantly cheaper than carbon fiber. Basalt fiber is made from a single material, crushed basalt, from a carefully chosen quarry source and unlike other materials such as glass fiber, essentially no materials are added. The basalt is simply washed and then melted. The manufacture of basalt fiber requires the melting of the quarried basalt rock at about 1,400 °C (2,550 °F) . The molten rock is then extruded through small nozzles to produce continuous filaments of basalt fiber.

[0021] Basalt fabrics are yarns manufactured to varying thickness, weight, weave pattern and weaving technique according to end-use requirements, from basalt fibers.

Basalt yarns and fabrics woven therefrom and fire resistant; heat resistant to 700+ centigrade; UV resistant (will not degrade with long term exposure to sunlight) ; strong and abrasion resistant; and anti- static (will not accept an electrical charge (insulator)).

[0022] The inner textile layer may have material such as silicone dots applied to the inner face thereof, so that contact between the cover and the object to be protected is minimized if not eliminated, and to thereby enhance the moisture vapor transmission away from the object.

[0023] Textiles suitable for the outer layer include woven, knit and non-woven fabrics made of basalt fibers having a size of typically between 6 and 15 denier to provide a fabric weighing between 5 and 6 ounces per square yard.

[0024] Textiles suitable for the inner layer include woven, knit and non-woven fabrics such as lightweight warp or circular knit fabrics using nylon, polyester, Nomex* and equivalent fabrics, spunbond nylon and equivalents and well as the basalt fabrics described above. [0025] Accordingly, in one aspect, the invention relates to a protective cover comprising a textile layer and an air permeable, moisture-vapor-transmissive, expanded

polytetrafluoroethylene membrane layer attached to the textile layer, the cover having an MVTR of at least 4000 g/m ² /day.

[0026] In another aspect, the invention relates to a fabric for use in protective covers, the fabric comprising at least three layers including an outer woven, knit or non- woven basalt fabric layer and an inner woven, knit or non- woven fabric layer or basalt fabric layer, and a moisture- vapor transmissive, air permeable and oleophobic expanded polytetrafluoroethylene membrane layer between the outer and inner layers; the fabric having an MVTR of at least 4000 g/m ² /day.

BRIEF DESCRIPTION OP THE DRAWINGS

[0027] These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:

[0028] FIG. 1 is a cross section through a laminated protective cover in accordance with an exemplary embodiment of the invention;

[0029] FIG. 2 is a cross section similar to Figure 1 but with an additional textile layer interposed between the inner and outer layers;

[0030] PIG. 3 is a cross section similar to Figure 3 but with a plurality of spacers applied to the exposed inner face of the inner layer;

[0031] FIG. 4 is a partial perspective view of a composite fabric for making a protective cover in accordance with another embodiment of the present invention in which the outermost layer is constructed of treated fibers or yarns;

[0032] FIG. 5 is a partial perspective view of a

protective cover in accordance with the invention applied over a military weapon; and

[0033] FIG. 6 is a comparison of the relative humidity shift when using a prior art cover with the cover according to the present invention, shown over a 30 minute time span.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Referring to Figure 1, a laminated protective cover 10 according to the present invention is composed of

laminated layers 12/14/16 of different materials. The protective cover can comprise a sheet of predetermined length and form and used to cover the intended object, much like a tarp. In addition, the laminated material forming the protective cover may be cut and sewn to fit more precisely a specific object or item of equipment. The seams of this cut and sewn cover may also have seams that are taped or

otherwise covered with a compatible material or are welded, in either case so that the finished cover is durably

waterproof .

[0035] In the exemplary embodiment, at least three laminated layers are employed. These layers include an outer textile fabric or face layer 12 made from basalt fibers; an interior intermediate layer 14; and an inner textile layer 16. The outer textile layer 12 is composed of suitable woven or non-woven basalt fibers of between 6 and 15 denier producing a fabric weighing 5 to 6 ounces per square yard or less .

[0036] An interior intermediate layer 14 is provided in the form of a hydrophobic film or membrane with good air permeability and moisture-vapor-transmission properties. In the exemplary embodiment, layer 14 is an expanded

polytetrafluoroethylene (ePTPE) layer. The expansion of polytetrafluoroethylene opens billions of microscopic pores in the resulting film or membrane 14 to enhance air

permeability and water vapor transmission rate.

[0037] The ePTPE layer or membrane is also preferably treated to render it permanently oleophobic, waterproof and hydrophobic. A treated membrane of this type is commercially available from BRA Technologies under the trade name eVENT* Fabric. The oleophobic property of this membrane is

particularly beneficial in that equipment, particularly military equipment, is often sprayed with oil to minimize corrosion. The ePTPE membrane so treated is rendered resistant to hydraulic fluid, diesel fuel, weapon lubricants and similar field chemicals. Instead of coating the membrane with polyurathene, event fabrics are treated with a patented hydrophobic polymer to achieve oleophobic properties. eVent fabric's oleophobic polymer is applied by means of a

supercritical gas treatment, eliminating the use of solvents during the production process. This new technology enables both the gas and polymer to completely penetrate the pores of the eVent fabric's membrane, encapsulating each and every fibril during treatment but maintaining open the pores in the fabric thus maintain air permeability.

[0038] It is believed that the unique value that eVENT* or similar fabric with similar properties offers is its ability to eliminate moisture condensation on the article covered while providing a completely waterproof protection (resists liquid water penetration at pressure as high as 10 meters of hydrostatic head) . Moisture condenses on the surfaces of the equipment being covered if the protective cover cannot

"breathe" . This happens due to environmental temperature swings during the storage.

[0039] For example, if an object is covered with a nonbreathable protective cover and the environmental

conditions are 25°C temperature and 50% relative humidity, then a drop of ambient temperature by 12°C would drive the relative humidity inside to over 100% and hence lead to condensation. Utilizing an eVENT* type membrane would keep the relative humidity ineide equilibrated to the ambient conditions by allowing the moisture vapors under the fabric to escape out.

[0040] Moisture or condensation is the primary cause of the corrosion that occurs to items contained under the cover as the climate outside the cover changes, in a preferred embodiment, the cover allows for sufficient air permeability thereby allowing the humidity and pressure changes caused by changed in environmental conditions to stabilize so the risk of condensation forming under the cover and on the equipment or asset being protected is minimized.

[0041] Figure 6 shows how a cover, manufactured according to the first embodiment of the present invention, allows the relative humidity to escape from under the cover. The cover enables the air to get to equilibrium faster, thereby reducing or eliminating the condensation under the cover. As shown in Figure 6, the prior art (standard technology) cover maintains the relative humidity level over a 30 minute time span. In contrast, the cover of the present invention drastically reduces the relative humidity over the same 30 minute time span.

[0042] The existing technology claims the cover materials are breathable based upon a measured moisture vapor

transmission rate (MVTR) primarily attributed to the

monolithic or micro-porous polyurethane coating applied to the cover material. This means a higher pressure under the cover must be attained and condensation must occur and be absorbed into the polyurethane layer before moisture will start to transfer through the cover. In the prior art, a wet system of moisture traps the humidity and creates a

difference in pressure that leads to condensation and corrosion of equipment.

[0043] The impact of air permeability on relative humidity (shown in Figure 6) was determined using a test chamber, which was developed to evaluate the technology. To keep the experiment simple, the temperature inside the test chamber was maintained at an equivalent temperature as outside the test fixture at 82+/- 2deg.F. Also, the %RH (relative humidity) outside the test fixture was measured at a constant 48% RH. The conditions in the test chamber are then

developed (hot rod and water bath) to generate a constant RH of around 85+/- 2% with the test sample sealed inside the chamber. The door to the chamber is then opened exposing the test sample to the outside environment. The test area is approximately 1 square foot of surface area and the size of the chamber is approximately 1.5 cubic feet. With the sealed door now open, the data is taken by measuring the change in relative humidity inside the chamber with a hygrometer. A test is taken every minute to help determine a rate of which the change in RH is occurring inside the chamber.

[0044] The management of relative humidity offered by the new invention is compelling and can be measured several ways. First, the chart shows the cover material of the new

invention allowing relative humidity to pass through almost immediately. The curve of the chart shows the rate of RH change is relatively linear in terms of time. The chart shows approximately a 1% change in RH/minute/square foot.

Over the same time period, zero change in RH has occurred with the current/existing technology. The next stage is to quantify the level of relative humidity or moist air passing through the new invention. It is known what the weight of dry air is at 0.075lbs/ft ³ . Using a psychometric chart we can calculate the weight of moisture in the chamber at 85% relative humidity and also at 50% relative humidity and thus extrapolate the rate in grains or grams of moisture being transferred through the new invention cover material. [0045] It is known the weight of 1 cubic foot or air at 68F at 65% RH is 0.075lbs. Therefore, to measure the quantity or rate of moisture removed by the new cover material using the test chamber discussed, the following mathematical model is used. 1.5 cubic feet of chamber at 0.075 x 85% relative humidity. 1.5 x 0.075 x 133 = 14.96 grains of moisture in chamber. Comparatively 1.5 x 0.075 x 80 = 9.0 grains of moisture outside chamber. Thus 14.96 - 9.0 = 5.96 grains moisture removed in 30 minutes. Thus 6 / 30 - moisture removal rate 0.2 grains moisture

removed/minute . Thus actual cover material rate 0.2 / 1.5 = 0.12 grains of moisture/minute/cubic foot. Or multiply by 27 = 3.25 grains of moisture removed/minute/cubic yard.

[0046] Returning now to the construction of the protective cover according to a first embodiment of the invention, the inner textile layer 16 faces the object to be covered, and it is therefore preferable that the exposed surface 19 be smooth so as not to scratch covered equipment. This textile fabric layer 16 may be composed of woven, knit, and non-woven fabrics such as lightweight tricot warp knits of polyester or nylon. Such materials include Style 1158 manufactured by Homwood and available from KTex of Wayne NJ, or Style #0862, a 100% semi-dull nylon 6,6 with 52 courses and 42 wales and a weight of 0.9 oz./sq. yd., available from Somerset Industries of Gloversville, NY. Also suitable are non-woven spunbond nylon fabrics such as Cerex Advanced Fabrics Orion style #70 having a weight of 0.7 oz./sq. yd. and a thickness of 6-7 mil . [0047] Another suitable fabric is yellow Nexus ^® nonwoven polyeeter having a weight of 1-1.2 oz. /yd ² , and a thickness of 0.008-0.012 in,, also available from Precision Fabrics Group. The inner textile layer 16 may also be hydrophilic, either by treatment or choice of fibers and construction, helping to wick moisture away from the covered object and to spread the moisture laterally, facilitating the vapor transmission through the cover to the outside. The inner textile layer 16 may also be rendered electrically conductive by either weaving in of inherently conductive fibers or by topical (i.e. coating, printing, etc.) treatment. Yet another suitable material for the inner layer 16 is a basalt fabric layer similar to that described in connection with the upper layer 12.

[0048] Referring now to Figure 2, a second embodiment illustrates a laminated protective cover 18 that includes an outer textile or face layer 20 similar to outer textile or face layer 12 in Fig. 1, overlying an interior textile fabric layer 22 incorporating super-absorbent polymers {SAPs) . The interior textile fabric layer 22 is preferably a suitable non-woven fabric enclosing the SAP's in an otherwise

conventional fashion. The interior textile fabric layer 22 in turn overlies an ePTFE film or membrane 24 similar to membrane 14 described in connection with Figure 1. The inner most layer 26 is a textile fabric that may be of a material similar to inner textile layer 16 described hereinabove in connection with Fig. 1. Use of SAPs in the intermediate fabric layer 22 minimizes the possibility of reabeorption of moisture back into the space below the cover. [0049] Figure 3 illustrates a variation of the embodiment shown in Figure 1. As such, the outer textile or face layer 28, intermediate membrane 30 and inner textile layer 32 are similar to the corresponding layers 12, 14 and 16 described hereinabove in connection with Figure 1. Here, however, the cover 26 also includes a plurality of silicone (or other suitable material) spacers or dots 34 applied to the exposed face 36 of the inner layer 32. The "dots" 34 may be applied in any random or patterned configuration and serve to maintain a space between (or at least minimize contact between) the object to be covered (not shown) and the bottom surface 31 of the inner textile layer 32.

[0050] With the above configurations, the laminated protective cover allows moisture to be expelled readily from the interior covered area through the laminated cover itself to the outside environment. In this regard, the cover fabric and cover itself preferably have an MVTR of at least 4000 to about 8000 g/m ² /day and as high as 14000 g/m ² /day or more, per ISO 15496 (inverted cup method) . The cover thus provides environmental protection and resistance to penetration of water, wind and sand. The cover may be especially useful in the prevention of corrosion during transportation of military vehicles or other equipment, and protection from

contamination by chemical and biological warfare agents.

[0051] In the specific comparative example below, an ePTFE laminate cover in accordance with the invention is

constructed of three layers including: (a) a woven Basalt fabric layer as described above in Fig. 1; (b) ePTFE membrane as shown and described in connection with Fig. 1; and (c) either a Nexus ⁰ polyester spunlace, 30 g/tn2 , available from Precision Fabrics Group or a woven Basalt fabric layer as described above in Fig. 1 or similar. The ePTFE membrane is available from BHA Technologies, Inc. under the name eV5004- 3L.

[0052] In one example, the following commonly used protective cover materials were compared against the above ePTFE laminate cover: (1) Herculite* 90 Coated Cover Fabric available from Manart-Hirsch Co., Inc., NY; (2) Sunbrella* Marine Canvas Cover Fabric available from Great Lakes Fabrics Inc., MI as their product number 4630; and (3) Polyethylene shrink wrap (Marine Boat cover) available from Shrinkwrap International Inc . , MI

[0053] Mild Steel corrosion coupons were obtained from Metal Samples Company, AL. Bach coupon was 2" x 1" x 1/16" in dimension. Ten such coupons were wrapped in each of the four cover materials and left in an open parking lot for a period of two weeks. At the end of two weeks, the condition of the coupons was evaluated for signs of rusting. They were graded on a scale of 1 to 5, with 1 indicating that none of the ten coupons were visually rusted and 5 indicating that all ten coupons were visually rusted.

[0054] The results from this evaluation are given in the table below. Also listed is the moisture vapor transmission rate of each of the four laminates.

[0055] Table 1

[0056] It is also within the scope of this invention to add a layer of air (gas) permeable insulation such as

Primaloft* within the laminate 10, specifically under the intermediate membrane 14, to retain heat under the cover. In addition, a metal (e.g. aluminum) reflective coating may be applied to the exposed inner face 19 of the inner layer 16 for reflecting heat and/or for its electrostatic dissipative properties if required.

[0057] Another variation includes the addition of a durable water repellant coating to the individual fibers that are used to make up the exposed face of the outer textile layer. Since this is not a continuous coating "on" the outer surface of the exposed face, such a water repellant coating results in little to no impact on air permeability of the entire cover material.

[0058] Each of the embodiments described above are used in conjunction with a multi-layer cover to provide improved cover durability including resistance to wear and abrasion and resistance to environmental conditions including solar radiation, temperature and humidity.

[0059] The outer layer (12, 20 or 28) material generally includes a fabric outer layer composed of high strength yarns made from polymer such as nylon, polyester or aramid or from a woven or non-woven Basalt fabric.

[0060] In addition to the outer layer, the composite includes a "breathable* middle or intermediate inner layer (14, 22 or 30) . This intermediate layer is preferably a polymeric membrane that permits high levels of moisture vapor transport. The breathable middle layer can be composed of such materials as expanded polytetrafluoroethylene,

microporous polyurethane, or other materials that provide both moisture vapor transport and resistance to the

penetration of liquid water, acids, bases, oils, greases and salt spray.

[0061] The multi-layer cover also includes a lightweight, flexible fabric inner layer (16, 26 or 32) . The inner surface layer may be made front open mesh tricot knits made of polyester or similar fabric, which provides support for the middle layer during lamination and which provides a flexible substrate for the entire cover that has minimal resistance to air or moisture transport or from a woven or non-woven Basalt fabric designed to exhibit similar properties. [0062] A fire retardant application to the laminated cover according to the present invention is generally not required because of the inherent fire retardant characteristics of Basalt in the outer textile layer. In certain cover

applications, however, there is the potential that the cover may become exposed to a combustible environment, where there is a risk that the cover may eupport combustion and result in a dangerous environment for the equipment being protected or the persons operating/maintaining/guarding the equipment in which case a fire retardant treatment may be required or desired to one or more layers of the cover.

[0063] In each of these various embodiments described herein, an added fire retardant application can also be included either as an additional coating or added to the various outer textile layere, intermediate layers or inner textile layers as a coating or as part of one of the layers of the cover.

[0064] In order to enable the cover to have a fire retardant quality, any materials used (such as nylon and polyester) , which support combustion, can be treated with a flame retardant topical treatment (such as available from Alexium Inc . ) or conversely the cover can be made with materials that are inherently non-combustible, such as aramid, mod-acrylic or other non-combustible materials. When creating a fire-resistant material it is critical that the material still remains air permeable, lightweight and still fire-resistant .

[0065] Prior art covers would coat the material (nylon or polyester) of the cover with a bromide and phosphate coating, which does not allow for air permeability. In a preferred embodiment of the present invention, the cover is treated with a FR (fire retardant) compound such as that compound manufactured by Alexium Inc. and provided by the Duro Company of Fall River, MA, which prevents oxygen from getting into the nylon, thereby preventing the nylon from burning. When the material of the cover is treated with this compound, the material will melt, but not burn due to the treatment and the bonding technique. Meanwhile, the treated fabric remains breathable.

[0066] The Alexium brand product is unique in that is utilizes Reactive Surface Treatment (RST) , utilizing

microwave energy to direct a precursor's polymerization onto the substrate's (fabric's) surface. It then uses a gas plasma to introduce minute quantities of the chemical to be permanently bonded to the fabric, providing unique new fire retardant functions to the fabric without adversely impacting the fabric's inherent properties such as MVTR, Air

permeability or overall weight. The Fire retardant chemistry is a new nano non-halogenated formulation that gives the fabric the desired self-extinguishing, no drip and no melt properties .

[0067] Additionally, carbon fibers, bundles or yarns as used in the prior art protective covers to provide static dissipative or electrostatic discharge (ESD) or anti-static characteristics are not required given the electrically insulating characteristics of Basalt. Many objects that are protected by covers need BSD protection, which is not provided by prior art covers unless such protection is added to the cover. In the prior art, there was the potential that the cover may become exposed to a build up of static

electricity, which creates a risk that the cover will support an electrical charge and result in a dangerous environment for the equipment being protected (electronic or software, etc.) and the persons operating the equipment. Therefore, it is preferred that the cover exhibit electro-static

dissipating properties which is provided by a laminate cover according to the teachings of the invention having a basalt inner and/or outer layer.

[0068] The electro-static dissipating BSD component applied to the multi-layer fabric is generally and typically configured to give an object made with the multi-layer fabric system, such as an enhanced performing protective cover, an electro-etatic decay performance of less than 0.5 seconds for 5000 volts measured at both a top and bottom portion of said enhanced performing protective cover.

[0069] An additional feature of another embodiment of the invention is therefore to impart a cost effective and durable electrical conductive or electro-static dissipative (BSD) performance to the fabric material using a screen printing technology of an electrically conductive ink. The print lay- down of ink is critical to conductivity performance and in the case of the overall concept of the present invention, preventing loss of air permeability of the cover.

[0070] In a preferred embodiment of the present invention, if required to augment or enhance the natural BSD protection provided by a Basalt outer textile layer, a lower surface (17, 25, 33 and 35) of the outer layer (12, 20 or 28) of the fabric material may be treated with a printed carbon

treatment or conversely can be made with a fabric material that is produced with ESD yarns or fibers. When the lower surface (17, 25, 33 or 35) of the outer layer (12, 20 or 28) is treated with carbon material, the surface can be entirely treated or more preferably, partially treated, such as with a pattern. The placement of the carbon on the lower surface (17, 25 or 33) of the outer layer (12, 20 or 28) is superior to the prior art usage of carbon on an upper eurface of the outer layer of the cover, because the carbon on the upper surface is subject to breakage and degradation due to UV solar breakdown.

[0071] To ensure protection of the conductive print and long term function, the print is applied ONLY to the inside of the cover fabric laminate preferably, as needed, on either the inside of the outer textile layer or the inner textile layer. Because the print/ink is a water based polyurethane compound with a durable carbon particle component, when the ink is applied to the fabric, there is no significant loss in air permeability. If the print is applied to the ePTPE, the very small pore sizes (0.03 microns) are filled with the ink, blocking substantial but not all air flow. When the carbon print is applied to the inside of the woven nylon face fabric, the print adheres to the large yarn fibers and as a result in the woven fabric blocks very little air flow.

Openings in the face fabric are orders of magnitude (500x) larger. Thus with the membrane part of the cover controlling the overall air permeability of the laminate the ink must be printed on the fabric and not the membrane. Effective coverage to attain to meet static dissipation requirements is based upon the level of carbon in the ink and the surface area printed on to the fabric. Trials done to date that provide optimum discharge used a 15 - 20% print lay down in a diamond shape pattern with approximately 1.5 - 2.0mm lines over a 1.0 - 1.5 square centimeter area.

[0072] One compelling aspect of this feature of the invention is that even though the printed ink is located on the inside of the laminate, the porous nature of the various cover materials and laminate layers used allow volume electrical conductivity through the fabric/layers and thus allow static dissipation through the fabric. Static

dissipation or static decay test method Federal Standard 191A and 4046 and NFPA-99 challenges the conductive material to provide decay of 5000volts in less than 0.5 seconds usually less than 0.1 seconds.

[0073] Further testing has shown that the ESD printing on the inside of the cover laminate does not significantly impact air permeability performance of the membrane and thus does not impact or reduce the level of relative humidity transported through the laminate. A cover material

manufactured with the fabric of the invention with ESD printing as described by this feature of the invention can still maintain greater than 1% relative humidity

transfer/square foot of surface area/per minute.

[0074] It is contemplated and within the scope of the present invention that each of the additional levels of durability described above can be used individually or in combination with one another. Each of these embodiments can also be used in conjunction with each of the previously described covers, including but not limited to, the use of super-absorbent polymers, a plurality of silicone spacers or dots 34, as well as the use of various fabric combinations previously disclosed.

[0075] Some of the applications for these laminate fabrics are protective covers that are particularly useful in situations where there is need for protection against dust, sand, rain, microbes and UV light exposure, while minimizing corrosion. For example: (a) Protective covers for military and civilian helicopters and other aircraft; (b) Protective covers for military ground vehicles; <c) Protective covers for ground aviation equipment; (d) Protective covers for shipboard equipment; (e) Boat covers; (f) Vehicle covers (e.g., motorcycles, automobiles, etc.); (g) Military Tank hatch covers; and (h) Personal arms protective covers.

[0076] Figure 5 illustrates one of many applications for the protective covers as described herein. Specifically, a cover 38 is shown in place, covering a military weapon 40.

[0077] Composite fabric systems within the scope of the present invention could include additional layers, selected to provide specific new or additional attributes to the composite fabric system and within the composite laminate. Such systems might include one or more layers to reduce sound transmission. Another would be to include a metal or metallized film layer that would reflect heat or dissipates static or provide EMI shielding. Another type of layer that could be included might include materials designed to absorb particular parts of the electromagnetic spectrum, such as infrared radiation to reduce IR signal or detection, radio signals or other means of detection. Yet another type of layer could be included to degrade biological or chemical toxins .

[0078] Providing additional insulation value is another example of a particularly useful additional composite layer. A preferred composite layer for retaining heat while

maintaining composite moisture vapor transport would be to include a gas permeable insulating layer such as Primaloft* under the permeable membrane layer. Such a system would enable maintaining a warm environment within a shelter or cover while allowing moisture to escape.

[0079] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention which is not to be limited except by the allowed claims and their legal equivalents.