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Title:
COMPOSITE MATERIALS WITH MEMBRANE
Document Type and Number:
WIPO Patent Application WO/2021/050849
Kind Code:
A1
Abstract:
Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer.

Inventors:
OLSON CORY MICHAEL (US)
SOMASUNDARAM VIJANDERAN (US)
Application Number:
US2020/050367
Publication Date:
March 18, 2021
Filing Date:
September 11, 2020
Export Citation:
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Assignee:
NORTH FACE APPAREL CORP (US)
International Classes:
B32B3/26; A41D19/00; A41D31/102; A41D31/30; A42B1/00; A42C5/04; A43B7/12; A43B23/02; A47G9/08; B32B5/02; B32B5/26; B32B27/12
Domestic Patent References:
WO2020219275A12020-10-29
Foreign References:
US20100316819A12010-12-16
KR20090079645A2009-07-22
Other References:
MATT GUGEL: "All about waterproof fabrics", 4 June 2017 (2017-06-04), XP002801458, Retrieved from the Internet [retrieved on 20201211]
Attorney, Agent or Firm:
RIESEN, Michael J. (Gambrell & Russell LLP,Promenade, Suite 3100,1230 Peachtree Street, N.E, Atlanta Georgia, US)
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Claims:
CLAIMS

What is claimed is:

1. A composite material comprising: a shell fiber layer; and a membrane disposed adjacent the shell fiber layer, wherein the composite material exhibits a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127; wherein the composite material exhibits an air permeability of between .25 and 1 cubic feet per minute (cfin) as measured using American Society for Testing and Materials (ASTM) D737; wherein the composite material exhibits a moisture vapor transmission rate (MVTR) of between 30 kilogram per square meter per 24 hour (kg/sqm/24hr) and 55Kg/sqm/24hr as measured using Japanese Industry Standards (JIS) L1099-B1.

2. The composite material of claim 1, wherein a fabric weight associated with the composite material is between 90 grams per square meter (gsm) and 200gsm.

3. The composite material of claim 1, wherein a fabric weight associated with the composite material is between 90gsm and 180gsm.

4. The composite material of claim 1, wherein a fabric weight associated with the composite material is between 91gsm and 177gsm.

5. The composite material of claim 1, wherein the shell fiber layer comprises one or more of nylon, polyester, or elastane.

6. The composite material of claim 1, wherein the shell fiber layer consists essentially of one or more of nylon, polyester, or elastane.

7. The composite material of claim 1, wherein the shell fiber layer comprises about 100 weight percent (wt%) polyester from a total of 100wt% of the shell fiber layer.

8. The composite material of claim 1, wherein the shell fiber layer comprises greater than 90 wt% polyester from a total of 100wt%.

9. The composite material of claim 1, wherein the shell fiber layer comprises about 58wt% nylon, about 37wt% polyester, and about 5wt% elastane.

10. The composite material of claim 1, wherein the shell fiber layer comprises about 93wt% nylon and about 7wt% elastane.

11. The composite material of claim 1, wherein the shell fiber layer comprises about 62wt% nylon, about 33wt% polyester, and about 5wt% elastane.

12. The composite material of claim 1, wherein the shell fiber layer comprises about 93wt% nylon and about 7wt% elastane.

13. The composite material of claim 1, wherein the shell fiber layer comprises about 75wt% polyester and about 25wt% nylon.

14. The composite material of claim 1, wherein the shell fiber layer comprises 96% nylon, 4% elastane.

15. The composite material of claim 1, wherein the membrane is coupled to the shell fiber layer.

16. The composite material of claim 1, wherein the membrane is glued to the shell fiber layer.

18. A composite material comprising: a shell fiber layer; and a membrane disposed adjacent the shell fiber layer, wherein the composite material exhibits a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127; and wherein the composite material exhibits an air permeability of between .75 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737.

19. A composite material comprising: a shell fiber layer; and a membrane disposed adjacent the shell fiber layer, wherein the composite material exhibits a low range hydrostatic water resistance of above 5000 millimeter as measured using American Association of Textile Chemists and Colorists (AATCC) 127; wherein the composite material exhibits an air permeability of above .25 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737; wherein the composite material exhibits a moisture vapor transmission rate (MVTR) of above 30 kilogram per square meter per 24 hour (kg/sqm/24hr) as measured using Japanese Industry Standards (JIS) L1099-B1.

20. An article comprising the composite material of any one of the preceding claims, wherein the article comprises a garment, gloves, footwear, headwear, bib pants, pants, a jacket, a tent, a sleeping bag, and a backpack.

Description:
COMPOSITE MATERIALS WITH MEMBRANE

BACKGROUND

[0001] Some items, such as snow pants, footwear, tents, etc., may be useful for keeping users comfortable. Keeping users comfortable may comprise keeping users dry from rain, hail, snow, etc. Making items out of material that is sufficiently water-resistant may keep users dry. Keeping users comfortable may comprise allowing hot air to escape so that users may remain cool. Making items out of material that is sufficiently breathable may allow hot air to escape. Improvements are needed.

SUMMARY

[0002] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The example composite material may exhibit a low range hydrostatic water resistance of above 5000 millimeter (mm) as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of above .25 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737. The example composite material may exhibit a moisture vapor transmission rate (MVTR) of above 30 kilogram per square meter per 24 hour (kg/sqm/24hr) as measured using Japanese Industry Standards (JIS) L1099-B1.

[0003] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The example composite material may exhibit a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of between .25 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737. The example composite material may exhibit a moisture vapor transmission rate (MVTR) of between 30 kilogram per square meter per 24 hour (kg/sqm/24hr) and 60Kg/sqm/24hr as measured using Japanese Industry Standards (JIS) L1099-B1.

[0004] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The example composite material may exhibit a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of between .25 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737. The example composite material may exhibit a moisture vapor transmission rate (MVTR) of between 30 kilogram per square meter per 24 hour (kg/sqm/24hr) and 55Kg/sqm/24hr as measured using Japanese Industry Standards (JIS) L1099-B1.

[0005] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The example composite material may exhibit a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of between .75 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737.

[0006] Articles are described herein. An example article may comprise composite material described herein. The example article may comprise a garment, gloves, footwear, headwear, bib pants, pants, a jacket, a tent, a sleeping bag, and a backpack. Other articles may be used.

DETAILED DESCRIPTION

[0007] Composite materials are described herein. The composite materials may be or comprise laminate materials having a plurality of layers. An example composite material may comprise a shell and a membrane. The shell may comprise a shell fiber layer. The shell may comprise various materials such as polymers. The shell may comprise polyester, nylon, recycled polyester, elastane, or combinations thereof. Other materials may be used. The membrane may be or comprise a breathable membrane. The membrane may be or comprise a water proof or water repellant membrane. The membrane may be formed from various process such as fiber spinning (e.g., electrospinning). Together, the shell and membrane may have a fabric weight. Various combinations of shell and membrane weight may be used. The membrane may have a weight of less than 9gsm, less than 8gsm, less than 7gsm, less than 6gsm, less than 5gsm, less than 4gsm, or less than 3gsm. Other weight membranes may be used. The shell and the membrane may be disposed adjacent each other and may be coupled together, for example using adhesive.

[0008] The composites of the present disclosure show improved performance over comparative conventional materials. As shown more clearly in Tables 1-3, the composite materials of the present disclosure are identified using ID’s: LV6W, LV6Z, LV74, LWEN,

LV71, LWEQ, LV75, LWEP, LV7B, LV7D, and LWEO. The comparative examples are identified as A-L. The Appendix, which is hereby incorporate herein by reference in its entirety shows improved performance of the composite materials after 20 launderings.

[0009] Table 1 matches “High”, “Medium”, and “Low” labels for example value ranges for various measurements: [0010] Table 2 shows attributes of various jackets:

[0011] Table 3 shows attributes of various articles:

[0012] Table 4 matches labels shows in Table 1 with jackets identified in Table 2.

[0013] Table 5 matches labels shows in Table 1 with articles identified in Table 3.

[0014] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The shell fiber layer may comprise one or more of nylon, polyester, or elastane. The shell fiber layer may consist essentially of one or more of nylon, polyester, or elastane. The shell fiber layer may comprise about 100 weight percent (wt%) polyester from a total of 100wt% of the shell fiber layer. The shell fiber layer may comprise greater than 90 wt% polyester from a total of 100wt%. The shell fiber layer may comprise about 90wt%, 91wt%, 92wt%, 93wt%, 94wt%, 95wt%, 96wt%, 97wt%, 98wt%, 99wt%. Other loadings may be used. The shell fiber layer may comprise about 58wt% nylon, about 37wt% polyester, and about 5wt% elastane. The shell fiber layer may comprise about 93wt% nylon and about 7wt% elastane. The shell fiber layer may comprise between 50wt% and 100wt% nylon. The shell fiber layer may comprise nylon by weight percent wt% as 51wt%, 52wt%, 53wt%, 54wt%, 55wt%, 56wt%, 57wt%, 58wt%, 59wt%, 60wt%, 61wt%, 62wt%, 63wt%, 64wt%, 65wt%, 66wt%, 67wt%,

68wt%, 69wt%, 70wt%, 71wt%, 72wt%, 73wt%, 74wt%, 75wt%, 76wt%, 77wt%, 78wt%,

79wt%, 80wt%, 81wt%, 82wt%, 83wt%, 84wt%, 85wt%, 86wt%, 87wt%, 88wt%, 89wt%,

90wt%, 91wt%, 92wt%, 93wt%, 94wt%, 95wt%, 96wt%, 97wt%, 98wt%, 99wt% based on

100wt% of the composite material. Other loadings may be used. The shell fiber layer may comprise about 62wt% nylon, about 33wt% polyester, and about 5wt% elastane. The shell fiber layer may comprise about 93wt% nylon and about 7wt% elastane. The shell fiber layer may comprise about 75wt% polyester and about 25wt% nylon. The shell fiber layer may comprise 96% nylon, 4% elastane.

[0015] The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The membrane may be coupled to the shell fiber layer. The membrane may be glued to the shell fiber layer.

[0016] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The example composite material may exhibit a low range hydrostatic water resistance of above 5000 millimeter (mm) as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of above .25 as measured using American Society for Testing and Materials (ASTM) D737. The example composite material may exhibit a moisture vapor transmission rate (MVTR) of above 30 kilogram per square meter per 24 hour (kg/sqm/24hr) as measured using Japanese Industry Standards (JIS) L1099-B1.

[0017] The example composite material may exhibit a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of between .25 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737. The example composite material may exhibit a moisture vapor transmission rate (MVTR) of between 30 kilogram per square meter per 24 hour (kg/sqm/24hr) and 55Kg/sqm/24hr as measured using Japanese Industry Standards (JIS) L1099-B1.

[0018] A fabric weight associated with the example composite material may be between 90 grams per square meter (gsm) and 200gsm. A fabric weight associated with the example composite material may be between 90gsm and 180gsm. A fabric weight associated with the example composite material may be between 91gsm and 177gsm. Other fabric weights and component weights may be used.

[0019] The example composite material may exhibit a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of between .75 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737.

[0020] A fabric weight associated with the example composite material may be between 90 grams per square meter (gsm) and 200gsm. A fabric weight associated with the example composite material may be between 90gsm and 180gsm. A fabric weight associated with the example composite material may be between 91gsm and 177gsm.

[0021] Articles are described herein. An example article may comprise composite material described herein. The example article may comprise a garment, gloves, footwear, headwear, bib pants, pants, a jacket, a tent, a sleeping bag, and a backpack.

Appendix

37 psi