Note: Descriptions are shown in the official language in which they were submitted.
WO 2009/048504 CA 02701064 2010-03-26PCT/US2008/010820
TITLE OF THE INVENTION
COMFORTABLE PROTECTIVE GARMENTS
FIELD OF THE INVENTION
This invention relates to garment constructs and garments
prepared therefrom having a functional layer and an inner layer formed
of a plurality of textiles, at least two of which are dissimilar textiles,
adhered to the functional layer. In some embodiments, the garment
constructs or garments prepared therefrom have an outer layer adhered
to the side of the functional layer opposite to the inner layer.
BACKGROUND OF THE INVENTION
Garments have been described having an outer protective layer
ordinarily permeable to liquid water and a waterproof breathable layer
affixed inside the outer layer. Optionally, these constructs are provided
with an adjacent, but not affixed, inner liner textile.
Garments have also been constructed using a waterproof lining,
generally formed from pattern pieces cut out of sheets and then joined
together at seams, typically by sewing. This lining is generally loosely
disposed against the inner side of the outer layer. However, air gaps
between the outer layer and the waterproof lining reduce water vapor
permeability and heat transmission. Further, all sewn seams must be
water-proofed by providing seam tape over the seam on the surface of
the functional waterproof layer.
Garments have been described wherein the outer material is
adhered to the functional waterproof layer before pattern pieces of the
garment are cut out. In this embodiment, the functional layer must have
as many perforating seams as are required for the outer material
including decorative seams and seams required for appliqués. Thus, the
lining side of these garments contains a large number of seam sealing
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tapes which are unattractive, create friction upon contact with the body
and can become detached upon rubbing against the body.
Articles of the present invention have been described containing
an outer material part adhered via a continuous or discontinuous
adhesive layer to a functional layer part composed of a plurality of pieces
of waterproof, water-vapor-permeable functional materials. The outer
material and functional material composites are joined together by
stitched seams which are each waterproofed by waterproof seam sealing
tape placed on the functional layer surface oriented towards the outer
material part.
SUMMARY OF THE INVENTION
An aspect of the present invention relates to garments or garment
panels comprising a functional layer having a first side and a second
side; an inner textile layer comprising a plurality of dissimilar textile
pieces forming a non-homogenous surface; and a discontinuous
adhesive layer which affixes the inner textile layer to the first side of the
functional layer. The dissimilar textile pieces of the inner textile layer can
be abutted to each other or have at least portions of which are free of
contact with each other.
The garment or garment panel may further comprise an outer
textile layer affixed to the second side of the functional layer. This outer
textile layer may be seamless or may comprise a plurality of dissimilar
textile pieces abutted together to form a non-homogenous surface.
Another aspect of the present invention relates to garments or
garment panels comprising a functional layer having a first side and a
second side; an inner textile layer comprising a plurality of dissimilar
textile pieces forming a non-homogenous surface; and a discontinuous
adhesive layer which affixes the inner textile layer to the first side of the
functional layer.
Another aspect of the present invention relates to a method of
making a garment construct. In this method, a functional layer having a
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first side and a second side and an outer perimeter is provided. An inner
textile layer comprised of a plurality of textile pieces, at least two of
which
are dissimilar is then affixed to the first side of the functional layer via a
discontinuous layer of adhesive to form a non-homogenous surface. In
some embodiments, this method further comprises affixing an outer
textile layer with an outer perimeter to the second side of the functional
layer.
Yet another aspect of the present invention relates to a method of
making a garment. In this method, a functional layer with a first side and
a second side is provided. An outer textile layer is affixed to the second
side of the functional layer to create an outer shell or bond shell material
or laminate. The outer shell material is then cut to form garment
constructs. A plurality of textile pieces at least two of which are
dissimilar are also provided for an inner layer of the garment construct.
The inner layer textile pieces are cut to form a desired pattern. These
inner layer textile pieces are then affixed in the desired pattern to the
first
side of the functional layer of the outer shell garment or garment panel
via a discontinuous adhesive layer. These garment constructs are
assembled via seams to form a finished garment.
BRIEF DESCRIPTION OF THE FIGURES
Figure 1 is a side view of the layers in an exemplary bondable
shell useful in producing garments or garment panels in accordance with
of the present invention.
Figure 2 is a side view of the layers of a bondable shell wherein
the layer of discontinuous adhesive in the form of dots is first applied to a
release layer and subsequently transferred to the first side of the
functional layer.
Figure 3 is a side view of the layers of a garment construct
created with a bondable shell and two dissimilar liner textiles.
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Figure 4 is a side view of the layers of an exemplary garment
portion formed with an inner textile layer and comprising a sewn-on
pocket.
Figure 5 shows a side view of the layers of an exemplary garment
or garment panel formed using an inner textile layer comprised of a
plurality of dissimilar textile pieces, namely an insulation-filled textile
and
a second textile.
Figure 6 shows a top view of a garment or garment portion formed
using textile liners having different stretch characteristics.
Figure 7 shows a side view of a garment or garment panel formed
using inner textile pieces having different air permeabilities.
Figure 8 is a top view of a garment or garment portion having a
plurality of dissimilar textile pieces forming an inner textile layer which
covers at least a portion of the bondable shell having a functional layer.
Figure 9 shows a side view of an exemplary seam sealed garment
or garment panel formed by affixing a bondable shell to a liner
comprising multiple dissimilar textiles.
Figure 10 shows a cross section of a drawstring tunnel.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides durably waterproof, highly
breathable multilayered garment constructs with improved design
freedom for garment production. The present invention also relates to
methods for producing these garment constructs and garments thereof.
By "bondable shell" as used herein it is meant at least one textile
or non-textile material which is able to be bonded to an inner lining or
other layer. Preferably the bondable shell further comprises a functional
layer and adhesive.
By "garment construct" as used herein it is meant one or multiple
joined panels of textile laminates which, upon assembly, make up a
finished garment.
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By "textile laminate" as used herein it is meant a textile or a
plurality of textile pieces adhered to a functional layer.
By "textile" as used herein it is meant any wovens, nonwovens,
felts, knits, natural fiber materials, synthetic fiber materials and is
inclusive of, but not limited to leathers, vinyls, or other protective
materials useful in garment construction.
By "dissimilar textile pieces" as used herein it is meant two or
more textile pieces exhibiting different textile characteristics including,
but not limited to, material contents, thicknesses, breathability
characteristics, waterproof characteristics, insulation, and other
measurable textile characteristics. A plurality of dissimilar textile pieces
is two or more.
By "non-homogenous surface" as used herein it is meant the
surface topography resulting from the joinder of two or more dissimilar
textile pieces.
By "discontinuous adhesive" as used herein it is meant the
adhesive is disposed in any manner that does not fully cover or coat a
given side of a functional layer textile, or textile layer, including, but not
limited to, discrete adhesive dots, lines of adhesive, adhesive grid
patterns, random adhesive patterns, or any other arrangement that
bonds the inner textile pieces to the first side of the functional layer so
that the largest distance between any two adjacent bond points is less
than 2cm. The close proximity of bond points ensures intimate contact
between the bonded layers.
The present invention provides garment constructs useful in the
production of garments.
A garment or garment panel of the present invention comprises a
functional layer. The functional layer 7 preferably comprises at least one
material which is waterproof or waterproof and breathable, the functional
layer 7 can be a single material or a combination of materials. Examples
of materials which may be present in the functional layer include, but are
not limited to microporous polytetrafluoroethylene (PTFE) membranes,
dense PTFE, or PTFE membrane coated with protective coatings such
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as polyurethanes, or polyolefin films, polyurethane films, silicone and
silicone-containing films, polyester films, as well as other fluoropolymer
containing films such as skived PTFE and fluorinated ethylene propylene
(FEP), composite barrier membranes, composites having microporous
polytetrafluoroethylene (PTFE) membranes. The functional layer 7 is
preferably a seamless layer or a membrane layer of fewer pieces than
either the outer shell or the inner layer of the garment construct to reduce
the required seam sealing needed.
The garment or garment panel of the present invention further
comprises an inner textile layer. The inner textile layer comprises a
plurality of textile pieces, at least two of which are dissimilar, thereby
forming a non-homogenous surface. Examples of dissimilar textile
pieces useful in this layer include, but are not limited to textiles such as
lightweight knits, heavyweight knits, fleeces, wovens, batting, such as
Primaloft insulation, or down-filled baffle chambers with our without
quilting, other thermally insulating materials, and foams. The dissimilar
textile pieces of the inner textile layer can be abutted to each other or
can be free of contact with each other. The inner layer of the garment or
garment panel may cover all or a portion of the functional layer.
The ability to use dissimilar textile pieces in the inner layer of the
garment constructs of the present invention provides for more flexible
and stylish design of garments with targeted regions of breathability,
stretch, warmth, softness and/or aesthetics integrated into the garment
upon its production.
The garment or garment panel further comprises a discontinuous
adhesive 10 layer which affixes the inner textile layer to a first side of the
functional layer. This discontinuous adhesive 10 layer of the garment or
garment panel is preferably a re-meltable adhesive. The adhesive used
for the present invention can be applied in either a discontinuous or
continuous pattern. In order to maintain breathability when a continuous
adhesive pattern is used, the adhesive must be breathable. If a
discontinuous adhesive 10 pattern is used, the adhesive 10 can be either
breathable or non-breathable. Because a discontinuous pattern of hot
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meltable adhesive dots can be applied by a variety or methods, the
specific hot melt adhesive should be chosen so that its rheological
characteristics match those required by the application process as well
as by the end application. For instance, in garment applications, the hot
melt adhesive should have a remelt temperature higher than that of
consumer garment heat cycles such as home laundry, home drying, dry
cleaning, and ironing. In addition, the hot melt adhesive should have a
remelt temperature low enough to minimize damage to textiles (e.g.
glazing, chemical breakdown, dye transfer or shade change.) Given
these upper and lower temperature constraints, the hot melt adhesive
ideally has a softening point between 170 degrees Fahrenheit and 350
degrees Fahrenheit. Meltable polyurethane adhesives which are
suitable for this application can be formulated in accordance with United
States Patent Number 4,814,412 or are commercially available from
various suppliers such as Bostick, Noveon, and other polyurethane
adhesive suppliers.
In one embodiment, the garment or garment panel further
comprises an outer textile layer 15 affixed to the second side of the
functional layer. Examples of outer textile layers include, but are not
limited to wovens, knits, non-wovens, The outer textile layer 15 may be a
seamless layer of the garment or garment panel or may comprise a
plurality of dissimilar textile pieces abutted together to form a non-
homogenous surface. The functional layer 7 and the outer textile layer
15 of the garment or garment panel are preferably aligned so that the
outer perimeter of the functional layer 7 and the outer perimeter of the
outer textile layer 15 are coincident with each other.
The garment or garment panel of the present invention is useful in
production of simple and stylish garments which are preferably light-
weight, waterproof and breathable as well as aesthetically pleasing on
the inside and outside of the garment. The ability to use dissimilar textile
pieces in the inner layer allows flexibility in production of garments with
targeted regions of breathability and/or warmth through use of dissimilar
textile regions of, for example, down-filled baffles, polyester batting
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insulation, fleece, light-weight knits, heavy-weight knits, wovens, and/or
no textile at all.
The garment or garment panel of the present invention is
additionally useful in production of garments having regions of specific
functionality. For example, the inner textile layer may comprise a
dissimilar textile piece having a low-wicking property located in chosen
regions as to provide low wicking to the garment or garment panel and/or
finished garment. Low wicking may be desirable around garment
openings including, but not limited to the sleeve cuffs, garment hemline,
and collar regions. In yet another permutation of this invention, inner
textile pieces containing an anti-microbial agent or anti-odor agent can
be incorporated into the inner textile layer so that the resulting garment
provides odor control in specific areas including but not limited to the
underarms, and other high perspiration areas.
In another embodiment, the present invention can be useful to
impart varying stretch characteristics within a garment construct. By
providing stretch textile pieces as part of inner textile layer, a garment or
garment panel can be made which has differing stretch characteristics
within a garment construct. Thus, this invention allows designers to make
protective garments with longitudinal stretch in some regions, transverse
stretch in other regions, bi-directional stretch in yet other regions, and no
stretch in yet other regions. Thus, protective garments with varied
regional stretch are able to be created without the use of seams 23 in the
protective layer.
The present invention further allows the inner layer of a garment
to be assembled into a finished lining for the garment independent of the
exterior shell of the garment. The advantage to this is that the lining and
the exterior shell may then be placed into relative contact with each other
and heat and pressure can be used to set the liner to the exterior shell.
It is a surprising result to be able to easily form a garment with
waterproof or liquid proof seams 23 and a customizable lining. Other
benefits include but are not limited to performance mapping of the
outside of the garment by the use of materials having low and high
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abrasion characteristics without affecting the interior mapping of
comfort/insulation. Also, color blocking designs can be done on the
outside of a garment without disrupting the inner textile layer design.
Figure 1 is a side view of the layers in an exemplary bondable
shell 5 useful in producing garments or garment panels in accordance
with of the present invention. In this embodiment, the bondable shell 5
comprises an outer textile layer 15 affixed to the second side 9 of a
functional layer 7. In this embodiment, a layer of discontinuous adhesive
in the form of dots is applied to the first side of the functional layer 7
for further affixing of an inner textile layer having a plurality of textiles,
at
least two or which are dissimilar, thereto.
Figure 2 is a side view of the layers and a method of producing a
bondable shell 5 wherein the layer of discontinuous adhesive 10 is
shown as dots and is first applied to a release layer 17 and subsequently
transferred to the first side 8 of the functional layer 7, the second side 9
of which is optionally affixed to an outer textile 15 layer. The release
layer is removed after the discontinuous adhesive is affixed to the
functional layer.
Figure 3 is a side view of the layers of an exemplary bondable
shell 5 comprising an outer textile layer 15 and a functional layer 7 and
having a discontinuous adhesive 10 useful to affix an inner textile layer
20. In this embodiment, an inner textile layer 20 comprised of a plurality
of dissimilar textile pieces are affixed via discontinuous adhesive 10 to
the first side 8 of the functional layer 7.
Figure 4 is a side view of the layers of an exemplary garment
portion formed with an inner textile layer 20 and comprising a sewn-on
pocket 22. The inner textile layer 20 is then affixed via discontinuous
adhesive 10 to the first side of the functional layer 7. The functional layer
with adhesive dots, and outer textile layer 15 are joined to form a
bondable shell 5. This construction of a garment or garment panel
enables the pocket 22 to be sewn to the inner textile layer and then
joined to the bondable shell 5 without requiring the stitch 21 to penetrate
the functional or liquid-proof membrane layer.
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Figure 5 shows a side view of the layers of an garment or garment
panel formed using an inner textile layer 20 comprised of a plurality of
dissimilar textile pieces, namely an insulation-filled textile 18 and a
second textile 19. As illustrated the insulation-filled textile 18 is formed
having multiple insulation-filled chambers 24. The chambers 24 are
formed of at least two similar or non-similar textiles with seams 23 which
may be stitched, glued or welded to house the insulation. The insulation-
filled liner is then affixed via discontinuous adhesive 10 to one side of the
functional layer 7, thereby avoiding penetration of the functional layer 7
by the seams used to form the chambers, and incorporating the
chambered liner onto a bondable shell 5 to create a desired garment or
garment panel.
Figure 6 shows a top view of an exemplary garment or garment
portion having an inner textile layer 20 formed using textiles 19 having
different stretch characteristics. By combining non-stretch textiles and
stretch textiles for the dissimilar textile pieces used to form a textile
layer,
an inner textile liner can be created having different amounts of stretch
and different stretch orientations. The inner textile layer 20 formed in this
embodiment is then affixed via discontinuous adhesive 10 to the first side
of the functional layer 7, thereby avoiding penetration of the functional
layer. The functional layer is shown bonded to an outer textile layer 15.
Figure 7 shows a side view of an exemplary garment or garment
panel formed with an inner textile layer 20 having textile pieces each
having different air permeability rates. By combining low air permeability
textiles and high air permeability textiles as dissimilar textile pieces used
to form a textile layer, an inner textile liner is created having regions with
differing air permeability rates affixed to a water-resistant membrane
barrier or functional layer 7 and an outer textile layer 15 to form a
garment or garment portion having regions of differing air permeabilities.
Figures 8A and 8B are views of an exemplary garment or garment
portion having a plurality of dissimilar textile pieces forming an inner
textile layer 20 which covers at least a portion of the bondable shell 5
having a functional layer. It may be desirable to have more than half of
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the bondable shell 5 covered with the inner textile layer 20 for certain
apparel. Figure 8 illustrates an embodiment having approximately 70% of
the bondable shell 5 covered with the inner textile layer.
Also provided is a process for production of a garment of the
present invention. The bondable shell 5 as described in Figure 1 may be
provided as a roll or in a sheet form. Garment constructions are formed
from the bondable shell 5 laminate. It may be desirable to provide at
least two different textiles on rolls for the inner textile layer. Dissimilar
textile pieces are then assembled into desired inner textile layers. The
outer shell garment constructions to which the inner textile layers are
affixed may be constructed independent of the inner layer constructions.
Alternatively panels may be constructed which comprise at lease inner
textile layers and outer textile layers, so that the panels may be
assembled into a final form creating a garment or article. Optionally, the
textile layers may be left unsealed about the borders or portions of the
borders to form sealing regions on the borders. For waterproof garment
construction, seam tape can be applied to the sealing regions at the
junctions of garment constructs. Advantages in this construction model
of the present invention include the desirability of creating an interior
design which is de-coupled from exterior design. Less seam tape is
required which leads to lighter weight and less bulk in the final garment
for any given amount of liner pieces.
Figure 9 shows a side view of an exemplary seam sealed garment
or garment panel formed by affixing a bondable shell 5 to an inner textile
layer 20 or liner comprising multiple dissimilar textiles. In this example,
the bondable shell 5 was sewn and then a seam seal reinforcement 26
or tape was applied over the seam 23. The inner textile layer 20 was
affixed (using adhesive) as shown so that the inner textile layer 20
overlapped the seam tape and was joined contiguously to an adjacent
inner textile layer 20 thereby making the seam tape not visible upon
viewing the inner textile layer. This construction technique enables the
creation of seam sealed articles wherein the seam sealing means are not
visible when viewed from the inner textile layer 20 side.
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Figure 10 illustrates a useful means to secure accessories
including but not limited to pockets and draw cord tunnels for draw cords
100 to the inside of garments. By affixing the accessory (e.g., pocket 22
or draw cord tunnel or the like) to a piece of textile 19, and subsequently
incorporating this piece of liner textile into the inner textile layer, the
accessory is able to be affixed (as shown here via stitches 21) to the
inner textile layer of the garment construct as one of a plurality of
dissimilar textile pieces forming a part an inner textile layer 20. The inner
textile layer 20 is then bonded via discontinuous adhesive 10 dots to the
at least a portion of the bondable shell 5. The bondable shell preferably
comprises a functional layer 7 which is laminated via a lamination
adhesive 150 to the outer textile layer 15. The present invention may be
used to affix accessories to either side of the functional layer.
Furthermore, accessory attachment via the present invention avoids the
need for seam sealing any stitching which might conventionally be used
to sew the accessory to the textile laminate. Moreover, the reinforcing
nature of the inner textile layer 20 enables the accessory to have greater
durability than if attached directly to the functional layer.
TESTS
Suter Test for Liduidproof Seams
To determine whether a protective barrier fabric or the seams of a
garment made from the protective barrier fabric are waterproof, the Suter test
procedure is used, which is based generally on the description in ISO 811-
1981. This procedure provides a low pressure challenge to the sample being
tested by forcing water against one side of the test sample and observing the
other side for indication that water has penetrated through the sample.
The sealed seam test sample is clamped and sealed between rubber
gaskets in a fixture that holds the sample so that water can be applied to an
area of the sample 3 inches in diameter (7.62 cm). The water is applied under
air pressure of 1 psig (0.07 bar) to one side of the sample. In testing a
fabric
laminate, the water would be applied to the face or exterior side. In testing
a
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sealed seam, water is applied to the face side of the sample and the opposite
side, or seam backer layer, is observed for leaks.
The opposite side of the sample is observed visually for any sign of
water appearing (either by wicking or the appearance of droplets) at the seam
edge for 3 minutes. If no water is observed, the sample has passed the test
and the sample is considered liquidproof.
Test for Durably Liquidproof Seams
To determine the durability of a liquidproof seam, the seam sample is
washed and dried generally following the conditions outlined in ISO 6330:1984
Procedure No. 3B. Specifically, the sample is loaded in a 4 pound (about 2 Kg)
load of laundry into a top loading washing machine set to a medium water level
(18 gallons, or equivalently 0.0681 m3), hot water temperature (140 F, or
equivalently, 60 C), warm rinse cycle and heavy duty wash cycle set for 10
minutes, with 90 g of TIDE powdered laundry detergent. The load is then
dried in a rotating dryer on a Hot setting for a 35-45 minute drying time.
This
wash/dry regimen is repeated five times.
The seam sample is then subjected to the Suter Test for Liquidproof
Seams, described above. If no water is observed upon testing, the sample has
passed the test and the sample is considered durably liquidproof.
Test for Moisture Vapor Permeabiltv
Moisture vapor transmission rates (MVTRs) were determined using the
procedure set forth in U.S. Pat. No. 4,862,730 using potassium acetate as the
salt and open pore ePTFE for the waterproof moisture vapor permeable
membranes. These membranes nominally had a porosity of between 75% and
80%, average pore size of 0.2 um, with a thickness of approximately 0.04 mm.
The environment was maintained at 50% relative humidity. The water bath was
maintained at 23 0.5 C. The samples were constrained in a 3" (about 7.5 cm)
diameter plastic hoop and placed on the bath with woven shell fabric facing
up.
The purpose of using the plastic hoop was to avoid any buckling of the sample.
The samples were conditioned on the bath with the salt cup on top for about 15
minutes before starting the test. The MVTR number is reported in the unit of
g/m2/day.
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The following non-limiting examples are provided to further
illustrate the present invention.
EXAMPLES
Example 1:
A seamless garment or garment panel having a liner layer with a
plurality of dissimilar textiles with varying moisture vapor permeability
was formed in the following manner:
A two-layer textile laminate was formed comprising a composite
barrier membrane as the functional layer laminated to a textile layer. In
this exemplary embodiment, the composite barrier membrane was a
composite of microporous polytetrafluoroethylene (PTFE) membrane
coated with a polyurethane, prepared according to U. S. Patent No.
4,194,041 using a water vapor permeable, nonporous polyurethane
coating on the ePTFE. This membrane was laminated on one side,
using a plurality of dots of moisture curable polyurethane adhesive, to a
polyester woven textile layer approximately 0.4 mm thick and having a
weight of approximately 100 grams per square meter. The other side of
the membrane was coated with a discontinuous thermoplastic
polyurethane adhesive 10 using a plurality of dots. A first panel having
rough dimensions of about 0.6 m by 0.6 m was then cut from this
adhesive 10 backed laminate.
A second panel with approximate dimensions of 0.306 m by 0.3 m
was cut from a polyester fleece textile approximately 1.3 mm thick and
having a weight of approximately 160 grams per square meter
A third panel with approximate dimensions of 0.306 m by 0.3 m
was cut from a polyester tricot knit textile approximately 0.2 mm thick
and having a weight of approximately 80 grams per square meter.
The second and third panel were then joined to create a fourth
panel at their respective edges by ultrasonically welding in a straight line,
6 mm from the panel edge, using a Sonobond Ultrasonic Welding
machine (Model No. SM86, Sonobond, PA).
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The fourth panel consisting of two discrete regions, was then
disposed on the thermoplastic adhesive 10 side of the first laminate
panel such that the edges of the first and fourth panel were coincident.
This panel was placed in a large format heat press (Maxipress Automatic
Air Operated Large Format Press, Model No. MAXI-3048AP, Geo Knight
and Co Inc., Brockton, MA) and pressed at 165 C for 2 minutes, creating
a single seamless garment or garment panel with two discrete dissimilar
textiles on the liner side. Each textile region of this sheet was then
tested using the Test for Moisture Vapor Permeability, and found to have
two distinct regions of moisture vapor permeability.
Example 2:
A seamless garment or garment panel having a liner layer with a
plurality of dissimilar textiles with varying moisture vapor permeability, a
functional layer 7 comprising a composite membrane barrier, and a
sealing region was formed in a manner substantially as described in
Example 1, with the following exceptions:
The second panel was formed with approximate dimensions of
0.289 m by 0.283 m.
The third panel was formed with approximate dimensions of 0.289
m by 0.283 m.
The fourth panel consisting of two discrete textile regions was
disposed on the thermoplastic adhesive 10 side of the first textile
laminate panel such that the edges of the first and fourth panel were not
coincident. Specifically, the edges of the fourth panel were 17 mm from
the edges of the first panel, leaving an exposed region of the composite
barrier membrane of the first panel 17 mm wide around the perimeter of
the bonded panel, referred to herein as the sealing region. Each textile
region of this sheet was then tested using the Test for Moisture Vapor
Permeability, and found to have two distinct regions of moisture vapor
permeability.
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Example 3:
A waterproof seam was formed between two garment constructs
having liner layers with a plurality of dissimilar textiles of varying
moisture
vapor permeability in the following manner:
Two seamless garment constructs, each having a plurality of .
dissimilar textiles of varying moisture vapor permeability and a functional
layer 7 comprising a composite membrane barrier were formed by the
method described in Example 2.
The textile laminate panels were then joined at one of their
respective sealing regions by sewing in a straight line, 6 mm from the
panel edge, using a Juki sewing machine (Model No. DLN-415-5, Juki
Corporation, Tokyo, Japan), set to 5.1 stitches per cm, followed by
trimming of 4 mm off the seam allowance to ensure that the edge of the
resultant 2 mm seam allowance was at least 4 mm from the edge of the
textile laminate panels in either of the non-sealing regions.
A 22 mm width seam tape (GORE SEAM seam tape obtained
from W.L. Gore and Associates, Elkton, MD), having a hot melt
polyurethane adhesive, was then applied to the sealing region by heating
the seam tape to a temperature sufficient to melt the polyurethane
adhesive 10 and passing the tape and seam through the nip of a pair of
pressure rollers in order to squeeze the molten adhesive 10 onto the
functional layer 7 surface so as to ensure good bonding of the tape to the
surface. The tape width was such that it covered the entire sealing
region and extended about 5 mm beyond the sealing region on each
laminate panel. The resulting seam between the two laminate panels
was tested using the Suter Test for Liquid-proof Seams and determined
to be liquid-proof based on passage of a 0.07 bar/3 minute challenge.
The seam was then subjected to the Test for Durably Liquid-proof
laminate, and after the washing regimen, the sample again passed the
0.07 bar/3 minute challenge.
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Example 4:
A seamless waterproof garment or garment panel containing a
sewn pocket 22on one side which does not compromise the liquid-
proofness of the waterproof garment or garment panel was formed in the
following manner:
A two-layer textile laminate was formed comprising a functional
layer 7 of composite barrier membrane laminated to a textile layer. The
composite barrier membrane was a composite of microporous
polytetrafluoroethylene (PTFE) membrane coated with a polyurethane,
prepared according to U. S. Patent No. 4,194,041 using a water vapor
permeable, nonporous polyurethane coating on the ePTFE. This
membrane was laminated on one side, using a plurality of dots of
moisture curable polyurethane adhesive, to a polyester woven textile
layer approximately 0.4 mm thick and having a weight of approximately
100 grams per square meter. The other side of the membrane was
coated with a discontinuous thermoplastic polyurethane adhesive 10
comprising a plurality of dots. A first panel having rough dimensions of
about 0.6 m by 0.6 m was then cut from this adhesive 10 backed
laminate.
A second panel with approximate dimensions of 0.6 m by 0.6 m
was cut from a polyester fleece textile approximately 1.3 mm thick and
having a weight of approximately 160 grams per square meter.
A third panel with approximate dimensions of 0.1 m by 0.15 m
was also cut from the same polyester fleece textile
The third panel was then attached to the second panel by sewing
in straight lines around 3 edges of the perimeter of the third panel, 6 mm
from the panel edge, using a Juki sewing machine (Model No. DLN-415-
5, Juki Corporation, Tokyo, Japan), set to 5.1 stitches per cm, thus
forming a pocket on the third panel.
The third panel was then disposed on the thermoplastic adhesive
side of the first textile laminate panel such that the edges of the first
and third panel were coincident. This panel was placed in a large format
heat press (Maxipress Automatic Air Operated Large Format Press,
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Model MAXI-3048AP, Geo Knight and Co Inc., Brockton, MA) and
pressed at 165 C for 2 minutes, creating a seamless waterproof panel
containing a on the fleece side. The resulting laminate panel with
attachment was tested using the Suter Test for Liquid-proof Seams and
determined to be liquid-proof based on passage of a 0.07 bar/3 minute
challenge.
Example 5:
A waterproof down-filled garment or garment panel was formed by
the following method:
A two-layer textile laminate was formed comprising a functional
layer 7 of composite barrier membrane laminated to a textile layer. The
composite barrier membrane was a composite of microporous
polytetrafluoroethylene (PTFE) membrane coated with a polyurethane,
prepared according to U. S. Patent No. 4,194,041 using a water vapor
permeable, nonporous polyurethane coating on the ePTFE. This
membrane was laminated on one side, using a plurality of dots of
moisture curable polyurethane adhesive, to a Polyester woven textile
layer approximately 0.4 mm thick and having a weight of approximately
100 grams per square meter. The other side of the membrane was
coated with a discontinuous thermoplastic polyurethane adhesive 10
comprising a plurality of dots. A first panel having rough dimensions of
about 0.6 m by 0.6 m was then cut from this adhesive 10 backed
laminate.
A second panel with approximate dimensions of 0.6 m by 0.6 m
was cut from a polyester tricot knit textile approximately 0.2 mm thick
and having a weight of approximately 80 grams per square meter.
A third panel with approximate dimensions of 0.6 m by 0.6 m was
cut from a nylon "down proof" woven textile approximately 0.15 mm thick
and having a weight of approximately 50 grams per square meter
The second and third panels were then attached along their
respective perimeters to form a fourth panel using a Juki sewing machine
(Model No. DLN-415-5, Juki Corporation, Tokyo, Japan), set to 5.1
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stitches per cm, leaving an unstitched portion of the perimeter
approximately 0.1 m in length, thus forming a space between the second
and third panels.
The space between the second and third panels was then filled
with down feathers, and the remaining 0.1 meters of the perimeter were
sewn shut to contain the down feathers between the two panels.
Straight lines were then stitched through this new panel using a
Juki sewing machine (Model No. DLN-415-5, Juki Corporation, Tokyo,
Japan), set to 5.1 stitches per cm, at an approximate spacing of 0.1 m, to
create down filled baffles.
The down filled, baffled, fourth panel was then disposed on the
thermoplastic adhesive 10 side of the first laminate panel with the tricot
knit oriented to the thermoplastic such that the edges of the first and
fourth panel were coincident. This panel was placed in a large format
heat press (Maxipress Automatic Air Operated Large Format Press,
MAXI-3048AP Geo Knight and Co Inc., Brockton, MA) and pressed at
165 C for 2 minutes, to create a down-filled garment construct.
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