Patent Application
20240328080
This application relates to the field of textiles, and particularly to garments and other articles of apparel designed for heat retention.
It is often desirable for a garment to include thermal regulation features. In some scenarios, it is desirable to provide articles of apparel that provide heat retention properties. For example, athletic performance apparel, including hunting jackets, boots, and other articles of apparel intended for outdoor use may include multiple layers and various materials designed to retain body heat in order to keep the wearer warm in cold weather. It is generally desirable for such garments and other articles of apparel to be relatively light in weight and capable of providing heat retention features without sacrificing other qualities, such as garment breathability and moisture wicking.
Ceramic materials have been used on garments in the past to provide heat retention qualities. Such ceramic materials are typically added as a thin layer to fabric and provide good heat retention features for the garment. Unfortunately, conventional ceramic materials and methods of applying such ceramic materials have diminished garment performance in other areas, including poor breathability and moisture management. In addition, many ceramic materials added to garments have resulted in an undesirable finish and have deteriorated quickly with repeated washing and wear. Furthermore, various alternative materials to ceramics which are capable of providing heat retaining qualities have result in garments with other undesirable qualities. For example, some alternative heat retaining materials provide an undesirable shiny finish on the garment with poor breathability and wash-fastness.
In other scenarios, it is desirable to provide thermal regulation in the form of a cooling effect to facilitate or enhance body cooling to the wearer of a garment or article of apparel. For example, an athlete generates heat as a result of physical activity, where skin and/or core body temperature rise during sustained physical exertion. Failure to properly move heat away from the body during exercise may lead to “overheating,” i.e., a rise in the core body temperature, potentially resulting in adverse health consequences, such as heat exhaustion or heat stroke. Accordingly, performance apparel may be configured to aid in the regulation of body temperature, with its aim being to keep the wearer cool. One approach configures a garment such that it draws moisture away from the skin. Other approaches equip the garment with tubes through which a cooling fluid flows, while still others provide the garment with pockets that receive cooling packs of various materials. These conventional approaches, however, suffer from disadvantages. Absorbent material, while increasing the comfort of the wearer, does not facilitate absorbing of heat. Cooling tubes and packs, while effective cooling mechanisms, add significant weight to the garment.
In view of the foregoing, it would be advantageous to provide garments and other articles of apparel incorporating material(s) for achieving a desired heat retention and/or thermal regulation effect for the wearer in particular scenarios. For example, in cold environment scenarios, it would be desirable to incorporate ceramic materials for heat retention without sacrificing other performance qualities. In warmer environments or scenarios in which the wearer's body temperature may increase due to physical activity (e.g., athletic performance), it would be desirable to provide a lightweight article of apparel effective to cool and/or temper the increase in temperature of the user. It would be advantageous if such garments provided excellent heat retention qualities while retaining good durability, breathability and moisture wicking qualities. Additionally, it would be advantageous if such garments provided a comfortable look and feel for the wearer.
In accordance with at least one embodiment, a method of manufacturing a garment comprises printing a material onto a first side of a fabric to form a printed layer including a plurality of printed segments of the material. Hinges for the fabric are defined by non-printed segments of the fabric that are located between printed segments, and the hinges facilitate folding of the fabric along one or more of the hinges.
In at least another embodiment, a garment comprises a printed layer comprising a material located on a first side of a fabric defining a portion of the garment, the printed layer including a plurality of printed segments of the material. Hinges for the fabric are defined by non-printed segments of the fabric that are located between printed segments, and the hinges facilitate folding of the fabric along one or more of the hinges.
The printed segments can comprise a heat retention material and/or a thermal regulation material.
The above described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. While it would be desirable to provide a garment that provides one or more of these or other advantageous features, the teachings disclosed herein extend to those embodiments which fall within the scope of the appended claims, regardless of whether they accomplish one or more of the above-mentioned advantages.
Example embodiments of garments or articles of apparel incorporating a material as a printed layer along a surface or side of fabric material forming the garment are now described with reference to the drawings. As described herein, the material can comprise a heat retaining or heat retention material (e.g., a ceramic, such as silica) and/or a thermal regulation material including one or more system reactive components so as to achieve heat retaining and/or thermal regulation properties for the garment.
With reference to
As shown in
With continued reference to
In at least one embodiment, the ceramic ink comprises at least two percent ceramic by weight and less than fifty percent ceramic by weight. In at least one embodiment, the ceramic print is provided by an ink comprising between five percent and fifteen percent ceramic by weight, and particularly about ten percent ceramic by weight. The ceramic may be any of various ceramics appropriate for inclusion on a fabric including both oxide ceramics and non-oxide ceramics. In at least one embodiment, the ceramic material in the ceramic print is a high temperature molten silica. However, it will be recognized that the ceramic may be any of various other ceramic materials such as zirconium carbide, aluminum oxide, or any of various other ceramic materials.
As shown in
With reference now to
The house shapes 52 are provided in a nested arrangement 64, as shown in
As shown in
With continued reference to
While the ceramic print 36 has been described herein as covering some percentage of the area on an inner side 24 of the fabric panel 20, it will be recognized that it is desirable to distribute the ceramic print evenly over the coverage area. For example, a ceramic print could cover fifty percent of a fabric panel by covering all of the left side of the panel, but none of the right side. However, it is generally more desirable for the ceramic print 36 to be provided in a pattern that extends over the entire fabric panel 20, while the ink portions 38 of the ceramic print 36 cover only some percentage of the overall fabric panel 20. Accordingly, a print pattern such as that shown in
With reference now to
With continued reference to
At step 106, the printer prints the ceramic ink onto the sheet of fabric according to a predetermined pattern. As a result of the pattern, the printed sheet of fabric will include print covered portions where the ink has been printed on the surface of the fabric, and non-print portions where no ink is on the surface of the fabric. In at least one embodiment, the predetermined pattern is similar to that described above with reference to
Next, in step 108, the fabric with the printed pattern is cut into a shape that forms a fabric panel of a garment or other article of apparel. The fabric panel may be any of various fabric panels for use on the article of apparel, such as fabric panel for a torso portion of a shirt, a fabric panel for a sleeve, a fabric panel for a shoe upper, or any of various other fabric panels.
In step 110, the formed fabric panel is incorporated into a garment. The fabric panel is arranged on the garment such that the ceramic print on the fabric is exposed on the inside of the garment. Placement of the ceramic print on the inside of the garment can have particular advantages as improved heat retention is provided when the ceramic print is provided in direct contact with the skin of the wearer.
The garment 10 with the ceramic print 36 has been demonstrated to provide excellent performance characteristics with respect to heat retention, while also retaining good performance characteristics in other areas such as moisture retention and breathability. One example test illustrating these performance characteristics is provided below.
As previously noted, certain patterns of linear printed segments of ceramic print can be provided so as to impart flexure or hinge lines for the fabric along such printed segments, where the hinge lines are defined by exposed or non-printed areas or segments located between the printed segments.
In general, a printed ceramic pattern can be provided on a fabric panel that includes an arrangement of printed segments spaced apart by non-printed segments, called hinges. Each segment and hinge may possess any dimensions suitable for its intended purpose. In addition, the segments and hinges may be ordered in a manner as previously described herein in relation to
As depicted in
As noted above, the hinges 503, 515, 520 are areas to which no ceramic print has been applied, while the segments 510A-510F of the hexagons 502, 504 are printed areas. Areas that are printed are generally less flexible than non-printed areas. Accordingly, the textile structure (the base fabric) is free to flex along the hinge lines relative to the printed segments. With this configuration, the hinges 503, 515, 520 maintain the fold or drape of the base fabric, allowing it to flex/move along the hinges 503, 515, 520. This can be particularly useful, e.g., in bedding applications (where the fabric panel comprises a bedding component, such as a fitted sheet or a top sheet).
Experiments were conducted on fabrics with the ceramic print as described above in comparison to various commercially available fabrics with or without added heat retention features. These experiments utilized a hot plate to expose the test fabrics to a conductive heat source. First, the test fabrics were cut into appropriate samples sizes (e.g., 5×5 inch fabric swatches) to be tested and then were allowed to condition at 45 degrees Fahrenheit for 24 hours. Next, a copper plate was placed on a hot plate and allowed to heat up to 85 degrees Fahrenheit. After the copper plate was heated to 85 degrees Fahrenheit, the sample fabric was placed on the copper plate and observed with a thermal imaging camera. The samples were exposed to the copper plate for 10 minutes. After this 10 minute duration, the copper plate and fabric sample were moved to a cooling rack away from the heat source. The fabric sample was then observed while cooling for an additional 10 minutes with the thermal imaging camera.
The results of the testing showed that fabrics treated with the ceramic print provided excellent heat retention qualities as well as excellent breathability, wear and wash-fastness. One exemplary test performed according to the above procedure evaluated a standard commercially available fleece fabric in comparison to the same fleece fabric with the above-described ceramic print applied to the fabric. The results of this test are shown in
As an alternative to a ceramic print for the fabric that provides heat retention properties to the fabric, the fabric can include a printed layer comprising a coating that includes system reactive components that are effective to delay/diminish the rise in skin temperature (compared to a garment lacking the coating) and/or improve the overall moisture management capacity of the fabric, either of which may improve wearer comfort. The system reactive components can be applied in a similar manner, e.g., via printing, as a ceramic print so as to form the same or similar types of printed patterns of segments and non-printed areas or segments located between printed segments that function as hinge lines in a similar manner as the ceramic print as described herein.
In an example embodiment, the printed layer comprises a thermal regulation material including one or more system reactive components, where the printed layer is disposed on an inner substrate or fabric surface (i.e., surface of the fabric which, when incorporated into an article of apparel or garment, faces the body of the wearer). The thermal regulation material is effective to alter the temperature regulation and/or moisture management properties of the substrate or fabric layer. By system reactive, it is intended to mean a compound that reacts to environmental conditions within a system. That is, the system reactive materials are selectively engaged in response to conditions of a wearer wearing the article of apparel. In particular, the compound absorbs, directs, and/or mitigates fluid (heat or water) depending on existing system conditions. For example, a component may initiate an endothermic reaction (e.g., when exposed to water). By way of further example, a component may be capable of selectively absorbing and releasing thermal energy (heat). By way of still further example, a component may be capable or conducting and/or directing heat from one location to another location within a system.
The system reactive components can include a cooling agent, a latent heat agent, and/or a heat dissipation agent. The cooling agent is an endothermic cooling agent, i.e., it creates a system that absorbs heat. Specifically, the cooling agent generates an endothermic reaction in aqueous solution, absorbing energy from its surroundings. Accordingly, the cooling agent possesses a negative heat of solution when dissolved in water. By way of example, the endothermic cooling agent possesses a heat of enthalpy in the range −10 cal/g to −50 cal/g. In particular, the endothermic cooling agent possesses a heat of enthalpy in the range −20 cal/g to −40 cal/g. With this configuration, when the cooling agent is contacted by water (i.e., the sweat of the wearer), the cooling agent is capable of cooling (i.e., lowering the temperature of) the water.
The cooling agent may be a polyol. By way of example, the cooling agent includes one or more of erythritol, lactitol, maltitol, mannitol, sorbitol, and xylitol. In an embodiment, the cooling agent is selected from one or more of sorbitol, xylitol and erythritol. Sorbitol is a hexavalent sugar alcohol and is derived from the catalytic reduction of glucose. Xylitol is produced by catalytic hydrogenation of the pentahydric alcohol xylose. Erythritol is produced from glucose by fermentation with yeast. Crystalline xylitol is preferred. The cooling agent may be present in an amount of about 15 wt % to about 35 wt % (e.g., about 25 wt %).
The latent heat agent is capable of absorbing and releasing thermal energy from a system while maintaining a generally constant temperature. In an embodiment, the latent heat agent is a phase change material (PCM). Phase change materials possess the ability to change state (solid, liquid, or vapor) within a specified temperature range. PCMs absorb heat energy from the environment when exposed to a temperature beyond a threshold value, and release heat to the environment once the temperature falls below the threshold value. For example, when the PCM is a solid-liquid PCM, the material begins as a solid. As the temperature rises, the PCM absorbs heat, storing this energy and becoming liquefied. Conversely, when temperature falls, the PCM releases the stored heat energy and crystallizes or solidifies. The overall temperature of the PCM during the storage and release of heat remains generally constant.
The phase change material should possess good thermal conductivity (enabling it to store or release heat in a short amount of time), a high storage density (enabling it to store a sufficient amount of heat), and the ability to oscillate between solid-liquid phases for a predetermined amount of time. Additionally, the phase change material should melt and solidify at a narrow temperature range to ensure rapid thermal response.
Linear chain hydrocarbons are suitable for use as the phase change materials. Linear chain hydrocarbons having a melting point and crystallization point falling within approximately 10° C. to 40° C. (e.g., 15° C. to 35° C.) and a latent heat of approximately 175 to 250 J/g (e.g., 185 to 240 J/g) may be utilized. In particular, a paraffin linear chain hydrocarbon having 15-20 carbon atoms may be utilized. The melting and crystallization temperatures of paraffin linear chain hydrocarbons having 15-20 carbon atoms fall in the range from 10° C. to 37° C. and 12° C.-30° C., respectively. The phase transition temperature of linear chain hydrocarbons, moreover, is dependent on the number of carbon atoms in the chain. By selecting a chain with a specified number of carbon atoms, a material can be selected such that its phase transition temperature liquefies and solidifies within a specified temperature window. For example, the phase change material may be selected to change phase at a temperature near (e.g., 1° C.-5° C. above or below) the average skin temperature of a user (i.e., a human wearer of the apparel, e.g., 33° C.-34° C.). With this configuration, the phase change material begins to regulate temperature either upon placement of the apparel on the wearer or shortly after the wearer begins physical activity.
In an embodiment, the paraffin is encapsulated in a polymer shell. Encapsulation prevents leakage of the phase change material in its liquid phase, as well as protects the material during processing (e.g., application to the substrate) and during consumer use. The resulting microcapsules may possess a diameter of about 1 to about 500 μm. In an embodiment, the paraffin PCM is present in an amount of about 25 wt % to about 45 wt % (e.g., about 35 wt %).
The heat dissipation agent is effective to conduct heat and/or direct heat from one location to another location within the system (e.g., within the thermal regulation printed layer and/or substrate/fabric material). In an embodiment, the heat dissipation agent possesses a high heat capacity, which determines how much the temperature of the agent will rise relative to the amount of heat applied. By way of example, the heat dissipation agent is a silicate mineral such as jade, e.g., nephrite, jadeite, or combinations thereof. The heat dissipation material may be present in an amount (dry formulation) of about 30 wt % to about 50 wt % (e.g., about 40 wt %).
The system reactive components are present with respect to each other in a ratio of approximately 1:1 to 1:2. By way of example, the ratio of temperature reactive components-cooling agent, latent heat agent, and heat dissipation agent—may be approximately 1:2:2, respectively. As indicated above, in system reactive component mixture, the cooling agent is present in an amount of from 15 wt % to 35 wt %; the latent heat agent is present in an amount of from 25 wt % to 45 wt %. Similarly, the heat dissipation agent is present in an amount of from 25 wt % to 45 wt %.
In addition to the temperature reactive components, the thermal regulation material forming the segments of the printed layer further includes a binder effective to disperse the temperature reactive components and/or to adhere the temperature reactive components to the substrate or fabric layer (e.g., to the yarns/fibers forming the fabric). The binder may be an elastomeric material possessing good elongation and tensile strength properties. Elastomeric materials typically have chains with high flexibility and low intermolecular interactions and either physical or chemical crosslinks to prevent flow of chains past one another when a material is stressed. In an embodiment, polyurethane (e.g., thermoplastic polyurethane such as polyester-based polyurethane) is utilized as the binder. In other embodiments, block copolymers with hard and soft segments may be utilized. For example, styrenic block copolymers such as a styrene-ethylene/butylene-styrene (SEBS) block copolymer may be utilized.
Thus, printed segments of the thermal regulation material including one or more system reactive components can be applied via any suitable form of printing process (e.g., via a rotogravure apparatus) so as to define linear printed segments of the thermal regulation material in any suitable shapes and patterns, including patterns as previously described herein and depicted, e.g., in
The patterns of printed linear segments of the thermal regulation material can also impart flex or hinge lines/hinges (where the hinges are defined by the non-printed areas or segments located between the printed segments) for the fabric upon which the pattern is printed in the same or similar manner as described herein for ceramic printed patterns. This facilitates easy folding of fabric portions along such hinges that may be desirable for particular applications.
An example embodiment of a rotogravure apparatus that can be used to apply or imprint a ceramic and/or a thermal regulation material in any suitable patterns including linear printed segments (including patterns as depicted in
The foregoing detailed description of one or more embodiments of garments with ceramics and/or other heat retaining material(s) and methods of making the same are presented herein by way of example only and not limitation. It will be recognized that there are advantages to certain individual features and functions described herein that may be obtained without incorporating other features and functions described herein. Moreover, it will be recognized that various alternatives, modifications, variations, or improvements of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be desirably combined into many other different embodiments, systems or applications.
Furthermore, presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the appended claims. Therefore, the spirit and scope of any appended claims should not be limited to the description of the embodiments contained herein.
This application is a continuation-in-part of U.S. patent application Ser. No. 16/790,556, filed Feb. 13, 2020, which is a divisional of U.S. patent application Ser. No. 15/615,537, filed Jun. 6, 2017, which is a divisional of U.S. patent application Ser. No. 13/618,835, filed Sep. 14, 2012. This application is also a continuation-in-part of U.S. patent application Ser. No. 17/707,147, filed Mar. 29, 2022, which is a divisional of U.S. patent application Ser. No. 16/113,057, filed Aug. 27, 2018, which claims priority to U.S. Provisional Patent Application Ser. No. 62/550,678, filed Aug. 27, 2017. This application is further a continuation-in-part of U.S. patent application Ser. No. 18/340,948, filed Jun. 26, 2023, which is a continuation of U.S. patent application Ser. No. 17/356,824, filed Jun. 24, 2021, which is a continuation of U.S. patent application Ser. No. 16/038,241, filed Jul. 18, 2018, which is a divisional of U.S. patent application Ser. No. 14/507,270, filed Oct. 6, 2014, which claims priority to U.S. Provisional Patent Application Ser. No. 61/886,835, filed Oct. 4, 2013. The disclosures of the aforementioned applications are all incorporated herein by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 62550678 | Aug 2017 | US | |
| 61886835 | Oct 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15615537 | Jun 2017 | US |
| Child | 16790556 | US | |
| Parent | 13618835 | Sep 2012 | US |
| Child | 15615537 | US | |
| Parent | 16113057 | Aug 2018 | US |
| Child | 17707147 | US | |
| Parent | 14507270 | Oct 2014 | US |
| Child | 16038241 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17356824 | Jun 2021 | US |
| Child | 18340948 | US | |
| Parent | 16038241 | Jul 2018 | US |
| Child | 17356824 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16790556 | Feb 2020 | US |
| Child | 18740700 | US | |
| Parent | 17707147 | Mar 2022 | US |
| Child | 18740700 | US | |
| Parent | 18340948 | Jun 2023 | US |
| Child | 18740700 | US |
