BREATHABLE HYDROSTATICALLY-RESISTANT STRUCTURES

Abstract

The invention provides a breathable structure that includes a fibrous substrate and a cross-linked polymer that contains hydrophobic moieties. The fibrous substrate contains a plurality of fibers, and the cross-linked polymer coats portions of the plurality of fibers.

Description

FIELD OF THE INVENTION

The present disclosure generally relates to breathable structures (e.g. textile materials) having desirable hydrostatic resistance.

BACKGROUND OF THE INVENTION

Outdoor enthusiasts and others have long demanded functional articles, such as water-resistant outerwear, to protect them from the elements. Typically, this demand has been met by structures such as fabric or insulation having water-proof or water-repellent films or membranes laminated thereto. Such films/membranes impart improved hydrostatic resistance to structures, making them effective at preventing or reducing the ability of water to penetrate through the structure to the wearer. However, to maintain comfort, in addition to inhibiting water reaching the body from outside clothing, a water-repellent or water-proof article should also be able to remove vapor produced by the body (e.g., during physical exertion). Unfortunately, although such articles are often classified as being breathable, they in fact do not offer significant moisture vapor transport. Exceptions include certain monolithic membrane films, which are used as breathable barriers in textile structures such as outerwear. Such monolithic membranes promote the permeation of water vapor from within a structure through the use of a hydrophilic polymer layer which absorbs the water vapor and transmits it to the external environment. However, monolithic membranes typically experience significant swelling of the hydrophilic layer, which significantly alters the vapor removal characteristics of the membrane and user comfort.

Thus, generally speaking, there is an inverse relationship between the level of an article's hydrostatic resistance and its ability and to permit the escape of vapor from within. Consequently, the tradeoff for water-resistant articles is compromised performance characteristics, such as comfort and breathability. Further, many breathable articles tend to have very limited insulating properties. Still further, fibrous substrates (e.g., fabrics) laminated to certain membrane types tend to be inflexible and/or generate noise when in use. Accordingly, despite claims, many waterproof and water-repellant articles tend to suffer from less-than desirable attributes, including limited insulative properties, and undesirable moisture vapor transmission rates and air permeability.

Thus, a need remains for breathable structures useful, e.g., in outerwear articles, that offer desirable hydrostatic resistance without unduly compromising other properties, such as moisture vapor transmission rates and air permeability.

While certain aspects of conventional technologies have been discussed to facilitate disclosure of the disclosure, Applicant in no way disclaims these technical aspects, and it is contemplated that the claimed disclosure may encompass one or more of the conventional technical aspects discussed herein.

In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was, at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY OF THE INVENTION

Briefly, the present invention satisfies the need for breathable structures that offer desirable hydrostatic resistance without unduly compromising other properties, such as moisture vapor transmission rates and air permeability. The present disclosure may address one or more of the problems and deficiencies of the art discussed above. However, it is contemplated that the invention may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claimed invention should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.

Certain embodiments of the presently-disclosed breathable structures, articles comprising the breathable structures, and methods for making the breathable structures have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the structures, articles, and methods as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled “Detailed Description of the Invention,” one will understand how the features of the various embodiments disclosed herein provide a number of advantages over the current state of the art. For example, embodiments of the inventive breathable structure offer desirable hydrostatic resistance while maintaining a desirable moisture vapor transmission rate and/or air permeability.

In a first aspect, the invention provides a breathable structure comprising a fibrous substrate and a cross-linked polymer comprising hydrophobic moieties, wherein the fibrous substrate comprises a plurality of fibers, and wherein the cross-linked polymer coats portions of the plurality of fibers.

In a second aspect, the invention provides an article comprising the breathable structure according to the first aspect of the invention.

In a third aspect, the invention provides a method of making the breathable structure according to the first aspect of the invention, or the article according to the second aspect of the invention.

These and other features and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, aspects, and advantages of the disclosure will be readily understood from the following detailed description taken in conjunction with the accompanying drawings, which are not necessarily drawn to scale, wherein like numerals denote like elements, and wherein:

FIG. 1 depicts a portion of a nonwoven web comprising polyester fibers.

FIG. 2 is an enlarged view of fibers in an embodiment of nonwoven web.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the present invention and certain features, advantages, and details thereof, are explained more fully below. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the disclosure in detail. It should be understood, however, that the detailed description and any specific example(s), while indicating embodiments of the invention, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

Embodiments of the present invention provide structures having hydrostatic resistance akin to that afforded by a membrane, but without the accompanying loss of breathability or air permeability.

In a first aspect, the invention provides a breathable structure comprising a fibrous substrate and a cross-linked polymer comprising hydrophobic moieties, wherein the fibrous substrate comprises a plurality of fibers, and wherein the cross-linked polymer coats portions of the plurality of fibers.

As used herein, the fibrous substrate is a substrate that comprises a plurality of fibers. For example, in some embodiments, the fibrous substrate is fabric, flannel, denim, a nonwoven, a woven, or a knit structure.

In some embodiments, the fibrous substrate is or comprises one or more nonwovens, for example, spunbonded webs (e.g., comprising filaments), melt blown webs, multi-directional, single- or multi-layer carded webs, air-laid webs, wet-laid webs, spunlaced webs, high-loft nonwoven insulation, low-loft non-woven insulation, needled nonwoven (e.g., high density needled non-woven), fleece, and/or composite webs comprising more than one nonwoven layer.

In some embodiments, the fibrous substrate is or comprises one or more wovens, for example: woven structures, twill woven structures, satin woven structures (the foregoing optionally being reinforced structures, e.g., with double or multiple warps and/or wefts); knits, felts, fleeces and/or needle-punched structures.

In some embodiments, the fibrous substrate is flannel. In some embodiments, the fibrous substrate is denim.

In some embodiments, the breathable structure and/or the fibrous substrate has a thickness of 0.9 to 50 mm (e.g., 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9, 15.0, 15.1, 15.2, 15.3, 15.4, 15.5, 15.6, 15.7, 15.8, 15.9, 16.0, 16.1, 16.2, 16.3, 16.4, 16.5, 16.6, 16.7, 16.8, 16.9, 17.0, 17.1, 17.2, 17.3, 17.4, 17.5, 17.6, 17.7, 17.8, 17.9, 18.0, 18.1, 18.2, 18.3, 18.4, 18.5, 18.6, 18.7, 18.8, 18.9, 19.0, 19.1, 19.2, 19.3, 19.4, 19.5, 19.6, 19.7, 19.8, 19.9, 20.0, 20.1, 20.2, 20.3, 20.4, 20.5, 20.6, 20.7, 20.8, 20.9, 21.0, 21.1, 21.2, 21.3, 21.4, 21.5, 21.6, 21.7, 21.8, 21.9, 22.0, 22.1, 22.2, 22.3, 22.4, 22.5, 22.6, 22.7, 22.8, 22.9, 23.0, 23.1, 23.2, 23.3, 23.4, 23.5, 23.6, 23.7, 23.8, 23.9, 24.0, 24.1, 24.2, 24.3, 24.4, 24.5, 24.6, 24.7, 24.8, 24.9, 25.0, 25.1, 25.2, 25.3, 25.4, 25.5, 25.6, 25.7, 25.8, 25.9, 26.0, 26.1, 26.2, 26.3, 26.4, 26.5, 26.6, 26.7, 26.8, 26.9, 27.0, 27.1, 27.2, 27.3, 27.4, 27.5, 27.6, 27.7, 27.8, 27.9, 28.0, 28.1, 28.2, 28.3, 28.4, 28.5, 28.6, 28.7, 28.8, 28.9, 29.0, 29.1, 29.2, 29.3, 29.4, 29.5, 29.6, 29.7, 29.8, 29.9, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 mm), including any and all ranges and subranges therein.

In some embodiments, the breathable structure and/or the fibrous substrate has a density of 0.9 to 50 kg/m³ (e.g., 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9, 15.0, 15.1, 15.2, 15.3, 15.4, 15.5, 15.6, 15.7, 15.8, 15.9, 16.0, 16.1, 16.2, 16.3, 16.4, 16.5, 16.6, 16.7, 16.8, 16.9, 17.0, 17.1, 17.2, 17.3, 17.4, 17.5, 17.6, 17.7, 17.8, 17.9, 18.0, 18.1, 18.2, 18.3, 18.4, 18.5, 18.6, 18.7, 18.8, 18.9, 19.0, 19.1, 19.2, 19.3, 19.4, 19.5, 19.6, 19.7, 19.8, 19.9, 20.0, 20.1, 20.2, 20.3, 20.4, 20.5, 20.6, 20.7, 20.8, 20.9, 21.0, 21.1, 21.2, 21.3, 21.4, 21.5, 21.6, 21.7, 21.8, 21.9, 22.0, 22.1, 22.2, 22.3, 22.4, 22.5, 22.6, 22.7, 22.8, 22.9, 23.0, 23.1, 23.2, 23.3, 23.4, 23.5, 23.6, 23.7, 23.8, 23.9, 24.0, 24.1, 24.2, 24.3, 24.4, 24.5, 24.6, 24.7, 24.8, 24.9, 25.0, 25.1, 25.2, 25.3, 25.4, 25.5, 25.6, 25.7, 25.8, 25.9, 26.0, 26.1, 26.2, 26.3, 26.4, 26.5, 26.6, 26.7, 26.8, 26.9, 27.0, 27.1, 27.2, 27.3, 27.4, 27.5, 27.6, 27.7, 27.8, 27.9, 28.0, 28.1, 28.2, 28.3, 28.4, 28.5, 28.6, 28.7, 28.8, 28.9, 29.0, 29.1, 29.2, 29.3, 29.4, 29.5, 29.6, 29.7, 29.8, 29.9, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 kg/m³), including any and all ranges and subranges therein.

In some embodiments, the breathable structure and/or the fibrous substrate has a weight of 25 to 600 gsm (g/m²) (e.g., 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219, 220, 221, 222, 223, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 255, 256, 257, 258, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268, 269, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289, 290, 291, 292, 293, 294, 295, 296, 297, 298, 299, 300, 301, 302, 303, 304, 305, 306, 307, 308, 309, 310, 311, 312, 313, 314, 315, 316, 317, 318, 319, 320, 321, 322, 323, 324, 325, 326, 327, 328, 329, 330, 331, 332, 333, 334, 335, 336, 337, 338, 339, 340, 341, 342, 343, 344, 345, 346, 347, 348, 349, 350, 351, 352, 353, 354, 355, 356, 357, 358, 359, 360, 361, 362, 363, 364, 365, 366, 367, 368, 369, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 380, 381, 382, 383, 384, 385, 386, 387, 388, 389, 390, 391, 392, 393, 394, 395, 396, 397, 398, 399, 400, 401, 402, 403, 404, 405, 406, 407, 408, 409, 410, 411, 412, 413, 414, 415, 416, 417, 418, 419, 420, 421, 422, 423, 424, 425, 426, 427, 428, 429, 430, 431, 432, 433, 434, 435, 436, 437, 438, 439, 440, 441, 442, 443, 444, 445, 446, 447, 448, 449, 450, 451, 452, 453, 454, 455, 456, 457, 458, 459, 460, 461, 462, 463, 464, 465, 466, 467, 468, 469, 470, 471, 472, 473, 474, 475, 476, 477, 478, 479, 480, 481, 482, 483, 484, 485, 486, 487, 488, 489, 490, 491, 492, 493, 494, 495, 496, 497, 498, 499, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, or 600 gsm), including any and all ranges and subranges therein.

In some embodiments, the breathable structure comprises a low density high loft fibrous substrate (e.g., a high loft nonwoven) having, at a weight of 200 gsm, a thickness of at least about 20 mm (e.g., at least 30 mm, or, e.g., about 28-48 mm), and a density of less than 10 kg/m³ (e.g., less than about 7 kg/m³).

In some embodiments, the breathable structure comprises a high density (e.g., high density needled) fibrous substrate having, at a weight of 200 gsm, a thickness of less than about 15 mm (e.g., less than 10 mm, or, e.g,. about 1-10 mm), and a density of greater than about 20 kg/m³ (e.g., greater than about 30 kg/m³, e.g., about 35 to 45 kg/m³).

In some embodiments, the breathable structure and/or the fibrous substrate has a drape of less than or equal to 3.5 cm, e.g., 1.0 cm to 3.5 cm (e.g., 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, or 3.5 cm), including any and all ranges and subranges therein, as measured in accordance with Method ASTM D1388.

In some embodiments, the fibrous substrate of the breathable structure comprises either one or more filaments of indefinite length, or a plurality of fibers.

In some embodiments, the plurality of fibers comprises staple fibers (i.e., fibers having a standardized length). For example, in some embodiments, the plurality of fibers comprises staple fibers having a length of 5 to 120 mm (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, or 120 mm), including any and all ranges and subranges therein (e.g., 12 to 90 mm, 40 to 60 mm, etc.).

Generally speaking, fibers may be crimped or uncrimped. Various crimps, including spiral and standard (e.g., planar) crimp, are known in the art.

While the fibers may be linear, optionally with crimp, in some embodiments, the fibrous substrate comprises fibers that have a desirable shape that is not linear or linear with crimp. While persons having ordinary skill in the art are familiar with various desirable shapes to choose for the fiber, which are contemplated as being used in embodiments of the invention, some non-limiting examples include Y-shaped fibers, bow-tie shaped fibers, etc.

In some embodiments, the plurality of fibers is actually one or more filaments. A filament is a single long threadlike continuous textile fiber/strand. Unlike staple fibers, which are of finite length, filaments are of indefinite length, and can run for yards or miles. In some embodiments, the filament ranges in length from 5 inches to several miles, including any and all ranges and subranges therein. For example, in some embodiments, the filament may be at least 5 inches in length (e.g., at least 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 inches in length, or any range or subrange therein). In some embodiments, the filaments may be at least 1 foot in length (e.g., at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, or 1000 feet in length, or any range or subrange therein).

In some embodiments, the plurality of fibers in the fibrous substrate comprises synthetic fibers. Many synthetic fibers are known in the art, and any desired synthetic fibers may be used in the invention. Indeed, different fibers have different properties, and lend themselves toward advantageous uses in different applications. This information is well within the purview of persons having ordinary skill in the art. While a wide array of synthetic fibers may be used in the invention, in some embodiments, nonexclusive synthetic fibers that may be used in the invention are selected from nylon, polyester, polypropylene, polylactic acid (PLA), poly(butyl acrylate) (PBA), polyamide, acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, and combinations thereof. In particular embodiments, synthetic fibers comprise polyester fibers. For example, in some embodiments, the polyester is selected from poly(ethylene terephthalate), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate), poly-1,4-cyclohexelyne dimethylene (PCDT), polytrimethylene terephthalate (PTT), and terephthalate copolyesters in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In a particular embodiment, the polyester is polyethylene terephthalate. In some embodiments, the synthetic fibers comprise virgin fibers. In some embodiments, the synthetic fibers comprise recycled fibers (e.g., recycled polyester fibers).

The plurality of fibers comprises 0 to 100 wt % synthetic fibers, for example, 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt %, including any and all ranges and subranges therein (e.g., 10 to 100 wt %, 30 to 100 wt %, 51 to 100 wt %, 40 to 90 wt %, 20 to 80 wt %, etc.). In some embodiments, the fiber mixture comprises greater than 50, 55, 60, 65, 70, or 75 wt % synthetic fibers.

Denier is a unit of measure defined as the weight in grams of 9000 meters of a fiber or yarn. It is a common way to specify the weight (or size) of the fiber or yarn. For example, polyester fibers that are 1.0 denier typically have a diameter of approximately 10 micrometers. Micro-denier fibers are those having a denier of 1.0 or less, while macro-denier fibers have a denier greater than 1.0.

In some embodiments, the synthetic fibers have a denier of 0.7 denier to 8.0 denier, including any and all ranges and subranges therein. For example, in some embodiments, the synthetic fibers have a denier of 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, or 8.0 denier, including any and all ranges and subranges therein.

In some embodiments, the synthetic fibers comprise micro-denier fibers (e.g., fibers having a denier of 0.7 to 1.0 denier). In some embodiments, the synthetic fibers comprise macro-denier fibers (e.g., fibers having a denier of 1.1 to 8.0 denier). In some embodiments, the synthetic fibers comprise micro-denier fibers and macro-denier fibers.

In some embodiments, the plurality of fibers comprises synthetic fibers that are siliconized.

The term “siliconized” means that the fiber is coated with a silicon-comprising composition (e.g., a silicone). Siliconization techniques are well known in the art, and are described, e.g., in U.S. Pat. No. 3,454,422. The silicon-comprising composition may be applied using any method known in the art, e.g., spraying, mixing, dipping, padding, etc. The silicon-comprising (e.g., silicone) composition, which may include an organosiloxane or polysiloxane, bonds to an exterior portion of the fiber. In some embodiments, the silicone coating is a polysiloxane such as a methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino modified dimethylpolysiloxane. As is known in the art, the silicon-comprising composition may be applied directly to the fiber, or may be diluted with a solvent as a solution or emulsion, e.g. an aqueous emulsion of a polysiloxane, prior to application. Following treatment, the coating may be dried and/or cured.

As is known in the art, a catalyst may be used to accelerate the curing of the silicon-comprising composition (e.g., polysiloxane containing Si—H bonds) and, for convenience, may be added to a silicon-comprising composition emulsion, with the resultant combination being used to treat the synthetic fiber. Suitable catalysts include iron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, following siliconization, the fiber may be dried to remove residual solvent and then optionally heated to between 65° and 200° C. to cure.

Of the plurality of fibers, 0 to 100 wt % (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt %, including any and all ranges and subranges therein) of the synthetic fibers, if present, are siliconized

In some embodiments, the plurality of fibers comprises natural fibers. For example, in some embodiments, the plurality of fibers comprises one or more members selected from wool, cotton, tencel, kapok (cotton-like fluff obtained from seeds of a Kapok tree, which may optionally be further processed before use), flax, animal hair, silk, and down (e.g., duck or goose down).

The plurality of fibers comprises 0 to 100 wt % natural fibers, for example, 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt %, including any and all ranges and subranges therein (e.g., 0 to 50 wt %, 1 to 40 wt %, 5 to 25 wt %, 30 to 60 wt %, etc.). In some embodiments, the fiber mixture comprises less than 50, 40, 30, 20, or 10 wt % natural fibers.

In some embodiments, the fiber mixture comprises only synthetic fibers. In some embodiments, the fiber mixture comprises only natural fibers. In some embodiments, the fiber mixture comprises synthetic fibers and natural fibers.

In some embodiments, the plurality of fibers comprises 0 to 25 wt % synthetic binder fibers, said binder fibers having a bonding temperature lower than the softening temperature of synthetic fibers present in the plurality of fibers.

In some embodiments, the synthetic binder fibers make up, e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 wt % of the plurality of fibers, including any and all ranges and subranges therein.

In some embodiments, the synthetic binder fibers have a denier of 1.0 to 6.0 denier (e.g., 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, or 6.0 denier), including any and all ranges and subranges therein (e.g., 1.0 to 3.0 denier, 1.5 to 2.5 denier, etc.).

In some embodiments, the binder fibers have a staple cut length of 38 to 105 mm, including any and all ranges and subranges therein. For example, in some embodiments, the length is 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, or 105 mm, including any and all ranges/subranges therein (e.g., 38-51 mm).

As indicated above, the binder fibers have a bonding temperature lower than the softening temperature of any synthetic fibers present in the plurality of fibers. In some embodiments, the binder fibers have a bonding temperature of less than or equal to 200° C. In some embodiments, the binder fibers have a bonding temperature of 50 to 200° C., including any and all ranges and subranges therein. In some embodiments, the binder fibers have a bonding temperature of 80° C. to 150° C. In some embodiments, the binder fibers have a bonding temperature of 100° C. to 125° C.

In some embodiments, the binder fibers comprise low-melt polyester fibers.

In some embodiments, the binder fibers are bicomponent fibers comprising a sheath and a core, wherein the sheath comprises a material having a lower melting point than the core.

In some embodiments, the fibrous substrate comprises binder fibers, and has been heat treated so as to melt all or a portion of the binder fibers. Persons having ordinary skill in the art will understand that, in such embodiments, although “binder fibers” may be recited in the fibrous substrate, said fibers may be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form.

In some embodiments of the fibrous substrate, the fiber members of the plurality of fibers are homogenously mixed, meaning, the fiber mixture of the plurality of fibers has a substantially uniform (i.e., 90 -100% uniform) composition.

The breathable structure comprises a cross-linked polymer that comprises hydrophobic moieties.

In some embodiments, the cross-linked polymer is fluorine-free.

In some embodiments, the cross-linked polymer does not comprise a fluorocarbon.

In some embodiments, the cross-linked polymer comprises cationic moieties.

In some embodiments, the cross-linked polymer comprises hydrocarbon groups (e.g., aliphatic hydrocarbon groups) that impart water repellency on the polymer. In some embodiments, the cross-linked polymer comprises chemically reactive groups for bonding to fibrous substrate surfaces.

In some embodiments, the polymer is formed from a polymeric composition comprising one or more self-crosslinking water-dispersible polymers (including copolymers) that can crosslink by application of thermal and/or photoinitiated stimuli. Examples of non-limiting polymers include the acrylic (co)polymers described in United States Patent Application No. 20170030010. In some embodiments, the self-crosslinking water-dispersible polymers comprise hydrocarbon groups (e.g., aliphatic hydrocarbon groups). In some embodiments, the self-crosslinking water-dispersible polymers comprise chemically reactive groups for bonding to fibrous surfaces and/or for crosslinking the polymers upon being subjected to an external stimulus such as heat.

In some embodiments, the polymer is formed from a polymeric composition comprising one or more polymers and/or prepolymers (e.g., monomers) having a weight average molecular weight (Mw) of 1,000 to 2,500 Daltons (e.g., 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, or 2500 Da, including any and all ranges and subranges therein, e.g., 1400 -2000 Da, 1500 -1800 Da, etc.), as measured using gel permeation chromatography (GPC) with polystyrene standard.

In some embodiments, the polymer is formed from a polymeric composition comprising a hydrocarbon (e.g., a constituent having an alkyl chain (e.g., C₄-C₂₀ alkyl, such as C₄, C₅, C₆, C₇, C₈, C₉, C₁₀, C₁₁, C₁₂, C₁₃, C₁₄, C₁₅, C₁₆, C₁₇, C₁₈, C₁₉, or C₂₀, or any range therein, e.g., C₆-C₁₄, C₈-C₁₂, etc.), a hydrocarbon wax, etc.). In some embodiments, the composition comprises a constituent having an alkyl chain with a terminal CH₃.

In some embodiments, the polymer is formed from a polymeric composition comprising one or more melamine rings.

In some embodiments, the polymer is formed from a polymeric composition that comprises formaldehyde.

In some embodiments, the polymer is formed from a polymeric composition comprising a melamine formaldehyde resin.

In some embodiments, the polymer is formed from a polymer composition comprising a functionalized melamine prepolymer, e.g., an alkyl (e.g., C₈-C₁₂ alkyl) functionalized melamine compound.

In some embodiments, the polymer formed from a polymeric composition comprises less than 1 wt % formaldehyde (e.g., less than 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99 wt %).

In some embodiments, the polymer is formed from a relatively monodisperse polymeric composition. In some embodiments, the polymeric composition has a dispersity (Mw/Mn) from GPC of 0.90 to 1.50. For example, in some embodiments, the PDI is 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.0, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, 1.25, 1.26, 1.27, 1.28, 1.29, 1.30, 1.31, 1.32, 1.33, 1.34, 1.35, 1.36, 1.37, 1.38, 1.39, 1.40, 1.41, 1.42, 1.43, 1.44, 1.45, 1.46, 1.47, 1.48, 1.49, or 1.50, including any and all ranges and subranges therein (e.g., 1.0 to 1.45, 1.1 to 1.35, etc.).

In some embodiments, the polymer formed from a polymeric composition does not comprise any free (non-polymerized) formaldehyde.

In some embodiments, the polymer is formed from a polymeric composition that comprises Altopel F³ (a commercially-available, fluorine-free hydrophobe-fortified self-crosslinking polymer marketed as a water repellent by Bolger & O'Hearn, Inc.)

In some embodiments, the polymeric composition is comprised within a polymer solution (e.g., a solvent-based solution, such as an aqueous-based solution) that comprises one or more additional components, such as an emulsifier or surfactant. Various additional components are described, e.g., in United States Application No. 20120114928. Emulsifiers and surfactants are well known in the art. In some embodiments, the solution comprises a cationic and/or non-ionic emulsifier or surfactant.

In various embodiments, the polymer solution is applied to the fibrous substrate (for example, by spraying the polymer solution onto the fibrous substrate, dipping the fibrous substrate in the polymer solution, or kiss-rolling the polymer solution onto the fibrous substrate), thereby coating portions of the plurality of fibers in the fibrous substrate with the polymer solution. The solution-applied fibrous substrate can then be subjected to a stimulus (e.g., heat) that cross-links the polymer, thereby forming the cross-linked polymer, which coats portions of the plurality of fibers.

FIG. 1 depicts a portion of a fibrous substrate, nonwoven web 10, which comprises polyester fibers 12. FIG. 2 is an enlarged view of nonwoven web 10, and depicts the polyester fibers 12 and binder fibers 16 which, in FIG. 2, have melted following heat treatment of the web, thus bonding together fibers within the web 10. In FIG. 2, there are various points of overlap 14, wherein fibers 12 overlap with one another and/or with binder fibers 16. Depending on the proximity of fibers (due to, e.g., number of fibers, density of substrate, etc.) some fibrous substrate embodiments will have more points of overlap 14 than others. As would be readily understood by persons having ordinary skill in the art, where a fibrous substrate has more points of overlap 14, there will often be less fiber surface area available to be coated by the polymer.

In some embodiments of the inventive breathable structure, 40 to 100% (e.g., 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.5, or 100%) of the surface area of the fibers in the fibrous substrate, including any and all ranges and subranges therein (e.g., 40-100%, 50 to 99%, 60 to 98%, 70 to 97%, 80 to 96%, 90 to 100%, etc.) is in direct contact with the cross-linked polymer. Where fibers have been treated with other chemistries, e.g., siliconization, the surface area of the chemistry-treated fibers will still be considered to be in direct contact with the cross-linked polymer, notwithstanding such chemistry (e.g., siliconization).

In some embodiments of the inventive breathable structure, greater than or equal to 40% (e.g., greater than or equal to 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99%) of the surface area of the fibers in the fibrous substrate is in direct contact with the cross-linked polymer.

In some embodiments, the inventive breathable structure comprises 0.25 wt % to 7 wt % (e.g., 0.25, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, or 7.0 wt %) of the cross-linked polymer, including any and all ranges and subranges therein (e.g., 1 to 5 wt %).

The term hydrostatic resistance, which may be used interchangeably herein with the term hydrostatic head, is a measure of the resistance of a structure to penetration by liquid water under static pressure. Hydrostatic resistance/hydrostatic head, as used herein, is calculated according to AATCC-127, which is hereby incorporated by reference herein, and is reported in centimeters of water. In some embodiments, the inventive breathable structure has a hydrostatic resistance of 30 to 700 cm of water (e.g., 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, or 700 cm of water), including any and all ranges and subranges therein. In some embodiments, the inventive breathable structure has a hydrostatic resistance of greater than or equal to 50 cm of water.

In some embodiments, the breathable structure has a hydrostatic resistance of HR2, and the fibrous substrate (or, breathable structure, in the absence of the cross-linked polymer), has a hydrostatic resistance of HR1, wherein:

$\frac{\left(HR2-HR1\right)}{HR1}\times 100\%\ge 50\%(e.g.,\ge 50,51,$

52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, or 75%).

In some embodiments, the breathable structure has a moisture vapor transmission rate (MVTR) (calculated according to ASTM E-96B, which is hereby incorporated by reference herein), of 200 to 1500 g/m²/day (e.g., 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000, 1010, 1020, 1030, 1040, 1050, 1060, 1070, 1080, 1090, 1100, 1110, 1120, 1130, 1140, 1150, 1160, 1170, 1180, 1190, 1200, 1210, 1220, 1230, 1240, 1250, 1260, 1270, 1280, 1290, 1300, 1310, 1320, 1330, 1340, 1350, 1360, 1370, 1380, 1390, 1400, 1410, 1420, 1430, 1440, 1450, 1460, 1470, 1480, 1490, or 1500 g/m²/day), including any and all ranges and subranges therein. In some embodiments, the breathable structure has a MVTR of greater than or equal to 300 g/m²/day.

In some embodiments, the breathable structure has a Frazier Air Permeability (calculated according to ASTM D737, which is hereby incorporated by reference herein), of 1 to 500 cfm (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219, 220, 221, 222, 223, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 255, 256, 257, 258, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268, 269, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289, 290, 291, 292, 293, 294, 295, 296, 297, 298, 299, 300, 301, 302, 303, 304, 305, 306, 307, 308, 309, 310, 311, 312, 313, 314, 315, 316, 317, 318, 319, 320, 321, 322, 323, 324, 325, 326, 327, 328, 329, 330, 331, 332, 333, 334, 335, 336, 337, 338, 339, 340, 341, 342, 343, 344, 345, 346, 347, 348, 349, 350, 351, 352, 353, 354, 355, 356, 357, 358, 359, 360, 361, 362, 363, 364, 365, 366, 367, 368, 369, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 380, 381, 382, 383, 384, 385, 386, 387, 388, 389, 390, 391, 392, 393, 394, 395, 396, 397, 398, 399, 400, 401, 402, 403, 404, 405, 406, 407, 408, 409, 410, 411, 412, 413, 414, 415, 416, 417, 418, 419, 420, 421, 422, 423, 424, 425, 426, 427, 428, 429, 430, 431, 432, 433, 434, 435, 436, 437, 438, 439, 440, 441, 442, 443, 444, 445, 446, 447, 448, 449, 450, 451, 452, 453, 454, 455, 456, 457, 458, 459, 460, 461, 462, 463, 464, 465, 466, 467, 468, 469, 470, 471, 472, 473, 474, 475, 476, 477, 478, 479, 480, 481, 482, 483, 484, 485, 486, 487, 488, 489, 490, 491, 492, 493, 494, 495, 496, 497, 498, 499, or 500 cfm), including any and all ranges and subranges therein.

In some embodiments, the fibrous substrate is as listed in Table I:

TABLE 1
Fibrous Substrate  Frazier Air Permeability
Fabric             1 to 160 cfm
High loft nonwoven 250 500 cfm

In some embodiments, the inventive breathable structure has a moisture vapor transmission rate of MVTR2, and the breathable structure, in the absence of the cross-linked polymer (i.e., the uncoated fibrous substrate), has a moisture vapor transmission rate of MVTR1, and:

$\frac{\left(MVTR1-MVTR2\right)}{MVTR1}\times 100\%\le 10\%.$

For example, in some embodiments,

$\frac{\left(\mathrm{MVTR}1-\mathrm{MVTR}2\right)}{\mathrm{MVTR}1}\times 100\%\le 10,9,8,7,6,5,4,3,\mathrm{or}2\%.$

In some embodiments, the inventive breathable structure has a Frazier air permeability of AP2, and the breathable structure, in the absence of the cross-linked polymer (i.e., the uncoated fibrous substrate), has a Frazier air permeability of AP1, and:

$\frac{\left(AP1-AP2\right)}{AP1}\times 100\%\le 10\%.$

For example, in some embodiments,

$\frac{\left(AP1-AP2\right)}{AP1}\times 100\%\le 10,9,8,7,6,5,4,3,\mathrm{or}2\%.$

In a second aspect, the invention provides an article comprising the breathable structure according to the first aspect of the invention.

Non-limiting examples of inventive articles include, for example, garments (e.g. outerwear garments such as coats, jackets, other rain gear, etc.), clothing, pillows, pads, sleeping bags, bedding (e.g., quilts, comforters), etc.

In some embodiments, the article is fabric or insulation (e.g., batting, fleece, flannel, etc.). In some embodiments, the article is a product comprising fabric or insulation (e.g., a sleeping bag, outerwear, active wear, a home good, etc.).

In a third aspect, the invention provides a method of making the breathable structure according to the first aspect of the invention, or the article according to the second aspect of the invention.

In some embodiments, the inventive method comprises applying to a fibrous substrate a polymer solution comprising a cross-linkable polymer comprising hydrophobic moieties, thereby forming an intermediate structure, then heating the intermediate structure, thereby cross-linking the polymer.

While the polymer solution may be applied in any art acceptable manner, in some embodiments, applying the polymer solution to the fibrous substrate comprises spraying the polymer solution onto the fibrous substrate, dipping the fibrous substrate in the polymer solution, or kiss-rolling the polymer solution onto the fibrous substrate.

In some embodiments, the polymer solution comprises 0.5 to 10 wt % of the cross-linkable polymer (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, or 10.0 wt %), including any and all ranges and subranges therein (e.g., 1 to 5 wt %).

In some embodiments, the invention is as described in the following clauses:

1. A breathable structure comprising a fibrous substrate and a cross-linked polymer comprising hydrophobic moieties, wherein the fibrous substrate comprises a plurality of fibers, and wherein the cross-linked polymer coats portions of the plurality of fibers.

2. The breathable structure according to clause 1, wherein the plurality of fibers comprise synthetic fibers.

3. The breathable structure according to clause 1 or clause 2, wherein the plurality of fibers comprise natural fibers.

4. The breathable structure according to any one of the preceding clauses, wherein greater than or equal to 50 wt % of the fibers in the fibrous substrate are synthetic fibers.

5. The breathable structure according to any one of the preceding clauses, wherein greater than or equal to 40% of the surface area of the fibers in the fibrous substrate is in direct contact with the cross-linked polymer.

6. The breathable structure according to clause 5, wherein greater than or equal to 60% of the surface area of the fibers in the fibrous substrate is in direct contact with the cross-linked polymer.

7. The breathable structure according to any one of the preceding clauses, comprising 0.25 wt % to 7 wt % of the cross-linked polymer.

8. The breathable structure according to clause 7, comprising 1 wt % to 5 wt % of the cross-linked polymer.

9. The breathable structure according to any one of the preceding clauses, wherein the cross-linked polymer does not comprise fluorine.

10. The breathable structure according to any one of the preceding clauses, wherein the structure does not comprise a fluorocarbon.

11. The breathable structure according to any one of the preceding clauses, wherein the plurality of fibers comprises polyester fibers.

12. The breathable structure according to any one of the preceding clauses, wherein the fibrous substrate is a non-woven web.

13. The breathable structure according to any one of clauses 1-11, wherein the fibrous substrate is fleece.

14. The breathable structure according to any one of clauses 1-11, wherein the fibrous substrate is fabric.

15. The breathable structure according to any one of clauses 1-11, wherein the fibrous substrate is non-woven insulation (e.g., high-loft nonwoven insulation, low-loft nonwoven insulation, or needled non-woven insulation, such as high density needled non-woven insulation).

16. The breathable structure according to any one of the preceding clauses, having a hydrostatic resistance of greater than or equal to 50 centimeters of water.

17. The breathable structure according to any one of the preceding clauses, having a hydrostatic resistance of HR2, wherein the breathable structure, in the absence of the cross-linked polymer, has a hydrostatic resistance of HR1, and wherein:

$\frac{\left(HR2-HR1\right)}{HR1}\times 100\%\ge 50\%.$

18. The breathable structure according to any one of the preceding clauses, having a moisture vapor transmission rate (MVTR) of greater than or equal to 300 g/m²/day.

19. The breathable structure according to any one of the preceding clauses, having a Frazier air permeability of 1 to 500 cfm.

20. The breathable structure according to clause 19, having a Frazier air permeability of 1 to 160 cfm (e.g., 1 to 20 cfm), wherein the fibrous substrate is fabric.

21. The breathable structure according to clause 19, having a Frazier air permeability of 250 to 500 cfm, wherein the fibrous substrate is a high loft nonwoven.

22. The breathable structure according to any one of the preceding clauses, having a moisture vapor transmission rate of MVTR2 and a Frazier air permeability of AP2, wherein the breathable structure, in the absence of the cross-linked polymer, has a moisture vapor transmission rate of MVTR1 and a Frazier air permeability of AP1, and wherein:

$\frac{\left(MVTR1-MVTR2\right)}{MVTR1}\times 100\%\le 10\%;\mathrm{and}/\mathrm{or}$ $\frac{\left(AP1-AP2\right)}{AP1}\times 100\%\le 10\%.$

23. An article comprising the breathable structure according to any one of the preceding clauses.

24. The article according to clause 23, wherein said article is a garment.

25. A method of making the breathable structure according to any one of clauses 1 to 22, the method comprising applying to a fibrous substrate a polymer solution comprising a cross-linkable polymer comprising hydrophobic moieties, thereby forming an intermediate structure, then heating the intermediate structure, thereby cross-linking the polymer.

26. The method according to clause 25, wherein said applying comprises spraying the polymer solution onto the fibrous substrate, dipping the fibrous substrate in the polymer solution, or kiss-rolling the polymer solution onto the fibrous substrate.

27. The method according to clause 25 or clause 26, wherein the polymer solution comprises 0.5 to 10 wt % of the cross-linkable polymer.

28. The method according to clause 27, wherein the polymer solution comprises 1 to 5 wt % of the cross-linkable polymer.

EXAMPLE

The invention will now be illustrated, but not limited, by reference to the specific embodiment described in the following example.

Example 1: An aqueous polymer solution is prepared by mixing Altopel F³ (a commercially-available, fluorine-free hydrophobe-fortified self-crosslinking polymer marketed as a water repellent by Bolger & O'Hearn, Inc.) with water. The polymer solution is applied, via kiss-roll, to PET fleece. Polymers in the Altopel F³ are cross-linked by heat treating the coated fleece at about 175° C., resulting in a breathable structure comprising about 2 wt % of the cross-linked polymer. The result is a treated structure having good hydrostatic resistance, while maintaining surprisingly good breathability and air permeability.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), “contain” (and any form contain, such as “contains” and “containing”), and any other grammatical variant thereof, are open-ended linking verbs. As a result, a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

As used herein, the terms “comprising,” “has,” “including,” “containing,” and other grammatical variants thereof encompass the terms “consisting of” and “consisting essentially of.”

The phrase “consisting essentially of” or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed compositions or methods.

All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.

Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present invention have been described and depicted herein, alternative aspects and embodiments may be affected by those skilled in the art to accomplish the same objectives. Accordingly, this disclosure and the appended claims are intended to cover all such further and alternative aspects and embodiments as fall within the true spirit and scope of the invention.

Claims

1. A breathable structure comprising a fibrous substrate and a cross-linked polymer comprising hydrophobic moieties, wherein the fibrous substrate comprises a plurality of fibers, and wherein the cross-linked polymer coats portions of the plurality of fibers.

2. The breathable structure according to claim 1, wherein the plurality of fibers comprise synthetic fibers.

3. The breathable structure according to claim 1, wherein the plurality of fibers comprise natural fibers.

4. The breathable structure according to claim 1, wherein greater than or equal to 50 wt % of the fibers in the fibrous substrate are synthetic fibers.

5. The breathable structure according to claim 1, wherein greater than or equal to 40% of the surface area of the fibers in the fibrous substrate is in direct contact with the cross-linked polymer.

6. The breathable structure according to claim 5, wherein greater than or equal to 60% of the surface area of the fibers in the fibrous substrate is in direct contact with the cross-linked polymer.

7. The breathable structure according to claim 1, comprising 0.25 wt % to 7 wt % of the cross-linked polymer.

8. The breathable structure according to claim 7, comprising 1 wt % to 5 wt % of the cross-linked polymer.

9. The breathable structure according to claim 1, wherein the cross-linked polymer does not comprise fluorine.

10. (canceled)

11. The breathable structure according to claim 1, wherein the plurality of fibers comprises polyester fibers.

12. The breathable structure according to claim 1, wherein the fibrous substrate is a non-woven web.

13-15. (canceled)

16. The breathable structure according to claim 1, having a hydrostatic resistance of greater than or equal to 50 centimeters of water.

17. The breathable structure according to claim 1, having a hydrostatic resistance of HR2, wherein the breathable structure, in the absence of the cross-linked polymer, has a hydrostatic resistance of HR1, and wherein: (HR2−HR1)/HR1×100%≥50%.

18. The breathable structure according to claim 1, having a moisture vapor transmission rate (MVTR) of greater than or equal to 300 g/m2/day.

19. The breathable structure according to claim 1, having a Frazier air permeability of 1 to 500 cfm.

20. The breathable structure according to claim 19, wherein: the fibrous substrate is fabric having a Frazier air permeability of 1 to 160 cfm; orthe fibrous substrate is a high loft nonwoven having a Frazier air permeability of 250 to 500 cfm.

21. (canceled)

22. The breathable structure according to claim 1, having a moisture vapor transmission rate of MVTR2 and a Frazier air permeability of AP2, wherein the breathable structure, in the absence of the cross-linked polymer, has a moisture vapor transmission rate of MVTR1 and a Frazier air permeability of AP1, and wherein: (MVTR1−MVTR2)/MVTR1×100%≤10%; and/or(AP1−AP2)/AP1×100%≤10%.

23. An article comprising the breathable structure according to claim 1.

24. The article according to claim 23, wherein said article is a garment.

25. A method of making the breathable structure according to claim 1, the method comprising applying to a fibrous substrate a polymer solution comprising a cross-linkable polymer comprising hydrophobic moieties, thereby forming an intermediate structure, then heating the intermediate structure, thereby cross-linking the polymer.

26-28. (canceled)