HYDROPHOBIC FABRIC

Abstract

A composite fabric that hydrophobic, durable, stretchable, breathable and elastic for aquatic environment includes a synthetic woven fabric with an integrated discontinuous layer or patterned layer of melted polyurethane. The integrated discontinuous layer or patterned layer of melted polyurethane is preferably formed by heat pressing a pattern into sheets of polyurethane that are in contact with sheets of the synthetic woven fabric to form a composite layered structure that is then cured in a heat stabilization process.

Description

FIELD OF THE INVENTION

The invention relates to the field of sports apparel and in particular the invention relates to a hydrophobic fabric and a method for making the same for sports apparel.

BACKGROUND ON INVENTION

A competitive swimmers, tri-athletes and the like can improve their performance by wearing the proper protective clothing both in form and in structure. There have been a number of improvements in fabrics that are used for competitive sports apparel. Ideally a fabric used to make sports apparel that involves exposure to an aquatic environment is made from a hydrophobic fabric that is durable, stretchable and elastic over multiple deformations.

SUMMARY OF INVENTION

The present invention is directed to a composite fabric and a method of making the same. The composite fabric has particular applications is making professional sports apparel, such as professional swimming apparel, but also has applications for making sports apparel for a number a sport activities. The composite fabric is hydrophobic, durable, stretchable, breathable and elastic.

The composite fabric includes a woven synthetic fabric and an integrated discontinuous layer or patterned layer of melted polyurethane. The synthetic woven fabric is formed by warping and weaving (rolls of yarn) of synthetic material, such polyester, polyamide or a combination thereof. The integrated discontinuous layer or patterned layer of melted polyurethane on the synthetic woven fabric attaches to the fiber strings or yarns of the synthetic woven fabric and enhances the hydrophobic properties of the composite fabric that is formed. Further, the droplets or segments of melted polyurethane combined with the fibers strings or yarns of the woven synthetic fabric act like micro-springs between the fiber strings or yarns of the synthetic woven fabric adding the durability and elasticity of the composite fabric formed, while maintaining a high degree of breathablity of the composite fabric.

The integrated discontinuous layer or patterned layer of melted polyurethane (droplets or segments) can be generated by placing continuous sheets of polyurethane on top of the synthetic woven fabric and heat pressing a pattern into the sheet of polyurethane to form a composite layered structure fabric between the synthetic woven fabric and a patterned polyurethane layer. After the composite layer structure formed, the composite layered structure is cured through a heating process or heat stabilization process, thereby creating the composite fabric with the integrated discontinuous layer or patterned layer of melted polyurethane (droplets or segments) attached to fiber strings of the synthetic woven fabric. The heating process or heat stabilization process involves putting the composite layered structure fabric through an oven at a temperature range of 170 to 210 degree Celsius for a time of proximately 60 to 90 seconds.

In accordance with the method of the present invention the campsite layered structure is formed using heat press process. In the heat press process, sheet roles synthetic woven fabric and a sheet roles of polyurethane that are fed and through a heated drum or cylinder press. Typical pressure applied is 6-Bar on the sheet roles synthetic woven fabric and a sheet roles of poly-urethane and the and the contact heated drum or cylinder press cylinder is heated to 200 approximately Celsius) The heated drum or cylinder press includes at least one patterned drum or cylinder.

As the sheet roles synthetic woven fabric and a sheet roles of polyurethane are simultaneously fed through the heated drum or cylinder press, wherein the patterned drum or cylinder presses and transfers a pattern onto treated portions of the sheet roll of polyurethane and forms the composite layered structure between the synthetic woven fabric and the patterned polyurethane layer. After the composite layered structure is formed, the composite layered structure is then fed through an oven and cured, such as described above, to form the integrated discontinuous layer or patterned layer of melted polyurethane on the synthetic woven fabric (composite fabric).

Prior to forming the composite layered structure and/or after the composite layered structure is formed the synthetic woven fabric and/or the composite layer structure can be treated to Durable Water Repellent (DWR) Hydrophobic process. A DWR Hydrophobic process can be includes applying a hydrophobic chemical solution or hydrophobic chemical on the synthetic woven fabric by spraying or dipping, or vapor depositing the on the synthetic woven fabric or on the composite layered structure. Also prior to forming the composite layer structure the synthetic woven fabric woven fabric can be dye, washed, dried or heat treated to obtain the desired color the synthetic woven fabric, remove impurities from the synthetic woven fabric and/or stabilize the synthetic woven fabric.

The composite fabric includes a woven synthetic fabric with the integrated discontinuous layer or patterned layer of melted polyurethane, can be formed using other method including combining sheet rolls of woven synthetic fabric with pre-patterned sheet roles of polyurethane in a heat press process or deposition of polyurethane beads on surface of sheet rolls of woven synthetic fabric and heat pressing an/or curing the deposited polyurethane beads to form the integrated discontinuous layer or patterned layer of melted polyurethane with the woven synthetic fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a structure of a woven synthetic fabric.

FIG. 2 illustrates a representation of a composite fabric formed form a woven synthetic fabric and an integrated discontinuous layer or patterned layer of melted polyurethane (composite fabric).

FIG. 3 illustrates a representation of a strand of yarn that forms composite fabric, shown in FIG. 2.

FIG. 4 is a block-flow diagram that outlines the steps for forming a woven synthetic fabric and an integrated discontinuous layer or patterned layer of melted polyurethane (composite fabric), in accordance with the method of the invention.

FIG. 5 illustrates a process mechanism for performing the steps for forming a woven synthetic fabric and an integrated discontinuous layer or patterned layer of melted polyurethane (composite fabric), in accordance with the method of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a structure of a synthetic woven fabric 100. The synthetic woven fabric 100 is formed by warping 101/101′ and weaving 103/103′ (rolls of yarn) of synthetic material, such polyester, polyamide or a combination thereof.

FIG. 2 illustrates a representation of a composite fabric 203 formed form a synthetic woven fabric 201 and an integrated discontinuous layer or patterned layer of melted polyurethane 205/205′/205″ (composite fabric).

FIG. 3 illustrates a representation 300 of a strand of yarn 301 that forms composite fabric 203, showing droplets or segments of melted polyurethane 305/305′/305″ that combine with the fibers strings of the strand of yarn 301 of the synthetic woven fabric 201. The droplets or segments of melted polyurethane 305/305′/305″ act like micro-springs between the fiber strings of the strands of yarn 301 of the synthetic woven fabric 201, thereby adding the durability and elasticity of the composite fabric formed, while also maintaining a high degree of breathablity of the composite fabric 203.

FIG. 4 is a block-flow diagram 400 that outlines the steps for forming a synthetic woven fabric and an integrated discontinuous layer or patterned layer of melted polyurethane (composite fabric 203). In the step 401, a suitable synthetic woven fabric is provided, such as described above. The synthetic woven fabric is preferably formed from yarn strands of polyester or polyamide. In the step 403, a patterned polyurethane layer is formed on top of the synthetic woven fabric this is provide in the step 401 to form a composite layered structure. The composite layered structure can be formed by contacting the woven synthetic fabric with sheets of polyurethane and heat pressing a patterns into the sheets of polyurethane to form the composite layered structure. Typical pressure applied to the sheet or layer of polyurethane and synthetic woven fabric is 6-Bar and the temperature applied the sheet or layer of poly-urethane is 200 approximately Celsius.

Still referring to FIG. 4, prior to the step 403 of patterning a polyurethane layer on the woven synthetic fabric, the synthetic woven fabric can be treated with Durable Water Repellent (DWR) Hydrophobic process. After the step 403 of patterning a polyurethane layer on the synthetic woven fabric to form the composite layered structure, in the step 405, the composite layered structure is cured in a heating process or heat stabilization process to form an integrated discontinuous layer of melted polyurethane on the synthetic woven fabric, referred to herein as a composite fabric. The heating process or heat stabilization process involves putting the composite layered structure fabric through an oven at a temperature range of approximately 170 to 210 degree Celsius for a time of proximately 60 to 90 seconds.

After the step 403 patterning a polyurethane layer on the synthetic woven fabric to form the composite layered structure, the composite layered structure can be can be treated with Durable Water Repellent (DWR) Hydrophobic process followed by the step 405 of curing the layered composite structure in the heating process or heat stabilization process to form the composite fabric with the integrated discontinuous layer of melted polyurethane on the synthetic woven fabric.

FIG. 5 illustrates a process mechanism 500 for performing the steps for forming a synthetic woven fabric 511 with an integrated discontinuous layer or patterned layer 557 of melted polyurethane (composite fabric 553). The process mechanism 500 can include sheet roles synthetic woven fabric 511 and a sheet roles of polyurethane 509 are simultaneously fed through the heated drum or cylinder press 507 with drums or cylinders 501 and 503. The drum or cylinder 501 is a patterned drum or cylinder with a pattern 552 that presses and transfers the pattern 552 into treated portions 509′ of the sheet roll of polyurethane 509 to form a patterned layer of polyurethane 555 on top of the treated portions 511 of the sheet roll of synthetic woven fabric 511′, to there by form a composite layered structure 551 between the treated portions 509′ of the sheet roll of polyurethane 509 and treated portions 511′ of the synthetic woven fabric 511′.

While the treated portions 509′ of the sheet roll of polyurethane 509 and treated portions 511′ of the synthetic woven fabric 511′ pass through heated drum or cylinder press 507, the pressure applied to treated portions 509′ of the sheet roll of polyurethane 509 and treated portions 511′ of the synthetic woven fabric 511′ is approximately 6-Bar and temperature applied to the treated portions 509′ of the sheet roll of polyurethane 509 and treated portions 511′ of the synthetic woven fabric 511′ through the patterned drum or cylinder 501 or both the patterned drum or cylinder and drums or cylinders 501 and 503 is approximately 200 degree Celsius.

After the composite layer structure 551 is formed, the composite layered structure 551 is cured through a heating process or heat stabilization process, wherein the composite layered structure 551 passes through and oven 555 to thereby generate the composite fabric 553 with the integrated discontinuous layer or patterned layer 557 of melted polyurethane (droplets or segments) attached to fiber strings of the synthetic woven fabric 511.

As described above the synthetic woven fabric 511 can be washed, dried dyed and or treated to a Durable Water Repellent (DWR) Hydrophobic process before generating the composite layered structure 551 and/or treated to a Durable Water Repellent (DWR) Hydrophobic process after generating the composite layered structure 551.

The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. It will be apparent to those skilled in the art that modifications can be made in the embodiments chosen for illustration without departing from the spirit and scope of the invention.

Claims

1. A composite fabric comprising: a) a synthetic woven fabric; andb) an integrated discontinuous layer or patterned layer of melted polyurethane on the a synthetic woven fabric.

2. The composite fabric of claim 1, wherein the integrated discontinuous layer or patterned layer is formed by placing sheets of polyurethane, pressing a pattern into the sheets of polyurethane to form a composite layered structure and curing the composite layered structure.

3. The composite fabric of claim 1, the pressing a pattern into the sheets of polyurethane to form a composite layered structure comprises putting sheets of the synthetic woven fabric and the sheets of sheets of polyurethane simultaneously through a heated drum or cylinder press.

4. The composite fabric of claim 3, wherein the heated drum or cylinder press includes a patterned drum or cylinder that transfers a pattern on to the sheets of polyurethane as the sheets of the synthetic woven fabric and the sheets of sheets of polyurethane simultaneously pass through a heated drum or cylinder press.

5. The composite fabric of claim 2, wherein the synthetic woven fabric is treated to a Durable Water Repellent (DWR) Hydrophobic process prior to forming the composite layered structure.

6. The composite fabric of claim 1, wherein the synthetic woven fabric comprises polyester, polyamide or a combination thereof.

7. A composite fabric comprising: a) a synthetic woven fabric; andb) an integrated discontinuous layer or patterned layer of melted polyurethane on the a synthetic woven fabric that is formed by generating a patterned polyurethane layer on the synthetic woven fabric to form a composite layered structure and curing the composite layered structure in the heating process or heat stabilization process.

8. The composite fabric of claim 7, wherein generating a patterned polyurethane layer on the synthetic woven fabric to form the composite layered structure comprising pressing a pattern into the sheets of polyurethane placed in contact with sheets of the synthetic woven fabric sheets and simultaneously putting the sheets of polyurethane and the sheets of synthetic woven fabric through a heated drum or cylinder press.

9. A method for making a composite fabric: a) proving a synthetic woven fabric;b) patterning a polyurethane layer onto the synthetic woven fabric to form a composite layered structure; andc) curing the composite layered structure to form a integrated discontinuous layer or patterned layer of melted polyurethane beads on the synthetic woven fabric.

10. The method of claim 9, further comprising treating the synthetic woven fabric with a Durable Water Repellent (DWR) Hydrophobic process prior to forming the composite layered structure.