Patent Application
20150104604
This invention relates to textile fabrics, and more particularly to textile fabrics responsive to changes in ambient temperature.
Thermal layering in home textile articles, such as blankets and the like, is considered one of the more effective means for personal insulation available. However, layered fabrics typically add bulk, and it is often difficult to provide levels of insulation appropriate for all areas of a user's body, as different areas of the body have different sensitivities to temperature and different abilities to thermo-regulate, e.g., by sweating.
The same issues also appear in other products, such as upholstery covers, e.g. for home furnishings, for furniture in institutional and contract markets, such as for offices, hotels, conference centers, etc., and for seating in transportation vehicles, such as automobiles, trucks, trains, buses, etc.
Standard textile fabrics have properties set during fabric construction that are maintained irrespective of, e.g., changes in ambient conditions and/or physical activity. These standard products can be effective, e.g., when layered with other textile fabrics for synergistic effect and enhancement of comfort.
According to one aspect of the disclosure, an insulated composite fabric comprises an inner fabric layer, an outer fabric layer, and an insulating-filler fabric layer enclosed between the inner fabric layer and the outer fabric layer. The insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric comprising multicomponent fibers formed of at least a first polymer and a second polymer disposed in side-by-side relationship. The first polymer and the second polymer exhibit differential thermal elongation or contraction to cause the multicomponent fibers to bend or curl and reversibly recover in response to changes in temperature, adjusting insulation performance of the textile fabric in response to ambient conditions.
Preferred implementations of this aspect of the disclosure may include one or more of the following additional features. At least one of the first and second polymers is a first thermoplastic polymer with low glass transition temperature. The first polymer is a polypropylene and the second polymer is a polyethylene (e.g., a linear low density polyethylene). The first polymer is a first polypropylene (e.g., an isotactic polypropylene) and the second polymer is a second polypropylene (e.g., a syndiotactic polypropylene) different from the first polypropylene. The multicomponent fibers further comprise a third polypropylene different from both the first polypropylene and the second polypropylene. The yarn has a denier of about 90 and to about 500, e.g., about 160. The yarn has a tenacity of about 0.5 grams-force per denier to about 5.0 grams-force per denier, e.g., about 2.3 grams-force per denier. The yarn has a filament count of 36 to 144. The yarn is a 72 filament yarn. In some examples, the multicomponent fibers have a round cross-section and the first and second polymers are arranged in a side-by-side configuration. The multicomponent fibers have a rectangular cross-section and the first and second polymers are arranged in a side-by-side configuration. The multicomponent fibers have a trilobal cross-section, and the first and second polymer may be arranged in a front-to-back, or left-to-right configuration. The multicomponent fibers have a delta cross-section. In some cases, the multicomponent fibers exhibit an overall average displacement of about −5% to about −60% (e.g., about −20% to about −40%) over a temperature range of from −22° F. (−30° C.) to 104° F. (+40° C.). The multicomponent fibers have a rectangular cross-section and serrated surface. The insulating-filler fabric layer can be attached by at least one of the inner and outer layer by sewing, tucking, laminating, or quilting. The inner and outer fabric layers can have the same or contrasting permeability. The inner and outer fabric layers have contrasting aesthetic properties.
In another aspect, an insulated composite fabric comprises an inner fabric layer, an outer fabric layer, and an insulating-filler fabric layer enclosed between the inner fabric layer and the outer fabric layer. The insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric incorporating yarn comprising multicomponent fibers formed of at least a polypropylene and a polyethylene disposed in side-by-side relationship. The polypropylene and the polyethylene exhibit differential thermal elongation or contraction to cause the multicomponent fibers to bend or curl and reversibly recover in response to changes in temperature, adjusting insulation performance of the insulated composite fabric in response to ambient conditions. The yarn has a denier of about 150 to about 160, and the multicomponent fibers exhibit an overall average displacement of about −5% to about −60% (e.g., about −20% to about −40%) over a temperature range of from −22° F. (−30° C.) to 104° F. (40° C.).
In some examples, the multicomponent fibers have a trilobal cross-section and the polypropylene and the polyethylene are arranged in a front-to-back configuration. The multicomponent fibers consist of about 50% polypropylene and about 50% polyethylene. The multicomponent fibers have a rectangular cross-section and serrated surface. The insulating-filler fabric layer can be attached by at least one of the inner and outer layer by sewing, tucking, laminating, or quilting. The inner and outer fabric layers can have the same or contrasting permeability. The inner and outer fabric layers have contrasting aesthetic properties.
In another aspect, a temperature responsive insulated composite fabric in the form of an article of apparel of or an apparel accessory can be comprised of the composite fabric. A second fabric portion having one or more contrasting properties from the first portion can be selected from contrasting stretch, contrasting water resistance, contrasting insulative properties, and contrasting air permeability.
The second fabric portion is formed of a second insulated composite fabric, the second insulated composite fabric comprising, a second inner fabric layer, a second outer fabric layer, and a second insulating-filler fabric layer enclosed between the second inner fabric layer and the second outer fabric layer. This composite fabric may form a temperature responsive home textile article. The article further comprise a second fabric portion, wherein the first and second fabric portions have one or more contrasting properties selected from contrasting stretch, contrasting water resistance, contrasting insulative properties, and contrasting air permeability. The second fabric portion is formed of a second insulated composite fabric, the second insulated composite fabric comprising: a second inner fabric layer, a second outer fabric layer, and a second insulating-filler fabric layer enclosed between the second inner fabric layer and the second outer fabric layer. The home textile article is selected from among a textile throw and a sleeping bag.
In another aspect of the disclosure, the disclosure features an insulated composite fabric comprising a unitary fabric element having a multiplicity of predetermined discrete regions of contrasting insulative capacities arranged based on insulative needs of corresponding regions of a user's body. At least two of the predetermined, discrete regions of contrasting insulative capacities comprise, in one or more first discrete regions of the unitary fabric element, loop yarn having a first pile height, and in one or more other discrete regions of the unitary fabric element, loop yarn having another pile height different from and relatively greater than the first pile height. The one or more first discrete regions correspond to one or more regions of the user's body having first insulative needs, and the one or more other discrete regions correspond to one or more regions of the user's body having other insulative needs different from and relatively greater than the first insulative needs.
Implementations of this aspect of the disclosure also include one or more of the following features. The insulated composite fabric consists essentially of the unitary fabric element. Additional unitary fabric elements are included in the insulated composite fabric. Each of the multiplicity of predetermined discrete regions extends generally across a width of the insulated composite fabric in a band form. The one or more first discrete regions correspond to one or more of an upper torso, head, and hip of the user's body. The one or more other discrete regions correspond to one or more of lower legs and feet, arms, and shoulders of the user's body. The unitary fabric element comprises a single face raised fabric and/or a double face raised fabric. The unitary fabric element comprises warp knit yarns and/or fibers, circular knit yarns and/or fibers, regular plaited yarns and/or fibers, reverse plaited yarns and/or fibers, or woven yarns and/or fibers. The unitary fabric element comprises a surface containing a chemical resin or a chemical binder for improved pilling resistance and/or abrasion resistance. An air permeability control element is laminated with the unitary fabric element to form a unitary fabric laminate. The air permeability control element is selected from the group consisting of: perforated membrane, crushed adhesive as a layer, foam adhesive as a layer, discontinuous breathable membrane, porous hydrophobic breathable film, and non-porous hydrophilic breathable film. An air and liquid water impermeable element is laminated with the unitary fabric element to form a unitary fabric laminate. The air and liquid water impermeable element is in the form of a breathable film select from the group consisting of: porous hydrophobic film and non-porous hydrophilic film. The unitary fabric element comprises yarns and/or fibers of one or more materials selected from the group consisting of: synthetic yarn and/or fibers, natural yarn and/or fibers, regenerate yarn and/or fibers, and specialty yarn and/or fibers. The synthetic yarn and/or fibers are selected from the group consisting of: polyester yarn and/or fibers, nylon yarn and/or fibers, acrylic yarn and/or fibers, polypropylene yarn and/or fibers, and continuous filament flat or textured or spun yarn made of synthetic staple fibers. The natural yarn and/or fibers are selected from the group consisting of: cotton yarn and/or fibers and wool yarn and/or fibers. The regenerate yarn and/or fibers are selected from the group consisting of; rayon yarn and/or fibers. The specialty yarn and/or fibers are selected from the group consisting of flame retardant yarn and/or fibers. The flame retardant yarn and/or fibers are selected from the group consisting of: flame retardant aramid yarn and/or fibers, and flame retardant polyester yarn and/or fibers. The one or more first discrete regions having a first pile height comprises loop yarn formed to a relatively lower pile using low sinker and/or shrinkable yarn. The one or more first discrete regions having a first pile height comprises loop yarn formed to a relatively lower pile height of up to about 1 mm. The one or more other discrete regions having another pile height different from and relatively greater than the first pile height comprises loop yarn formed to a relatively higher pile height in the range of greater than about 1 mm up to about 20 mm in a single face fabric. The one or more other discrete regions having another pile height different from and relatively greater than the first pile height comprises loop yarn formed to a relatively higher pile height in the range of greater than about 2 mm up to about 40 mm in a double face fabric.
In another aspect, the disclosure features an insulated composite fabric comprising an inner fabric layer, an outer fabric layer, and an insulating fabric layer attached to the outer fabric layer. The insulating fabric layer is a textile fabric having a raised surface facing towards the outer fabric layer. The raised surface includes a plurality of first discrete regions having a first pile height interspersed among a plurality of other discrete regions having contrasting pile height relatively greater than the first pile height.
Implementations of this aspect of the disclosure may also include one or more of the following features. The insulating-filler fabric layer has a terry sinker loop surface including a plurality of discrete regions of no terry sinker loop interspersed among regions of terry sinker loop. The insulating fabric layer has a weight of about 1 ounce (28.3 gms) per square yard (0.84 m2) to about 12 ounces (340.2 gms) per square yard (0.84 m2). The insulating-filler fabric layer is quilted to one or both of the inner fabric layer and the outer fabric layer. The insulating-filler fabric layer is stitched to one or both of the inner fabric layer and the outer fabric layer along a periphery of the insulated composite fabric. The insulating-filler fabric layer is laminated to one or both of the inner fabric layer and the outer fabric layer. The insulating-filler fabric layer is constructed to include face yarn that is positioned generally perpendicular to stitching or backing yarn. The insulating-filler fabric layer has a thickness (bulk) of about 0.1 inch (2.5 mm) to about 4.0 inches (10.2 cms). The first pile height in the first discrete regions is zero. Yarns forming the first discrete regions are relatively finer that yarns forming the other discrete regions. Yarns forming the first discrete regions have a denier per filament (dpf) of about 0.3 to about 5.0. The insulating-filler fabric layer provides insulation of about 0.2 clo/oz2 to about 1.6 clo/oz2 (where 1 clo equals 0.155 K m2/W and 1 ounce equals 28.3495 grams). The inner fabric layer comprises a woven fabric or a knit fabric. The knit fabric has single jersey construction, double knit construction, warp knit construction, or mesh construction. The inner fabric layer has air permeability of about 5 ft3/ft2/min (1.5 m3/m2/min) to about 300 ft3/ft2/min (91.4 m3/m2/min), tested according to ASTM D-737 under a pressure difference of ½ inch (12.7 mm) of water across the inner fabric layer. The outer fabric layer has air permeability of about 1 ft3/ft2/min (0.3 m3/m2/min) to about 100 ft3/ft2/min (30.5 m3/m2/min), tested according to ASTM D-737 under a pressure difference of ½ inch (12.7 mm) of water across the outer fabric layer. The outer fabric layer is treated with durable water repellent, an abrasion resistant coating, camouflage, or infrared radiation reduction. At least one of the inner fabric layer, the outer fabric layer, and the insulating-filler fabric layer includes flame-retardant material and/or is treated to provide flame-retardance. A waterproof membrane is laminated to an inner surface of the outer fabric layer, and disposed between the outer fabric layer and the insulating-filler fabric layer. The waterproof membrane is a vapor permeable membrane or is selected from a porous hydrophobic membrane, a hydrophilic non-porous membrane, and an electrospun membrane.
In another aspect, the disclosure features an insulated composite fabric comprising an inner fabric layer, an outer fabric layer, and a unitary fabric element between the inner fabric layer and the outer fabric layer. The unitary fabric element has a multiplicity of predetermined discrete regions of contrasting insulative capacities. The discrete regions are arranged based on insulative needs of corresponding regions of a user's body. In some implementations, at least two of the predetermined, discrete regions of contrasting insulative capacities comprise, in one or more first discrete regions of the unitary fabric element, loop yarn having a first pile height and/or a first pile density, the one or more first discrete regions corresponding to one or more regions of the user's body having first insulative needs, and in one or more other discrete regions of the unitary fabric element, loop yarn having a second pile height and/or a second pile density. The second pile height is different from and relatively greater than the first pile height and/or the second pile density is different from and relatively greater than the first pile density. The one or more other discrete regions correspond to one or more regions of the user's body having other insulative needs different from and relatively greater than the first insulative needs.
Implementations of this aspect of the disclosure may also include one or more of the following features. The outer fabric layer comprises a jacquard pattern to be exposed as an exterior surface of the insulated composite fabric. The inner fabric layer and/or the outer fabric layer comprise a light weight woven or knit having a density of about 2 oz./yard2 (67.8 gms/m2) to about 6 oz./yard2 (203.4 gms/m2). The inner fabric layer and/or the outer fabric layer comprise a knit having a density of about 1.0 oz./yard2 (33.9 gms/m2) to about 10.0 oz./yard2 (339.1 gms/m2). The unitary fabric element is connected to the outer fabric layer and connected to the inner fabric layer by stitching or quilting. The inner layer comprises a multiplicity of predetermined discrete regions of contrasting (or otherwise different) insulative capacities corresponding to the multiplicity of predetermined discrete regions of contrasting insulative capacities of the unitary fabric element. The multiplicity of predetermined discrete regions of the inner fabric comprises: in one or more in one or more first discrete regions of the inner fabric corresponding to the one or more first discrete regions of the unitary fabric element, loop yarn having a third pile height and/or a third pile density, and, in one or more other discrete regions of the inner fabric corresponding to the one or more other discrete regions of the unitary fabric element, loop yarn having a fourth pile height and/or a fourth pile density. The fourth pile height is different from and relatively greater than the third pile height, and/or the fourth pile density is different from and relatively greater than the third pile density. The outer layer comprises a multiplicity of predetermined discrete regions of contrasting insulative capacities corresponding to the multiplicity of predetermined discrete regions of contrasting insulative capacities of the unitary fabric element. The multiplicity of predetermined discrete regions of the outer fabric comprises: in one or more in one or more first discrete regions of the outer fabric corresponding to the one or more first discrete regions of the unitary fabric element, loop yarn having a third pile height and/or a third pile density, and, in one or more other discrete regions of the outer fabric corresponding to the one or more other discrete regions of the unitary fabric element, loop yarn having a fourth pile height and/or a fourth pile density. The fourth pile height is different from and relatively greater than the third pile height, and/or the fourth pile density is different from and relatively greater than the third pile density. The unitary fabric element has an air permeability of about 80 CFM (2,265 L/min.) to about 200 CFM (5,663 L/min.) in the one or more first discrete regions, and an air permeability of about 200 CFM (5,663 L/min.) to about 350 CFM (9,911 L/min.) in the one or more other discrete regions. Different regions of the insulated composite fabric have substantially the same or contrasting permeability as the respective regions of the unitary fabric element. The loop yarn in different regions of the one or more second discrete regions of the unitary fabric element have different pile densities. The loop yarn in different regions of the one or more second discrete regions of the unitary fabric element have different pile densities. Different regions of the plurality of other discrete regions have different pile densities.
Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
An insulated composite fabric, e.g., a textile home furnishings blanket or an outdoor blanket, may be tailored to the insulative requirements of different regions of the projected user's body, thus to optimize the comfort level of the person while sleeping. In most cases, the regions of a person's lower legs and feet and a person's arms and shoulders tend to be relatively more susceptible to cold and thus it will be desirable to provide a relatively higher level of insulation, e.g. relatively higher pile height and/or higher fiber or pile density, for greater comfort and sleep, while, in contrast, the region of a person's upper torso and regions of the person's hips and head, especially from the sides, tend to require relatively less insulation. In some implementations, the insulated composite fabric is a stand-alone, unitary engineered thermal fabric with regions of contrasting insulative capacity and performance arranged by body mapping concepts. Different regions of the unitary engineered thermal fabric can be formed of yarns having the same denier or different deniers. The insulated composite fabric can also be a composite fabric formed by stitching, quilting, attaching the unitary engineered thermal fabric with additional layers, or inserting the unitary engineered thermal fabric between two layers.
The term “pile,” as used herein, includes pile surfaces formed by any desired method, including but not limited to: loops, cut loops, loops cut on the knitting machine, loops cut off the knitting machine (i.e., after the fabric is removed from the knitting machine), and raised fibers.
Referring to
In some implementations, regions having different thermal insulation properties can also be formed on a unitary engineered thermal fabric by forming regions of pile having different pile densities. The pile in the different regions can have the same height or different heights.
Engineered thermal fabrics are created, and engineered thermal fabric articles, including insulated composite fabrics, e.g., thermal blankets, are formed of such engineered thermal fabrics, for the purpose of addressing thermal insulation and comfort level using the unitary engineered thermal fabric. The engineered thermal fabric articles reduce dependence on using multiple layers, while providing insulation and comfort. The engineered thermal fabric articles, e.g. garments and accessories, and home furnishings, such as blankets, throws, sleeping bags and the like, provide selected contrasting levels of insulation correlated to the requirements and/or desires of the underlying regions of the body, to create an improved comfort zone suited for a wide variety of thermal insulation needs.
Referring to
Referring to
As described above, the surfaces of the region 354 of the head, arms, and shoulders, and the region 352 of the lower torso, legs, and feet are plain velour, while the upper band region 356 and intermediate region 360 are low pile. Typically, the yarn and the pile density are maintained constant for all regions, again for simplicity of manufacture. The vertical widths of the respective regions represented in the drawing are by way of example only. Regions of any dimension can be arranged, tailored, e.g., for use by persons of different ages and different genders, etc. and for other factors, such as seasonality, etc.
Although particular patterns, e.g., formed by high pile, low pile and/or no pile (patterned with high pile regions and low pile regions, high pile regions and no pile regions, low pile regions and no pile regions, and/or high pile regions, low pile regions, and no pile regions), are shown in
For example,
In some implementations, one or more of the pile regions 384, 386, 388, 390 each can have a pattern formed of contrasting pile heights and/or the same pile height with contrasting pile densities. In the example shown in
The different pile regions can have different pile densities. Some pile regions can have 100% pile or a full raised surface, while some other regions can have less than 100% pile. Accordingly, using different pile densities in different pile regions, the regions can provide different thermal properties and aesthetic views even when they have the same pattern. The insulated composite fabric 380 can have a double face finish raised on both sides or a single face finish raised only on a single side.
In another example shown in
The unitary engineered thermal fabrics can be produced by any procedure suitable for creating regions with different pile heights and/or regions with no pile, in predetermined designs and arrangements. Examples of suitable procedures include, e.g., electronic needle and/or sinker selection, tubular circular or terry loop knit construction, e.g. by reverse plaiting (as described below with respect to
A pattern of contrasting pile height regions, including one or more regions with no loop pile yarn, is knitted, or otherwise formed, in a unitary fabric. If desired, multiple, different unitary engineered thermal fabrics can then be assembled to form an engineered thermal fabric article, e.g., a garment or the engineered insulated composite fabrics 300, 350 as shown in
During processing, the unitary engineered thermal fabrics may be dyed, and one or both surfaces finished to form regions of contrasting pile loop height, e.g., by raising one or both surfaces, or by raising one surface and cutting the loops on the opposite surface. The degree of raising will depend on the pile height of the loop pile yarn. For example, the knit can be finished by cutting the high loops, or shearing just the high pile, without raising the low loop pile height and/or the no loop pile height. Alternatively, the knit can be finished by raising the loop surface; the high loop will be raised higher on finishing to generate relatively higher bulk/greater thickness, and thus to have relatively increased insulative properties. Regions of contrasting bulk may also be obtained in a reverse circular knit terry construction by knitting two different yarns having significantly different shrinkage performance when exposed to dry or wet heat (e.g., steam or high temperature water) in a predetermined pattern. The very low shrinkage (e.g., 0 to 10% shrinkage) yarn may be spun yarn, flat filament yarn or set textured yarn, and the high shrinkage yarn (e.g., 20 to 60% shrinkage) may be heat sensitive synthetic yarn in flat yarn (like polypropylene) or high shrinkage polyester or nylon textured filament yarn. According to one implementation, the terry sinker loop yarn is cut on the knitting machine itself, where the velour height of the different yarns is identical, and the fabric is then exposed to high temperature (dry heat or wet heat), e.g. during dyeing, to generate differences in relative pile height between contrasting regions of the two types of yarn, based on the contrast in shrinkage characteristics. Contrasting pile height may also be achieved by knitting one yarn into loops to be cut to a desired height on the knitting machine or later in the finishing process in combination with a low pile knitted to a zero pile height (e.g., 0 mm sinker). The engineered thermal fabric articles may also include regions of no loop at all, to provide an additional contrasting level or height of pile (i.e., no pile).
The outer-facing surface (i.e., the technical back loop, or the technical face (jersey), where the latter is preferred for single face fabrics) of the engineered thermal fabrics may also be treated with a resin or chemical binder to form a relatively hard surface for resistance to pilling and/or abrasions, e.g. as described in U.S. Patent Application Publication No. 2005-0095940 and U.S. Pat. No. 7,038,177.
The pattern of contrasting pile heights, which may be varied to accommodate any predetermined design, can also be optimized for a variety of different thermal insulation preferences or uses. For example, referring again to
In some implementations, in addition to being engineered for controlled insulation, the unitary engineered thermal fabrics described above may be laminated to knit fabrics with velour of at least one pile height, e.g., low, high and/or any combination thereof, or to woven fabrics with or without stretch. Optionally, a membrane may be laminated between the layers of fabric to cause the laminate to be impermeable to wind and liquid water, but breathable (e.g., a porous hydrophobic or non-porous hydrophilic membrane), as in fabric product manufactured by Polartec, LLC, successor to Malden Mills Industries, Inc., as described in U.S. Pat. Nos. 5,204,156; 5,268,212 and 5,364,678. Alternatively, the laminate may be constructed to provide controlled air permeability (e.g., by providing an intermediate layer in the form of a perforated membrane, a crushed adhesive layer, a foam adhesive layer, or a discontinuous breathable membrane), as in fabric product manufactured by Polartec, LLC, successor to Malden Mills Industries, Inc., as described in U.S. patent application Ser. No. 09/378,344, and U.S. Patent Application Publication Nos. 2002-0025747, 2003-0104735 and 2005-0020160.
Referring again to
Referring to
As described above, the loop yarn 40 forming the technical back 34 of the knit fabric body 32 can be made of any suitable synthetic or natural material. The cross section and luster of the fibers or filaments can be varied, e.g., as dictated by requirements of intended end use. The loop yarn 40 can be a spun yarn made by any available spinning technique, or a filament flat or textured yarn made by extrusion. The loop yarn denier is typically between about 40 denier to about 300 denier. A preferred loop yarn is a 200/100 denier T-653 Type flat polyester filament with trilobal cross section, e.g., as available commercially from E.I. DuPont de Nemours and Company, Inc., of Wilmington, Del., or 2/100/96 texture yarn to increase tortuosity and reduce air flow, e.g., yarn from UNIFI, Inc., of Greensboro, N.C.
The stitch yarn 42 forming the technical face 36 of the knit fabric body 32 can be also made of any suitable type of synthetic or natural material in a spun yarn or a filament yarn. The denier is typically between about 50 denier to about 150 denier. A preferred yarn is a 70/34 denier filament textured polyester, e.g., as available commercially from UNIFI, Inc., of Greensboro, N.C. Another preferred yarn is cationic dyeable polyester, such as 70/34 T-81 from DuPont, which can be dyed to hues darker or otherwise different from the hue of the loop yarn, to further accentuate a pattern.
In the preferred method, the fabric body 32 is formed by reverse plaiting on a circular knitting machine. This is principally a terry knit, where loops formed by the loop yarn 40 cover or overlie the stitch yarn 42 on the technical face 36 (see
Referring now to
Also, the unitary engineered thermal fabrics can have pile of any desired fiber density and any desired pile height, with the contrast of insulative capacity and performance achieved, e.g., by relatively different pile heights (e.g., using different sinker heights), relatively different pile densities (e.g., using full face velour and velour with pattern of low pile or no pile), and relatively different types of yarns (e.g., using flat yarns with low shrinkage and texture yarns with high shrinkage). The unitary engineered thermal fabrics having contrasting high pile, low pile, and/or no pile may be generated, e.g., by electronic sinker selection or by resist printing, as described below, and as described in U.S. Provisional Patent Application No. 60/674,535, filed Apr. 25, 2005. For example, sinker loops of predetermined regions of the fabrics may be printed with binder material in an engineered body mapping pattern, e.g., to locally resist raising. The surface is then raised in non-coated regions. The result is a fabric having an engineered pattern of raised regions and non-raised regions. The printed regions may be formed of sub-regions of contrasting thermal insulation and breathability performance characteristics by use of different binder materials, densities of application, penetration, etc., thereby to achieve optimum performance requirements for each sub-region of the engineered printing pattern.
Other aesthetic effects may also be applied to the face side and/or to the back side of the engineered thermal fabric, including, e.g., color differentiation and/or patterning on one or both surfaces, including three dimensional effects. Selected regions may be printed, and other regions may be left untreated to be raised while printed regions remain flat, resisting the napping process, for predetermined thermal insulation and/or breathability performance effects. Also, application of binder material in a predetermined engineered pattern may be synchronized with the regular wet printing process, including in other regions of the fabric body. The wet printing may be applied to fabric articles made, e.g., with electronic sinker loop selection or cut loop (of the pile) of cut loop on the knitting machine and may utilize multiple colors for further aesthetic enhancement. The colors in the wet print may be integrated with the resist print to obtain a three-dimensional print on one or more regions of the fabric, or even over the entire fabric surface. The sizes, shapes and relationships of the respective regions represented in the drawing are by way of example only. Regions of any shape and size can be arranged in any desired pattern, tailored, e.g., for use by persons of different ages and different genders, etc. and for other factors, such as seasonality, etc.
In some implementations, an insulated composite fabric, such as the insulated composite fabrics 300, 350 of
As an example,
The insulating-filler fabric layer 123 can have features similar to or the same as the unitary engineered thermal fabrics of
In some implementations, the outer fabric layer 122 of the insulated composite fabric has a jacquard pattern to enhance the synergy with the insulating-filler fabric layer 123, and to provide the insulated composite fabric with aesthetic appeal. The outer fabric layer 122 and/or the inner fabric layer 121 can have a pattern, e.g., formed of regions having contrasting pile heights and/or pile densities, that corresponds to the pattern of the insulating-filler fabric layer to enhance the comfort level of the user. The patterned inner and outer fabric layers 121, 122 do not substantially restrict heat dissipation at the desired regions of the incorporated insulating-filler fabric layer, e.g., regions covering the hip. As a result, the thermal properties of an insulated composite fabric made from an insulated composite fabric are not substantially different from insulated composite fabrics that are made only from the unitary engineered thermal fabric included in the insulated composite fabric. The insulated composite fabric made from the insulated composite fabrics can also provide thermal features as discussed for the insulated composite fabrics 300, 350, e.g., thermal blankets, and can provide superior comfort to a user, e.g., by providing more insulation in predetermined region(s), and lower thermal insulation and better breathability in other region(s) than a conventional blanket provides. The outer and/or inner fabric layer can be a knit having a light weight, e.g., about 1.0 oz./yard2 (33.9 gms/m2) to about 6.0 oz./yard2 (203.4 gms/m2).
In some implementations, the insulating-filler fabric layer 123 is a textile fabric with raised surface on one side or both sides. The textile fabric of the insulating-filler fabric layer 123 is constructed to include face yarn (pile) that is positioned generally perpendicular to stitching or backing yarn. This type of construction can provide high bulk with good resiliency to maintain the thermal insulation of the insulating-filler fabric layer 123 even under compression.
Referring to
Alternatively or additionally, the insulating-filler fabric layer 123 may be formed from a double face knit fabric having reverse plaited terry sinker loop knit construction. Referring to
Referring to
Alternatively, or additionally, the insulating-filler fabric layer 123 may be formed from a fabric having a sliver knit construction. The sliver knit construction can be formed by circular knitting coupled with the drawing-in of sliver of fibers to produce a pile like fabric. The sliver knit construction allows for the use of relatively coarse fiber (e.g., 5 dpf to 15 dpf). This relatively coarse fiber can provide for good resiliency and resistance to compression, and can generate very high pile (e.g., pile height of 3 inches (7.6 cms) to 4 inches (10.2 cms)). The sliver fabric of the insulating-filler fabric layer can be finished as a single face fabric with a raised surface at the technical back, or as a double face fabric with raised surfaces on both the technical back and the technical face. Generally, the sliver knit construction is prone to “shedding” and may exhibit undesirable aesthetic appearance (e.g., poor finish) when raised on the technical face. However, when incorporated as a filler layer, the aesthetic appearance of the raised technical face is less critical since the fabric is enclosed between the outer “shell” fabric layer 122 and the inner “shell-liner” fabric layer 121 (
In some implementations, the insulating-filler fabric layer 123 may include elastomeric material for enhanced stretch and recovery. For example, the insulating-filler fabric layer 123 may include elastomeric yarns and/or fibers, e.g., incorporated in the backing or stitching yarns. In some examples, the insulating-filler fabric layer 123 has stretch without including elastomeric material.
The insulating-filler fabric layer 123 has a weight of about 1 ounce (28.3 gms) per square yard (0.84 m2) to about 12 ounces (340.2 gms) per square yard (0.84 m2), has relatively high thickness (bulk) (e.g., a thickness of at least about 0.1 inch (2.5 mm), e.g., about 0.1 inch (2.5 mm) to about 1.0 inch (2.5 cms)), and has high insulation per weight unit (e.g., about 0.2 clo/oz2 to about 1.6 clo/oz2).
The insulating-filler fabric layer 123 may consist of a hydrophobic fabric, which, in case of water penetration through the outer fabric layer 122 (
The inner and outer fabric layers 121, 122 (
In some cases, the inner fabric layer 121 and/or the outer fabric layer 122 can also include elastomeric material, such as elastomeric yarns and/or fibers incorporated in the construction of the respective fabrics, for enhanced stretch and recovery. The incorporation of elastomeric material in the inner and outer fabric layers 121, 122 can be particularly beneficial where the insulating-filler fabric layer 123 also has stretch, such that the inner fabric layer 121 and the outer fabric layer 122 can stretch and move with the insulating filler layer 123 for enhanced user comfort.
The moisture vapor transmission rate and the air permeability of the insulated composite fabric 120 can be controlled by the void or openness of the fabric or fabrics of the inner and/or outer fabric layers 121, 122. In some cases, for example, the control of the air permeability of the insulated composite fabric 120 can be achieved by controlling one or more parameters (e.g., yarn size, yarn count, and/or weave density (pick/fill)) of the fabric forming the inner “shell-liner” fabric layer 121 and/or the outer “shell” fabric layer 122. Alternatively, or additionally, the control of the air permeability of the insulated composite fabric 120 can be achieved by applying a coating or film lamination 124 (
The respective fabrics of the inner and outer fabric layers 121, 122 can be selected to provide the insulated composite fabric 120 with air permeability within a range of about 1.0 ft3/ft2/min (0.3 m3/m2/min) to about 300 ft3/ft2/min (91.4 m3/m2/min), according to ASTM D-737, under a pressure difference of ½ inch (12.7 mm) of water across the insulated composite fabric 120. Depending on the particular construction, the composite fabric 120 may be tailored toward different end uses. For example, the insulated composite fabric 120 can be constructed to provide cold weather insulation with relatively high air permeability. In this case, the respective fabrics of the inner and outer fabric layers 121, 122 can be selected to provide the insulated composite fabric 120 with an air permeability of about 100 ft3/ft2/min (30.5 m3/m2/min) to about 300 ft3/ft2/min (91.4 m3/m2/min), according to ASTM D-737, under a pressure difference of ½ inch (12.7 mm) of water across the insulated composite fabric 120.
Alternatively, the insulated composite fabric 120 can be constructed to provide cold weather insulation with relatively low air permeability. In this case, the respective fabrics of the inner and outer fabric layers 121, 122 can be selected to provide the insulated composite fabric 120 with an air permeability of about 1 ft3/ft2/min (0.3 m3/m2/min) to about 80 ft3/ft2/min (24.4 m3/m2/min), according to ASTM D-737, under a pressure difference of ½ inch (12.7 mm) of water across the insulated composite fabric 120.
In some cases, the inner fabric layer 121 can have relatively higher air permeability than the fabric of the outer fabric layer 122. Utilizing fabric with relatively higher air permeability for the inner fabric layer 121, which is disposed facing towards the user's body, can help to enhance vapor movement and vapor transmission away from the user's body to help prevent overheating. For example, the inner fabric layer 121 may have an air permeability of about 5 ft3/ft2/min (1.5 m3/m2/min) to about 300 ft3/ft2/min (91.4 m3/m2/min), tested according to ASTM D-737, under a pressure difference of ½ inch (12.7 mm) of water across the inner fabric layer 21, and the outer fabric layer 122 may have an air permeability of about 1 ft3/ft2/min (0.3 m3/m2/min) to about 100 ft3/ft2/min (30.5 m3/m2/min) (e.g., about 1 ft3/ft2/min (0.3 m3/m2/min) to about 30 ft3/ft2/min (9.1 m3/m2/min)), tested according to ASTM D-737, under a pressure difference of ½ inch (12.7 mm) of water across the outer fabric layer 122.
In some implementations, the outer fabric layer 122 with controlled air permeability is rendered flame retardant by including inherent and/or treated flame resistant or flame retardant yarns and/or fibers and/or is woven with 100% polyester or nylon treated for flame retardant features.
In a unitary engineered thermal fabric, the height of the higher sinker loop pile is about 2.0 mm to about 5.0 mm, e.g. the relatively higher loop pile height is typically about 3.5 mm and can be about 5 mm to about 6 mm after raising, and the relatively lower sinker loop pile is about 0.5 mm to about 1.5 mm. Regions with relatively higher loop pile generate significantly higher bulk than regions with relatively lower loop pile and, as a result, provide higher insulation levels. Regions with no loop pile do not generate any bulk, and subsequently can have very high breathability to enhance cooling, e.g., cooling by heat of evaporation.
An insulated composite fabric can be made from this unitary engineered thermal fabric alone, or with additional inner and outer fabric layers, such as the inner and outer fabric layers 121, 122 of
In another engineered thermal fabric article that includes a unitary engineered thermal fabric, one sinker loop pile yarn is employed with a variety of no loop pile in predetermined patterns and contrasting density to create a large region of no loop pile, e.g., in the neck and armpit areas, for minimum insulation; a region of mixed pile and no loop pile in the abdominal area, for medium insulation; and a region of 100% loop pile in the chest area, for maximum insulation.
An insulated composite fabric can be made from this unitary engineered thermal fabric alone, or with additional inner and outer fabric layers, such as the inner and outer fabric layers 121, 122 of
Referring next to
The engineered first layer 194 of the unitary engineered thermal fabric 190, i.e. the inner surface disposed to face the user's skin is further enhanced. For example, the layer may include synthetic fibers, like polyester, treated chemically to render the fibers hydrophilic. Also, spandex may be added to the plaited knit construction to achieve better stretch recovery properties, as well as to obtain two-way stretch, i.e., lengthwise and widthwise. For example, in one implementation, a triple plaited jersey construction is employed, with spandex yarn plaited between an inner layer of coarse fibers of synthetic material treated chemically to render the fibers hydrophilic and an outer layer of natural fibers, such as wool or cotton. The knit fabric may also be formed with double knit or double plaited jersey construction.
The second (outer) layer 192 of the unitary engineered thermal fabric may be provided with anti-microbial properties, e.g. for minimizing undesirable body odors caused by heavy sweating, e.g. due to high exertion, by applying anti-microbial chemicals to the surface 196 of the fabric 190 or by forming the second (outer) fabric layer 192 with yarn having silver ions embedded in the fibers during the fiber/yarn extrusion process or applied to the surface of the fibers (e.g., as described in U.S. Pat. No. 6,194,332 and U.S. Pat. No. 6,602,811). Yarn employed in forming the first (inner) fabric layer 194 may include fibers containing ceramic particles, e.g. ZrC (zirconium carbide) in order to enhance body heat reflection from the skin, and to provide better thermal insulation (e.g. as described in the U.S. Pat. No. 7,217,456).
An insulated composite fabric can be made from this unitary layer engineered thermal fabric alone, or with additional inner and outer fabric layers, such as the inner and outer fabric layers 121, 122 of
Unitary engineered thermal fabrics for use in insulated composite fabrics may be formed using a suitable knitting system for providing two and/or three contrasting pile heights in one integrated knit construction, which can be finished as single face or double face.
For example, in a first system, sinker loops of contrasting pile height may be generated at different, predetermined regions with high loop (about 3.5 mm loop height and 5 to 6 mm after being raised), low loop and no loop. In second system, the loop yarn may be cut on the knitting machine, forming regions of high pile height (up to about 20 mm) and no pile. In each system, using circular knitting, a single type of yarn may be employed, or yarns of different characteristics, e.g. contrasting shrinkage, luster, cross section, count, etc., may be employed in different regions.
In the case of loops yarn, e.g. as in the first system, the loops may be left as is (without raising), or the highest loops may be cut (leaving the lower loop and no loop “as is”), or both loops may be napped, in which case both loops will generate velour after shearing at the same pile height, and only after tumbling will pile differentiation be apparent, with generation of shearling in the higher loop and small pebble in the lower loop.
In the case of contrasting yarns, as in the second system, differentiation in pile height between different regions will be based on the individual yarn characteristics, which will become apparent after exposure to thermal conditions.
Maximum knitting capability for creation of the discrete regions of contrasting characteristics may be provided by use of electronic sinker loop selection, which will generate different loop heights in the knit construction, and electronic needle selection, which will generate different knit constructions of the stitch yarn, such as 100% knit, knit-tuck, knit-welt, and knit-tuck-welt, with different aesthetics and contrasting air permeability performance in predetermined regions, with our without sinker loops.
A unitary engineered thermal fabric is formed as described above with a pattern of one or more regions having a first pile height and one or more regions having no pile. The one or more regions of first pile height are formed with two different yarns of significantly different shrinkage performance. For example, the yarn having relatively high shrinkage is made of very fine micro fibers, e.g. 2/70/200 tx, and the yarn having relatively less or no shrinkage is made of relatively more coarse and longer fibers, e.g. 212/94 polyester yarn with ribbon shape. When exposed to heat, the fabric forms a textured surface without pattern, resembling animal hair, with long, coarse fibers (like guard hairs) extending upwards from among the short, fine fibers at the surface. This is almost a “pick and pick” construction, or can be termed “stitch and stitch” for knit construction.
An insulated composite fabric can be made from this unitary layer engineered thermal fabric alone, or with additional inner and outer fabric layers, such as the inner and outer fabric layers 121, 122 of
Two insulated composite fabrics (A, B) were made and their thermal properties were measured using infra-red photography. First insulated composite fabric (A) was made of a stand-alone unitary engineered thermal fabric having double raised surfaces. Second insulated composite fabric (B) included the same unitary engineered thermal fabric as used in the first insulated composite fabric (A). However, the unitary engineered thermal fabric in the second insulated composite fabric (B) was covered by an outer fabric layer and an inner fabric layer, each formed of a light weight knit (e.g., about 3 oz./yard2 (101.7 gms/m2)). The first and second insulated composite fabrics (A, B) were each placed over a thermal object held at a constant temperature of 104° C.
Referring to
While certain embodiments have been described above, other embodiments are possible.
For example, an entire insulated composite fabric, e.g., thermal blanket, may be constructed from the unitary engineered thermal fabric or the insulated composite fabric, or, in some cases, an insulated composite fabric may be formed to include multiple unitary engineered thermal fabrics or multiple insulated composite fabrics, e.g., in different regions. In some implementations, an insulated composite fabric may include the unitary engineered thermal fabric(s) or insulated composite fabric(s) only in sections, e.g., the different regions of the insulated composite fabrics 300, 350 of
Referring to
The second insulated composite fabric 450 can be used to cover a different portion of a user's body than the first fabric portion 430, and, like the first insulated composite fabric 430, may also have a construction as described above with regard to
Alternatively, or additionally, the first and second insulated composite fabrics 430, 450 can have contrasting stretch. For example, the first insulated composite fabric 430 may have relatively greater stretch (e.g., in the outer shell, the inner shell layer, and/or the insulting-filler) than the second insulated composite fabric 450.
In some cases, unitary engineered thermal fabrics can be used to form an insulated composite fabric. Each unitary engineered thermal fabric can consist of a plain textile fabric, e.g., a circular knit like single jersey (plaited or non-plaited), double knit, rib, warp knit, or woven with and/or without stretch. Or, as another alternative, the unitary thermal fabric may consist of a double face knit fabric having reverse plaited, terry sinker loop, and/or knit construction. Suitable fabrics for forming the unitary thermal fabrics are commercially, available, e.g., from Polartec, LLC, of Lawrence Mass., under the trademarks POWER STRETCH™ and BOUNDARY™.
In some cases, the unitary engineered thermal fabric for use in an insulated composite fabric may be incorporated into a laminate composite fabric with outer and inner fabric layers, and a barrier resistant to wind and liquid water, while providing water vapor transport through absorption-diffusion-desorption, including a hydrophilic barrier and/or adhesive layer adhered to the inner and/or outer fabric layer. Suitable laminate composite fabrics are commercially available, e.g., from Polartec, LLC, of Lawrence Mass., under the trademarks WINDBLOC® and POWER SHIELD®.
In some cases, enhancing the packability and/or compression (i.e., reducing the total volume of the insulated composite fabric) can be achieved by having voids or pile out regions (i.e., regions of no pile) in a predetermined pattern in the insulating-filler fabric layer. For example,
As mentioned above, the raised surface knit fabric of the insulating filler layer may have a construction made on a warp knitting, double needle bar raschel machine, where the pile yarns are grouped in a predetermined pattern, and some predetermined sections have voids (no pile yarn). For example,
In dynamic conditions (air flow or wind blowing onto the shell material having controlled air permeability), the thermal insulation in the void region may be reduced.
However, the loss of thermal insulation can be reduced by providing relative lower fleece/velour (e.g. lower than the interconnecting pile) in the void regions 512a, 512b. This can be done by adding additional pile yarn 530 (preferably in fine dpf like micro fiber under 5.0 denier, e.g., under 1.0 denier or between 0.3 denier and 5.0 denier) without generating interconnecting pile, but which is held by the stitch and backing yarn along the technical face (
While embodiments of insulating-filler fabrics have been described that include one or more raised surfaces, in some implementations, e.g., where relatively less insulation is needed, the insulating-filler fabric may instead have a regular knit construction (single or double face), which is finished on one side or both sides by brushing.
In some cases, the outer “shell” fabric layer, the inner “shell-liner” fabric layer, and/or the insulating-filler fabric layer may be formed of, and/or incorporate, flame-retardant materials (e.g., flame retardant fibers), or may be treated (e.g., chemically treated) to provide flame-retardance. In some implementations, the outer “shell” fabric layer is treated with durable water repellent (DWR), an abrasion resistant coating, camouflage, and/or infrared radiation reduction.
Although embodiments of insulated composite fabrics have been described in which an insulating-filler fabric layer is attached to one or both of an inner fabric layer and an outer fabric layer by sewing, in some cases, the insulating-filler fabric layer may be laminated to one or both of the inner fabric layer and the outer fabric layer.
Either or both of the insulating fabric layer 721 and the outer fabric layer 722 can have stretch in at least one direction. In some cases, for example, either or both of the insulating fabric layer 721 and the outer fabric layer 722 can include elastomeric material (e.g., spandex yarns and/or fibers) for enhanced stretch and shape recovery.
Referring still to
Either or both of the insulating fabric layer 721′ and the outer fabric layer 722 can have stretch in at least one direction. The moisture vapor transmission rate and the air permeability of the insulated composite fabric 720′ can be controlled, e.g. as discussed above with regard to
In some cases, the insulated composite fabric for use in an insulated composite fabric may be provided with water resistant properties. For example, the outer “shell” fabric layer may have a very tight construction (e.g., a tight woven construction) and may be treated with durable water repellent (DWR). Alternatively, or additionally, the insulated composite fabric may be provided with a waterproof membrane (e.g., a breathable waterproof membrane). For example,
In some embodiments, a reversible insulated composite fabric including an insulated composite fabric may also be provided. For example, the insulated composite fabric can be similar to that described above with reference to
In some cases, the insulating-filler fabric layer, or the unitary engineered thermal fabric, may consist of a terry sinker loop (in reverse plaiting or regular plaiting) in which the terry loop is left un-raised. A relatively higher sinker (e.g., 2 to 9 mm) can be used to form the terry sinker loop. In this construction, the terry sinker loop may be provided in a predetermined pattern or design, while having other section(s) without the terry sinker loop (i.e. having voids), to reduce the total weight, as well as increasing the pliability and increasing the “packability” (e.g., by permitting easier folding). As mentioned above, the terry sinker loop can be made in regular plaiting construction, or in reverse plaiting construction. In the case of reverse plaiting constructions, the technical face (jersey side) may be finished, and the technical back may be left in a terry sinker loop (un-napped), or the terry sinker loop may be left on the technical back, without napping the technical face jersey side (similar to regular plaited construction).
In some implementations, the insulating-filler fabric layer or the unitary engineered thermal fabric may be formed with plaited construction, e.g. plaited jersey or double knit construction, e.g. as described in U.S. Pat. No. 6,194,322 and U.S. Pat. No. 5,312,667, with a denier gradient, i.e. relatively finer dpf on the outer surface of the fabric and relatively more coarse dpf on the inner surface of the fabric, for better management of water (e.g. liquid sweat). In preferred implementations, one or more regions will be formed with full mesh, i.e. see-through holes, for maximum ventilation, and contrasting regions of full face plaited yarn for movement of moisture, with intermediate regions in other areas of the insulated composite fabric having relatively lesser concentrations of mesh openings, the regions being positioned to correlate with the ventilation requirements of the user's underlying body.
Although the term “blanket” is used throughout the disclosure, such a blanket can be understood to refer to other bedding components, such as linens, sheets, and others.
In some implementations, the insulating-filler fabric layer 123 can be formed from a bi-component fiber, as described in U.S. Patent Application Publication No. 2011-0052861. An example of a bi-component fiber 1010 is shown in
For example, in one embodiment, the first fiber component A has a relatively greater coefficient of thermal expansion (i.e., a relatively greater propensity to grow and/or expand in response to an increase in temperature) as compared to the second fiber component B. When the fiber 1010 is exposed to heat over a given critical temperature range, the first fiber component A expands at a relatively greater rate than the second fiber component B causing the fiber to bend (see, e.g.,
In any of the foregoing knit constructions, elastomeric yarn (e.g., spandex such as Lycra®) may be added to, e.g., the stitch yarn. For example, in some cases, spandex is incorporated into the stitch yarn for enhanced stretch and shape recovery. As the ambient temperature is increased, the fibers of the raised surface(s) begin to bend and/or curl toward the surface changing the loft, volume, and density, i.e., weight per volume, of the fabric, and, as a result, adjust the insulation performance of the fabric 1020.
Preferably, the changes in three dimensional configuration occur over a temperature range of between about 32° F. (0° C.) and about 120° F. (48.9° C.), more preferably, between about 50° F. (10° C.) and about 100° F. (37.7° C.).
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of the invention. For example, the bi-component fibers may have a variety of cross-sectional shapes.
The bi-component fibers can have plain surfaces and/or one or more serrated surfaces. For example,
In some embodiments, the bi-component fiber can include two non-compatible polymers (i.e., fiber components) or polymers with poor compatibility such as nylon and polyester. For example, in some cases the bi-component fiber may include nylon and polyester fibers disposed in side-by-side relationship. Fibers formed with non-compatible polymers or polymers with poor compatibility may exhibit a tendency to split; i.e., the individual fiber components may exhibit a tendency to separate, which can alter the effects of the bi-component response to changes in temperature.
In some embodiments, a temperature responsive textile fabric, such as the temperature responsive smart textile fabric of
Table 1 lists the particulars and performance of a number of sample yarns formed of bi-component fibers of this disclosure, each consisting of a first polymer (PH-835 polypropylene, manufactured by Basell Canada Inc., Corunna, Ontario, sold under the trademark Pro-Fax™ PH835 described in Material Safety Data Sheet PH835 of Basell, Issue Date: Mar. 28, 2000, Revision No.: New MSDS) and a second polymer (linear low density polyethylene, e.g., 8335 NT-7 LLDPE available from The Dow Chemical Company, Midland, Mich. and described in Material Safety Data Sheet 22539/1001 of Dow Chemical Company, Issue Date: Sep. 18, 2008, Version: 2.2) at a 50/50 ratio.
Referring to Table 1, sample yarn 1 was a 144 filament yarn. Sample yarn 1 had an average denier of 320.3, exhibited an average elongation of 101%, and had an average tenacity of 2.39 grams-force per denier (gpd). The filaments of sample yarn 1 have a round (RND) cross-section, in which the first and second polymers had been co-extruded in a side-by-side (S/S) configuration, e.g., as seen in
A total of four single fiber thermal displacement tests were run on test fibers of sample yarn 1 at the starting temperature of −30° C. (−22° F.). At −30° C. the individual fiber is in a substantially vertical orientation. As the temperature is increased to 0° C. (32° F.), the loft (i.e., the height of the fiber in the vertical direction) decreases. The loft of the fiber under test continues to decrease as the temperature is increased to +40° C. (104° F.).
The % Average Displacement for each of the four single fiber thermal displacements tests for sample yarn 1 was calculated by determining a % change in height (loft) H1 for the front view of the fiber under test and a % change in height (loft) H2 for a side view of the fiber under test and then taking an average of those two values. The fiber of sample yarn 1 exhibited an overall average displacement of −15% over the temperature range of −30° C. (−22° F.) to +40° C. (104° F.). Identical tests were conducted for sample yarns 2 and 3.
Sample yarn 2 was a 72 filament yarn. Sample yarn 2 had an average denier of 159.7, exhibited an average elongation of 111%, and had an average tenacity of 2.28 grams-force per denier (gpd). The filaments of sample yarn 2 have a trilobal (TRI) cross-section, in which the first and second polymers (PH-835 PP and 8335 NT-7 LLDPE, respectively) had been co-extruded, side-by-side, in a front-to-back (F/B) configuration, e.g., as seen in
A total of four single fiber thermal displacement tests were also run on test fibers of sample yarn 2. The fibers of sample yarn 2 exhibited a decrease in height with increasing temperatures. The fiber of sample yarn 2 exhibited an overall average displacement of −40% over the temperature range of −30° C. (−22° F.) to +40° C. (104° F.).
Sample yarn 3 was a 144 filament yarn having a trilobal cross-section, e.g., similar to the cross section seen in
A total of four single fiber thermal displacement tests were run on an individual filament of sample yarn 3. The fiber of sample yarn 3 also exhibited a decrease in height with increasing temperatures. The fiber of sample yarn 3 exhibited an overall average displacement of −12% over the temperature range of −30° C. (−22° F.) to +40° C. (104° F.).
The yarns exhibited an overall average displacement of about −5% to about −60%, e.g., about −20% to about −40%, over a temperature range of from −22° F. (−30° C.) to 104° F. (+40° C.).
In another embodiment, the filament yarn can have filaments with a trilobal cross-section, where the first and second polymers (PH-835 PP and 8335 NT-7 LLDPE, respectively) have been co-extruded side-by-side, in a left-to-right (L/R) configuration.
Other suitable polypropylenes include 36011 PP, available from Braskem PP Americas, Inc., and described in Material Safety Data Sheet CP360H Homopolymer Polypropylene published by Sunoco Chemical, Revision Date: Mar. 26, 2008, which references Material Safety Data Sheet code number C4001 published by Sunoco Chemicals, dated Jan. 25, 2006).
Other fiber cross-sections are also within the scope of this disclosure. For example, a component yarn can include bi-component fibers (polypropylene/polyethylene) having a rectangular cross-section. Other fibers may have a delta cross-section. In some case, for example, yarns may include fibers (e.g., multicomponent fibers) having different, relative cross-sectional shapes. For example, some yarns may include round fibers and tri-lobal fibers.
In some embodiments, a temperature responsive textile fabric, suitable for use in a fabric garment, can incorporate yarns that include tri-component fibers consisting of three types of propylene (e.g., Isotactic polypropylene (iPP), Syndiotactic polypropylene (sPP), and Polypropylene PP).
While yarns comprising fibers of various cross-sectional shapes have been described, other shapes are also within the scope of this disclosure, e.g., delta cross-section fibers, which can be incorporated into a multifilament yarn.
In some implementations, the textile fabric may be produced by any procedure suitable for combining yarns and/or fibers to create a finished fabric having at least one raised surface. The first and second materials of the multicomponent fibers can exhibit differential elongation in response to changes in relative humidity, or changes in level of liquid sweat (e.g., where the temperature responsive fabric is incorporated in a garment). The raised surface can be finished as fleece, velour, pile and/or terry loop. The temperature responsive textile fabric can be incorporated in an insulative layer in a multi-layer garment system. Accordingly, other embodiments are within the scope of the following claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2013/056709 | 8/27/2013 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 61698982 | Sep 2012 | US |
