LIGHT WEIGHT RAIN APPAREL

Abstract

An article of apparel such as a rain jacket includes a composite fabric formed of a textile layer including a plurality of yarns, each yarn including five to twenty-five filaments having non-circular cross-sectional shapes and a sealing layer applied as a coating directly to the interior surface of the textile layer and having a thickness of about 10 micrometers to about 30 micrometers.

Description

FIELD OF THE INVENTION

The present invention relates to articles of rain apparel and, in particular, a rain jacket.

BACKGROUND OF THE INVENTION

Rainwear typically includes multiple layers laminated together utilizing adhesive. However, providing multiple layers adds to the weight of the apparel. In addition, moisture can become trapped between the layers, further increasing the apparel's weight (due to the water retention), as well as causing a discomfort to the wearer. In addition, the trapped moisture requires a period of time for the apparel to completely dry (i.e., for the moisture to escape or evaporate from the apparel) before it is used again.

It would be desirable to provide a suitable article of apparel that sufficiently repels water, is lightweight, and inhibits or prevents pick-up of moisture between and/or within layers of the apparel thus enabling a more rapid drying time of the article of apparel after use.

BRIEF SUMMARY OF THE INVENTION

An article of rain apparel as a rain jacket is formed partially or completely of a composite fabric including a textile layer and a sealing layer. The textile layer comprises a plurality of yarns, each yarn including five to twenty five filaments, where each filament has a cross-sectional shape that is non-circular (e.g., polygonal). Each yarn in the textile layer may possess a denier ranging from about 20 to about 50. The denier per filament of each yarn can range from about 2.0 to about 4.0. The sealing layer is formed by coating a predetermined amount of flowable polymer such as polyurethane directly onto a surface of the textile layer to form a continuous layer along the textile surface. The polymer is cured, resulting in a membrane having a thickness of about 10 micrometers to about 30 micrometers.

The resulting article of apparel is lightweight, exhibits low moisture retention when exposed to water (e.g., when exposed to rain) as a result of having a low void volume within the textile layer and at the boundary between the textile layer and the sealing layer, and further dries quickly (due to its low moisture retention).

In other embodiments, a method of forming a composite fabric comprises applying, via a coating process, a liquid or semi-solid material to a surface of a textile material so as to form a solid material sealing layer directly on the textile material surface having a thickness of about 10 micrometers to about 30 micrometers. The textile material comprises a plurality of yarns, each yarn including five to twenty five filaments, where each filament has a cross-sectional shape that is non-circular. In the method, the applying via a coating process can comprise spreading the liquid or semi-solid material onto the surface of the textile and curing it to form a thin, first layer having a thickness that is less than 10 micrometers (e.g., about 3 micrometers), and then applying a thin, second layer of material onto the first layer of material, the second layer of material possessing a similar thickness (e.g., less than 10 micrometers and, in particular, about 3 micrometers). Third and subsequent thin layers may be applied until the desired thickness is achieved, thereby forming a layer of solid material having a thickness of about 10 micrometers to about 30 micrometers coating the surface of the textile layer.

The above and still further features and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an example embodiment of an article of apparel (a jacket in accordance with embodiments described herein.

FIG. 2A depicts a cross-sectional view of an embodiment of a yarn including round and circular filaments.

FIGS. 2B, 2C and 2D depict cross-sectional views of example embodiments of yarns including non-round filaments that can be used to form a textile layer as described herein.

FIGS. 3A and 3B each depicts a cross-sectional view of an example embodiment of an island-in-the-sea (INS) fiber that can be used to form one or more yarns in a textile layer as described herein.

FIGS. 4A, 4B and 4C are photographic images in magnification of a portion of a two layer structure in cross-section formed in a manner as described herein.

FIG. 5 depicts a photographic image in magnification of a portion of a two layer structure in cross-section consisting of a textile layer and a film secured to the textile layer via dot lamination.

Like reference numerals have been used to identify like elements throughout this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, reference is made to the accompanying figures that form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

Aspects of the disclosure are disclosed in the accompanying description. Alternate embodiments of the present disclosure and their equivalents may be devised without parting from the spirit or scope of the present disclosure. It should be noted that any discussion herein regarding “one embodiment”, “an embodiment”, “an exemplary embodiment”, and the like indicate that the embodiment described may include a particular feature, structure, or characteristic, and that such particular feature, structure, or characteristic may not necessarily be included in every embodiment. In addition, references to the foregoing do not necessarily comprise a reference to the same embodiment. Finally, irrespective of whether it is explicitly described, one of ordinary skill in the art would readily appreciate that each of the particular features, structures, or characteristics of the given embodiments may be utilized in connection or combination with those of any other embodiment discussed herein.

Various operations may be described as multiple discrete actions or operations in turn, in a manner that is most helpful in understanding the claimed subject matter. However, the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations may not be performed in the order of presentation. Operations described may be performed in a different order than the described embodiment. Various additional operations may be performed and/or described operations may be omitted in additional embodiments.

For the purposes of the present disclosure, the phrase “A and/or B” means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous.

As described herein, an article of apparel is formed that includes a composite fabric comprising a textile layer and a sealing layer in continuous contact with a surface of the textile layer, where the composite fabric minimizes (e.g., prevents) water penetration through the composite fabric as well as includes a structure that minimizes interstices between yarns of the fiber and/or the interface/boundary between the sealing layer and the textile surface, thereby minimizing (e.g., substantially eliminating) water retention within the composite fabric, thus rendering the article of apparel suitable for use as raingear or other outdoor use that shields a user from getting wet and improving overall dry time of the apparel.

As further described herein, the sealing layer (also called a waterproof layer or waterproofing layer) is applied to the textile layer in a manner and also the textile layer comprises a suitable configuration of yarns or filaments having suitable geometrical cross-sections or shapes, deniers and/or arrangements so as to reduce or minimize interstitial spacings or voids between the textile layer and the sealing layer as well as interstitial spacings or voids between yarns and/or filaments within the textile layer, which in turn reduces or minimizes introduction and/or retention of moisture/water within the textile layer or at a boundary between the textile layer and the sealing layer during use of the article of apparel. Such configuration further enhances the drying performance (i.e., reduces drying time) of the article of apparel in comparison to other, conventional rain gear after being subjected to a wet environment (e.g., wearing of the article of apparel outside and being subjected to rain for a period of time).

Referring to FIG. 1, an article of apparel may be in the form of a jacket 102 that includes a main trunk or torso section 104, a hood section 106 that extends from an upper portion of the torso section and is configured to pull over and cover portions of the head of the wearer, and arm sleeve sections 108 extending transversely from opposing upper side portions (which correspond with the shoulders of the wearer) of the torso section. The torso section 104 further includes a front side 110 that corresponds with the chest and abdomen of the wearer and a rear side (not shown) that corresponds with the back of the wearer. The jacket 102 can further include front pockets, a lengthwise extending closure member (e.g., a zipper) disposed at a central location along the front side 110, as well as any other structural features suitable for its intended purpose.

At least a portion of the article of apparel 102 (e.g., one or all of sections 104, 106, 108 of the jacket 102, as well as a portion 150 of a jacket section) is formed from a multilayer composite fabric 400 including an outer textile layer 405 and an inner (user-facing) sealing layer 420 (FIG. 4A). While FIG. 1 depicts section 150 at the torso section 104, it is noted that section 150 can be located at any portion(s) of the jacket 102 (e.g., at the hood section 106 or an arm sleeve section 108) and/or can be used to form or define the entire jacket. In other words, the composite fabric as described herein can be used to form one or more portions or the entire structure of an article of apparel or garment.

The textile layer 405 comprises a plurality of yarns combined in any suitable manner, e.g., via weaving, knitting and/or a nonwoven process, so as to be imparted with suitable properties such as a suitable thickness, suitable drape, suitable textured feel, etc. The yarns can be formed from fibers or filaments that comprise any suitable natural and/or synthetic polymer materials including, without limitation, polymer materials such as polyolefins (e.g., polyethylene, polypropylene, polybutylene, etc.), polyesters (e.g., polyethylene terephthalate), polyacrylamides, polyurethanes, polylactic acids, polyamides (e.g., nylon), polyvinyl alcohol, and any variety of copolymers or combinations thereof, where filaments forming one or more yarns can be mixed filaments having different cross-sectional shapes and/or different combinations of polymer components (e.g., homopolymer components or multi-polymer components). The textile layer can further be formed of any one or more combinations yarns having the same or varying degrees of elasticity. For example, the textile layer can be formed having 2-way or 4-way stretch characteristics. Some non-limiting examples of elastic or stretchable fabric materials suitable for forming the outer fabric layer are fabrics comprising one or more combinations of polyester-polyurethane copolymers referred to generally as elastane (e.g., Spandex or Lycra materials).

In example embodiments, the textile layer 405 can comprise a woven layer formed of yarns comprising a low count of filaments, where the yarns have a denier in the range from about 20 to about 50 (e.g., a denier in a range from about 20 to about 40, or from about 20 to about 30). One or more yarns used to form the textile layer 405 can include no more than about 25 filaments per yarn, such as from 5 to 25 filaments per yarn, or from 5 to 12 filaments per yarn, or even from 7 to 10 filaments per yarn. Thus, the DPF (denier per filament) can range from about 2.0 to about 4.0, such as from about 2.5 to about 3.5, or from about 2.7 to about 3.1. The low filament count and low denier yarns result in the formation of a lightweight textile layer having good drape and a soft texture and feel. In addition, the selection of low count filament yarns, in which the yarns have deniers combined with non-circular shapes as described herein, facilitates the formation of textile structures that minimize or eliminate voids within the textile structures which in turn also minimizes and reduces an amount of moisture absorption, trapping and retention within the textile structures.

In further example embodiments, the yarns forming the textile layer 405 contain filaments that are non-circular in cross-section so as to reduce or eliminate interstitial spacing, i.e., a number and/or size of interstices or voids within the textile layer (e.g., interstices between filaments forming yarns as well as between adjacent yarns within the textile structure). Such configuration of yarns and filaments forming the yarns, as well as how the sealing layer is applied to the textile layer 405 (as described herein) also reduces a number and/or size of interstices or voids at a boundary or contact area between the textile layer and the sealing layer. For example, the filaments can be formed and/or defined within the yarns having non-circular cross-sectional shapes such as oval or elliptical shapes and polygonal (e.g., three sided, four sided, five sided, etc.) shapes. Filaments that are provided with a non-circular shape can reduce the interstices therebetween due to the flatness or less rounded features of the filaments. For example, filaments of a yarn with polygonal shaped cross-sections have flat sides that complement each other so as to facilitate greater contact along adjacent surfaces or even potential interlocking between a plurality of filaments that cannot be achieved utilizing, e.g., round filaments.

Referring to the example embodiments of FIGS. 2A-2D, a cross-sectional view of a yarn is illustrated in each embodiment that includes seven filaments, where the yarn 200A in FIG. 2A includes filaments 202A having round or circular cross-sectional configurations (such as the filaments 515 for conventional yarns 510A, 510B in the fabric material of FIG. 5), the yarn 200B in FIG. 2B includes filaments 202B having triangular cross-sections, the yarn 200C in FIG. 2C includes filaments 202C having quadrilateral and, in particular, diamond shapes, and the yarn 200D in FIG. 2D includes filaments 202D having elongated round or elliptical shapes. In each of these figures, interstices may exist between filaments (e.g., interstices 204A between filaments 202A, interstices 204B between filaments 202B, interstices 204C between filaments 202C, and interstices 204D between filaments 202D). The yarn 200A including circular filaments 202A includes the greatest number of interstices 204A between the filaments that define a voids within the yarn. Stated another way, the void volume of yarn 200A is larger than void volumes defined by yarns 200B, 200C, 200D s including filaments 204B, 204C, 204D having non-circular cross-sections.

In particular, for polygonal shaped filaments as shown in the embodiments of FIGS. 2B and 2C, at least some of the filaments 202B, 202C that are adjacent or neighbor each other can substantially engage and/or interlock along their adjacent flat or substantially planar sides so as to greatly reduce a void size or substantially eliminate voids between the filaments (i.e., a feature which cannot be achieved utilizing circular filaments). Providing filaments having polygonal cross-sectional shapes in a suitable arrangement with each other allows for substantial interlocking and substantial contact between complementary planar surfaces of the filaments so as to substantially eliminate or significantly reduce any space or void between adjacent filaments within the yarn.

Yarns formed from filaments having non-circular cross-sectional shapes can further be substantially flat or ribbon shaped so as to define one or more generally flat surfaces for the yarns. For example, ribbon-shaped yarns formed with polygonal shaped filaments having complementary and substantially flat or planar sides can be formed with filaments placed in a side-by-side manner and with suitable orientations (e.g., yarns 200B and 200C as depicted in FIGS. 2B and 2C) so as to engage and/or interlock filaments with adjacent or neighboring filaments of the yarn. The formation and use of substantially flat or ribbon shaped yarns in turn facilitates a substantial reduction in interstices defined between adjacent yarns that form a woven textile or fabric.

The yarns including filaments with non-circular cross-sectional shapes can be formed in any suitable manner. In example embodiments, the yarns are formed such that their filaments are oriented in a similar lengthwise direction of the yarn but are not twisted together (i.e., no twisting process is required in the formation of the yarns). The filaments can be formed via any suitable extrusion process, such as a melt spun process in which molten polymer is extruded though a spinneret including orifices having suitable shapes and dimensions to form desired shapes and sizes of the filaments extruded from the spinneret orifices. The filaments are solidified as they emerge from the spinneret and can be laid down together on a forming surface to facilitate formation of a yarn of the filaments.

In a specific and non-limiting example embodiment, yarns can be formed comprising island-in-the-sea (INS) fibers, in which individual “island” polymer components or filaments are formed within a surrounding shell or “sea” polymer component. An example embodiment of an INS fiber that forms a yarn is depicted in cross-section in the embodiments of FIGS. 3A and 3B. Referring to FIG. 3A, a ribbon-shaped fiber 302A is formed including diamond shaped filaments 202C (e.g., seven filaments) provided as “islands” within a “sea” polymer component 310A. Similarly, an INS fiber that forms a yarn is also depicted in FIG. 3B, where a ribbon-shaped fiber 302B is formed including triangular shaped filaments 202B (e.g., seven filaments) provided as “islands” within a “sea polymer component 310B. Utilizing, e.g., a melt extrusion fiber spinning process, INS fibers can be formed having any suitable cross-sectional shapes (e.g., flat or ribbon shaped, round or circular, etc.) and can also be formed with any number of filaments having any suitable cross-sectional dimensions and shapes. For example, a spinneret can be provided with suitable channels and suitably shaped orifices that facilitate formation of INS fibers of various types, various cross-sectional dimensions and shapes, as well as formation of any suitable number of “island” filaments having various cross-sectional dimensions and shapes.

The INS fibers can comprise bicomponent or multi-polymer component fibers, in which the filaments forming the “islands” comprise a first polymer component (e.g., polypropylene, PET, etc.) and the “sea” polymer component comprises a second polymer component (e.g., polylactic acid or PLA). The second polymer component forming the “sea” is soluble or dissolvable in a particular solvent, while the first polymer component is substantially insoluble or non-dissolvable in the same solvent. Accordingly, INS fibers that are formed can be treated by exposure to a suitable solvent that dissolves away and removes the “sea” polymer component, leaving the “island” filaments intact and in an orientation that generally corresponds with the layout of the filaments within the INS fiber (i.e., prior to dissolution of the “sea” component). The INS fibers can be combined, e.g., in a weaving process, to form a textile or fabric, followed by dissolution of the “sea” polymer component of the INS fibers, thereby exposing yarns of oriented filaments having configurations such as shown, e.g., in FIGS. 2B and 2C.

The sealing layer 420 can be applied as a coating in any suitable manner directly to a side of the textile layer 405 formed with yarns including non-round filaments as previously described herein. In example embodiments, a flowable polymer is provided having a viscosity sufficient to permit leveling along the textile layer with or without the application of pressure. The flowable polymer may be applied via a knife or blade coating process in which the material is spread over the textile layer 405, where it is dried, cured and/or solidified to form the sealing layer 420. Alternatively, the flowable polymer may be atomized and applied as a spray coating to one side of the textile layer 405 that dries to form the sealing layer 420. This is in contrast with conventional rain garments, in which a preformed hydrophilic or hydrophobic film is adhered to the textile layer with an adhesive (described in greater detail below).

The flowable polymer may be a fluorine-free material layer that provides a suitable degree of hydrophobicity effective to repel water. An example embodiment of a suitable hydrophobic, flowable polymer is polyurethane that, when applied to the textile layer surface to form the sealing layer, has a water contact angle of greater than 90°, such as a water contact angle that is at least about 100°, or a water contact angle that is at least about 120°.

When applying the coating material (the flowable polymer (e.g., polyurethane)) to a surface of the textile layer 205 (or any other layer of the garment), the coating layer can be built up in thickness by application of the coating material in a series of sublayers or intermediate layers that combine to form the overall sealing layer. For example, the coating material can be applied as a liquid or semi-solid to a textile layer, and then spread with a suitable knife blade to achieve a generally level coating layer. The coating material can then be dried and/or cured, optionally with heating, to obtain a solid a first layer in continuous contact with the surface of the textile layer 405 and having a thickness of about 1-4 μm (micrometers or microns). The application and spreading process of coating material, followed by drying and/or curing of the material, can be repeated over the surface of the first layer (and each subsequent layer) so as to successively build up or add further material and increasing thickness to the sealing layer (e.g., in 1-4 micron thickness increments) as many times as desired to achieve a final desired overall thickness of the sealing layer that is at least about 10 μm. For example, the operation of applying the coating material (as a liquid or semi-solid) and then drying/curing to solidify the coating material can be repeated a plurality of times, such as three or more times, in order to achieve the desired thickness of the sealing layer 420.

A suitable application of the hydrophobic polymer material results in a sealing layer 420 that has a thickness of about 10 μm to about 30 μm (e.g., about 10 μm to about 20 μm, or from about 10 μm to about 15 μm). In some embodiments, the thickness of the final formed sealing layer 420 can vary along a dimension of the composite fabric, where the sealing layer thickness can vary from about 5 microns in thickness (at the most thin portion of the sealing layer) to about 30 microns in thickness (at the largest thickness of the sealing layer), where the average thickness of the sealing layer can be about 10-20 microns. The variance in thickness of the sealing layer 420 in the composite fabric 400 can be due to the uneven surface of the textile layer 405 to which the sealing layer is coated. In some embodiments, the yarns forming the textile layer 405, such as a woven textile layer, can form an uneven or undulating surface that results in depressions or valleys and bumps or hills along the textile layer surface (e.g., as a result of the overlapping between warp and weft yarns of the woven textile structure).

By providing the sealing layer as a built-up coating (e.g., built up by knife coating in a plurality of intermediate coating layers) on the textile layer to form the composite fabric, the sealing layer provides significant coverage against the surface of the textile layer so as to substantially contact the textile layer surface and prevent or substantially minimize voids between the sealing layer and the textile layer. As previously noted, certain types of textile layers can have uneven surfaces due to the texture of the formed textile. This can be based upon how the textile layer is formed. For example, a woven textile layer is defined by intersecting warp and weft yarns, which can result in an uneven, undulating surface for the textile layer. This can also be based upon the types of yarns used and the yarn compositions (e.g., deniers of yarns and filaments forming the yarns). The sealing layer formed as a coating and at a sufficient thickness (e.g., a thickness of at least about 10 μm) over the textile layer will result in the coating material filling in and making continuous contact with (i.e., conforming with the contour of) all uneven surface area portions of the textile layer so as to eliminate or substantially minimize or reduce spaces or voids between the sealing layer and the textile material. This is in significant contrast to a preformed film layer that is applied to a textile layer (e.g., via a dot lamination or other adhesion process), in which the substantially planar film (unlike the coated WP layer of the composite fabric described herein) cannot conform with the uneven contour of the textile layer such that spaces and voids exist between the two layers. By eliminating or significantly reducing void volume between the sealing layer 420 and the textile layer 405 of the composite fabric, water retention within the garment incorporating such composite fabric material will be significantly diminished in comparison to two layer fabric structures that incorporate a preformed film.

An example embodiment of a composite fabric 400 for use as part of an article of apparel is depicted in FIGS. 4A, 4B and 4C. In particular, a portion or section of a two layer composite fabric 400 is shown in cross-section in each of FIGS. 4A, 4B and 4C (magnified at varying degrees, with the greatest magnification provided in the view of FIG. 4C). Portions of the jacket 102 (FIG. 1), including section 150, can comprise the composite fabric structure as depicted in FIGS. 4A-4C. As shown, the composite fabric 400 includes a woven textile layer 405 comprising intersecting yarns (e.g., warp yarns 410A and weft yarns 410B that form the woven textile layer), where each yarn is flat or ribbon shaped and comprises non-round (e.g., diamond-shaped) filaments 412. Each yarn 410A, 410B includes about 7-10 non-round filaments 412. A sealing layer 420 (e.g., a polyurethane layer) is provided along one side of the woven textile layer. The composite fabric 400 is implemented within an article of apparel or garment (e.g., at section 150 of the jacket 102 of FIG. 1) such that the sealing layer 420 forms or defines the interior or wearer facing side of the article of apparel.

As can be seen, e.g., in the photographic image of FIG. 4C, the weft yarn 410B includes seven filaments 412A, 412B, 412C, 412D, 412E, 412F, 412G, with adjacent filaments being laterally positioned or stacked (one on top of another). As shown, voids or interstices 440 are present between some filaments 412A, 412B, 412C, 412D, 412E, 412F, 412G while substantially nonexistent between other filaments. With this configuration, the overall void volume of the textile 405 is minimized, being lower compared to a yarn including circular filaments or other filaments that do not interlock.

In addition, along the boundary 450 of the textile layer 405 and the sealing layer 420, little to no interstices or voids exist because the flowable material forming the sealing layer 420 has contoured to the topography of the textile layer 405. Stated another way, the relatively flat surfaces of the yarns 410A, 410B as well as the coating process for applying the sealing layer 420 to the textile layer 405 also minimizes, reduces or substantially eliminates gaps, interstices or voids 440 between the sealing layer 420 and the surface of the textile layer that is adjacent the sealing layer.

The substantial reduction or elimination of interstices or voids within the textile layer as well as at a boundary 450 between the textile layer 405 and the sealing layer 420 significantly minimizes or prevents capturing, trapping and retention of moisture within the two layer composite fabric structure that might otherwise occur. Despite the fact that the woven textile layer defined by intersecting yarns 410A, 410B has an uneven or undulating surface, the sealing layer 420 (by nature of it being coated onto the textile layer) substantially conforms to the uneven contour of the overall textile layer surface (as evident in the magnified view of FIG. 4C) such that little or no space exists between the two layers. In other words, an amount of water that may be trapped by the voids in the textile layer 405 along the boundary 450 of the textile layer 405 and the sealing layer 420 is reduced as a result of a reduction in spaces or interstices as well as overall or total void volume within the composite fabric structure due to the configuration of the textile layer and the sealing layer as applied to the textile layer. Contrast this, e.g., with a conventional two-layered structure including a preformed film layer laminated to a textile layer as depicted in FIG. 5, where interstices or voids are clearly present to a much greater degree within the conventional two layer structure and thus define a much greater void volume within the two layer structure in comparison to the composite fabric 400 of FIGS. 4A-4C.

Stated differently, this is in contrast with conventional waterproof garments (e.g., rain gear) in which a two layer structure is formed including an outer textile layer and an inner, preformed film layer adhered to a surface of the textile layer via an adhesive, typically dot lamination or other similar process. The reason for providing the preformed layer as a film is that a film of a certain thickness is typically less porous than a coating of a similar thickness and therefore is better at reducing the penetration or pass through of moisture through the preformed film layer. However, the preformed film layer is typically thick (e.g., greater than 30 micrometers in thickness) and can make a garment bulky and heavy (due to the weight of the adhesive and film), but can also increase the interstices or gaps present along the boundary between the film and the textile. These gaps serve as cavities that capture water, further weighing down the garment and increasing dry time.

An example embodiment of a conventional garment including a textile layer and a preformed film layer is depicted in the magnified photographic image of FIG. 5. The garment 502 has a two layered structure including a woven textile layer 505 comprising woven warp yarns 510A and weft yarns 510B. A preformed film 520 laminated to one side of the textile layer 505. The film 520 is secured to the textile layer 510 via a dot lamination process, where lamination dots 530 are spaced from each other in any suitable arrangement or pattern to facilitate adhering of the preformed film to the textile layer. The spacing between the lamination dots 530 results in interstices or voids 540A along the boundary 550 of the preformed film layer 520 and yarns 510A, 510B of the textile layer 505, and these voids can collect and retain water that penetrates either layer. In addition, the yarns 510A, 510B include a plurality of filaments 515 (e.g., more than 30 filaments per yarn) having cross-sectional shapes that are generally rounded or circular. The filaments 515 of each yarn 510A, 510B also combine in a manner that results in interstices or voids 540A within the yarn. These voids 540B between filaments 515 of yarns 510A, 510B as well as the voids 540A between the preformed film layer 520 and the textile layer 505 can result in the garment retaining water and taking a significant amount of time to dry (i.e., to evaporate moisture that exists within the voids). In addition, even when a preformed film is adhered in some manner other than using lamination dots, there can still be significant voids that exist between the generally flat and planar surface of the film that contacts an uneven (e.g., undulating) surface of the textile layer to which the film is secured. For example, in a scenario in which the textile is woven (such as depicted in FIG. 5), the surface of the woven textile is uneven due to the crossing warp and weft yarns located at the surface, such that the flat surface of the preformed film that engages with a corresponding surface of the woven textile layer has surface portions that do not continuously contact the surface of the woven textile resulting in spaces or voids defined therebetween.

It has been determined that providing a sealing layer at a thickness of at least 10 microns (or an average thickness of about 10-20 microns for a sealing layer that varies in thickness), in combination with a textile structure including low filament count yarns having non-circular filaments, such as polygonal filaments results in a lightweight structure for incorporation, e.g., in a garment or other article of apparel. In particular, it has been determined that a sealing layer having a sufficient thickness of at least about 10 microns effectively repels water from the garment surface and prevents or substantially minimizes water penetration or pass through when exposed to rainy or other wet environments. However, the sealing layer should be limited to having a thickness of no greater than about 30 microns, since any greater thickness would diminish desirable features such as the lightweight properties of the garment, its drape, hand and feel and would further increase the production costs for the garment. In addition, increased water repellency is not achieved over this threshold. A garment such as a jacket that incorporates the composite fabric structure as described herein is suitably lightweight, has suitable waterproof (WP) characteristics, dries quickly after exposure to water (e.g., exposure in a rainy environment) due to its low water retention properties, and can be easily folded or rolled up for storage (e.g., placement in a backpack, purse or other suitable carrier) when not being worn.

Tests were conducted to determine the effectiveness in relation to water repellency as well as water retention of the composite fabric structure 400 as described herein in comparison to other, conventional waterproof garments.

Water Repellency Effectiveness of Composite Fabric Structure

Tests were conducted for the composite fabric structure to determine its ability to provide effective water resistance against water penetrating the composite fabric structure when subjected to typical rain environment conditions. The tests were conducted utilizing a composite fabric including the same textile layer (formed as a woven textile with yarns including 5-25 quadrilateral or diamond shaped filaments) and with a sealing layer coated on the textile layer at different thicknesses. For example, sealing layer thicknesses were modified based upon a number of times a coating material (the flowable, hydrophobic polymer) was applied via a knife coating process to the textile layer 405 to build up the sealing layer 420 to a desired thickness. A single coating application results in a sealing layer having an average thickness of about 2-4 microns, whereas a double coating application results in a sealing layer having an average thickness of about 4-7 microns, and at triple coating application results in a sealing layer having an average thickness of at least 10 microns.

A hydrostatic pressure test was performed under SGS-IPS Standard AATCC 127. This test measures the resistance of a fabric material to the penetration of water under hydrostatic pressure (where the hydrostatic pressure is determined at failure or initial pass through of water through the fabric material). A typical wind driven rainstorm can provide a hydrostatic pressure of about 2 psi. The composite fabric formed with a sealing layer having a thickness of at least 10 microns showed water resistance (i.e., prevention of water passing through the composite fabric) at a hydrostatic pressure of about 3 psi (about 2100 mm in water depth). Lower thickness levels for the sealing layer 420 are not as effective against water penetration (i.e., are not considered waterproof under AATCC 127).

In addition, a Bundesmann Water Repellency/Rain Shower Test was performed on each fabric structure. The Bundesmann test utilizes an apparatus that simulates a rainstorm by showering water from a plurality of nozzles onto a test fabric material located within a compartment or housing of the apparatus. The test fabric material can be provided over a container to measure an amount of water that passes through the fabric material during the test. Test specimens were subjected to the Bundesmann test within the apparatus for a test period of about 10 minutes. From the Bundesmann test, it was determined that the sealing layer 405 having a thickness of at least 10 microns did not allow any water to pass through the fabric material (no water was present within the container underlying the test specimen). It was further determined that the fabric material formed with a sealing layer 420 having an average thickness of 2-4 microns (single pass material coating) had some water pass through the material (as determined by water present within the container), while the fabric material formed with a sealing layer 420 having an average thickness of 4-7 microns (double pass material coating) had a small amount of moisture pass through (determined by a smaller amount of moisture within the container).

Water Retention Effectiveness of Composite Fabric Structure

A series of tests were conducted to determine the effectiveness in water retention for the composite fabric structure as described herein.

Test 1

Samples of a composite fabric structure of the type depicted in FIGS. 4A-4C were tested and compared with other two layered fabric structures. The composite fabric structure included a textile layer formed with yarns comprising 5-25 quadrilateral or diamond shaped filaments and a polyurethane sealing layer coated onto the textile layer at an average thickness of about 10 microns. For comparison purposes, a two layer structure that includes a preformed film layer laminated to a textile layer that includes yarns having round filaments, as depicted in FIG. 5, was also provided.

A Bundesmann Water Repellency/Rain Shower Test was performed on each fabric structure. Test specimens were subjected to the Bundesmann test within the apparatus for a test period of 10 minutes. Each test specimen was weighed before and immediately after the Bundesmann test to determine an amount of water retention (based upon a weight difference).

As a result of the test, the composite fabric structure of FIGS. 4A-4C had a weight increase of 7.6% due to water absorbed and retained within the two layer structure. The two layer structure of FIG. 5 had a weight increase of 46.3%, indicating a much greater amount of water retention within the structure (i.e., due to the larger void volume defined within this two layer structure).

Test 2

A composite fabric test sample having a similar configuration as that depicted in FIGS. 4A-4C (woven textile with yarns having diamond shaped filaments with 5-25 filaments per yarn) was compared with other two layered fabric material test samples as follows: Sample A included a textile layer similar in configuration as the textile layer for the composite fabric, and a preformed hydrophobic layer of at least about 20 microns laminated to the textile layer; and Sample B included a textile layer similar in configuration as the textile layer for the composite fabric, and a preformed hydrophilic layer of at least about 20 microns laminated to the textile layer.

The test was conducted for each sample by submerging the sample in a bath of soapy water for a time period of 5 minutes. Each sample was dry weighed before the test, followed by weighing the sample wet after being withdrawn from the bath. A number of specimens of each sample type were tested, and the test results (based upon an average of the number of specimens for each sample type) are as follows:

Test Results

Sample	Dry Weight (g)	Wet Weight (g)	Wet Pick-Up (%)
Composite Fabric	0.0814	0.1277	56.93
Sample A	0.2045	0.3734	82.54
Sample B	0.1905	0.4506	102.45

The test results indicate that the composite fabric retains less water (indicating a lower void volume) in relation to the test samples that include a preformed layer.

Thus, the structural configuration for the composite fabric as described herein provided enhanced water resistance/waterproofing properties for an article of apparel (e.g., a rain jacket) in relation to other conventional articles of apparel. In particular, the textile layer including low filament count yarns with non-circular (e.g., polygonal shaped) filaments and a sealing layer that is coated over the textile layer reduces overall void volume of the composite fabric, thus minimizing water retention within the article of apparel when subjected to rain conditions. In addition, the sealing layer having a thickness of at least about 10 microns and not greater than about 30 microns sufficiently minimizes water pass through under typical rain conditions. Articles of apparel formed with the composite fabric exhibit suitable waterproof properties and minimal water retention (resulting in a rapid drying time after exposure to moisture), suitable lightweight properties, and a desired hand, drape and feel to the article of apparel. It is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. For example, the article of apparel (or a portion thereof) can include more than two material layers (e.g., 2.5 layers, 3 layers, etc.). By way of specific example, a mesh liner or scrim layer (e.g., a very lightweight and porous fabric layer having a basis weight that is less than the basis weight of the textile layer) can be provided as an interior layer for the article of apparel. Further, any one or more layers can be provided along either side of the textile layer and/or the sealing layer that faces away from the boundary between the two layers. Further still, one or more layers can also be provided between (and thus located within the boundary between) the textile layer and the sealing layer.

The textile layer and any other material layers defining an article of apparel (or a portion thereof) can have a thickness that is on the order of micrometers or microns (e.g., no greater than about 100 microns), millimeters (e.g., no greater than about 100 millimeters) or even greater thicknesses.

As noted herein, the garment of the present invention significantly reduces or minimizes penetration and absorption of water within the garment while also ensuring adequate waterproof (WP) protection in high humidity/raining environments and further being substantially lightweight with desirable drape.

It is to be understood that terms such as “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “medial,” “lateral,” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.

Claims

1. A rain jacket including arm sleeve sections and a torso section, the rain jacket comprising a composite fabric, wherein the composite fabric comprises: a textile layer comprising a plurality of yarns, each yarn including five to twenty five filaments, and each filament having a cross-sectional shape that is non-circular; anda sealing layer applied as a coating directly to the textile layer and having a thickness of about 10 micrometers to about 30 micrometers.

2. The rain jacket of claim 1, wherein the filaments of the yarns forming the textile layer have the same polygonal shape.

3. The rain jacket of claim 1, wherein each yarn includes 5 to 12 filaments.

4. The rain jacket of claim 1, wherein each yarn includes 7 to 10 filaments.

5. The rain jacket of claim 1, wherein each yarn has a denier ranging from about 20 to about 50.

6. The rain jacket of claim 1, wherein each yarn has a denier ranging from about 20 to about 30.

7. The rain jacket of claim 1, wherein the denier per filament of each yarn ranges from about 2.0 to about 4.0.

8. The rain jacket of claim 1, wherein the denier per filament of each yarn ranges from about 2.7 to about 3.1.

9. The rain jacket of claim 1, wherein the sealing layer comprises polyurethane.

10. The rain jacket of claim 1, wherein the sealing layer is free of fluorine.

11. The rain jacket of claim 1, wherein the sealing layer is applied as a coating so as to continuously contact a surface area of the textile layer.

12. The rain jacket of claim 1, wherein the sealing layer forms an interior surface of the rain jacket so as to face a user wearing the rain jacket.

13. A method of forming a composite fabric structure, the method comprising: applying, via a coating process, a liquid or semi-solid material to a surface of a textile material so as to form a solid material sealing layer directly on the textile material surface having a thickness of about 10 micrometers to about 30 micrometers;wherein the textile material comprises a plurality of yarns, each yarn including five to twenty five filaments, and each filament has a cross-sectional shape that is non-circular.

14. The method of claim 13, wherein each filament of the yarns forming the textile layer has a cross-sectional shape that is polygonal.

15. The method of claim 13, wherein the applying via a coating process comprises: (a) spreading the liquid or semi-solid material over the surface of the textile material;(b) drying the liquid or semi-solid material spread over the textile material surface to form an intermediate coating layer having an intermediate thickness that is less than 10 micrometers; and(c) repeating steps (a) and (b) to increase a thickness of the solid material until forming the sealing layer of solid material having a thickness of about 10 micrometers to about 30 micrometers.

16. The method of claim 15, wherein steps (a) and (b) are repeated a plurality of times.

17. The method of claim 13, further comprising forming the textile structure by: forming islands-in-the-sea fibers, wherein the filaments are formed within a sea polymer component; andremoving the sea polymer component from the non-circular filaments to form yarns comprising the filaments.

18. The method of claim 17, wherein each yarn is formed with 5 to 12 filaments.

19. The method of claim 17, wherein each yarn is formed with 7 to 10 filaments.

20. The method of claim 13, further comprising incorporating the composite fabric structure into a rain jacket.