WO2019222442A1

WO2019222442A1 - Composite materials and methods of manufacture

Info

Publication number: WO2019222442A1
Application number: PCT/US2019/032562
Authority: WO
Inventors: John Ly
Original assignee: North Face Apparel Corp
Current assignee: North Face Apparel Corp
Priority date: 2018-05-18
Filing date: 2019-05-16
Publication date: 2019-11-21
Anticipated expiration: 2020-11-18

Abstract

A composite material may comprise a wind resistant layer and a breathable layer. The breathable layer may comprise a material that may be more permeable than a material of the wind resistant layer. The composite material may comprise an insulating material disposed between the wind resistant layer and the breathable layer. The composite material may comprise a knit layer adjacent to the breathable layer. The composite material may be configured to allow air to circulate between the knit layer, the breathable layer, and/or the insulating material. The composite material may be configured to restrict the passage of air through the wind resistant layer.

Description

COMPOSITE MATERIALS AND METHODS OF MANUFACTURE

BACKGROUND

[0001] People engaging in outdoor activities must be prepared for contrasting climates and weather. Weather can be unpredictable. Also, sportspeople may experience varying body temperatures when engaging in different activities or segments of an outdoor activity.

Sportspeople may prepare for the possibilities by bringing gear for each possible climate or weather condition. Alternatively, sportspeople may bring gear that is adapted for a variety of climates or temperatures. Versatile gear may reduce the amount of gear that sportspeople must pack or carry.

SUMMARY

[0002] A composite material may be adapted for a variety of climates, temperatures, or weather conditions. The composite material may comprise a wind resistant layer. The composite material may comprise a breathable layer. The breathable layer may comprise a material that may be more permeable than a material of the wind resistant layer. The composite material may comprise an insulating material, such as down. The insulating material may be disposed between the wind resistant layer and the breathable layer. The composite material may comprise a knit layer. The knit layer may be adjacent the breathable layer. The composite material may be configured to allow air to circulate between the knit layer, the breathable layer, and/or the insulating material. The composite material may be configured to restrict the passage of air through the wind resistant layer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The following drawings illustrate generally, by way of example, but not by way of limitation, various examples discussed in the present disclosure. In the drawings:

[0004] FIG. 1 shows an example composite material.

[0005] FIG. 2 shows an example method. DETAILED DESCRIPTION

[0006] FIG. 1 shows an example composite material 100. The composite material 100 may comprise a wind resistant layer 101, an insulating material 102, a breathable layer 103, and/or a knit layer 104. The composite material 100 may be configured to permit passage of air through the knit layer 104, the breathable layer 103, and/or the insulating material 102. For example, the composite material 100 may be configured to permit air to circulate between a body of a user of an article of apparel comprising the composite material 100 and through the knit layer 104, the breathable layer 103, and/or the insulating material 102.

[0007] The composite material 100 may be configured to maintain a thermal temperature, such with the insulating material 102. For example, the composite material 100 may be configured to insulate a user of an article of apparel comprising the composite material 100

[0008] The composite material 100 may be configured to restrict the passage of air through the wind resistant layer 101. For example, the wind resistant layer 101 may comprise the outermost layer of an article of apparel comprising the composite material 100. The wind resistant layer 101 may prevent or limit wind passing through the resistant layer 101, the composite material 100, and to the body of a user of the article of apparel. The composite material 100 may be configured to prevent the escape or movement of the insulating material 102, such as by comprising one or more downproof layers.

[0009] The wind resistant layer 101 may be comprise a wind resistant or windproof material. Wind resistance of a material may be described by an amount of cubic feet per minute (CFM) of about a 30-mile-per-hour wind that can pass through one square foot of the material. Windproofness may be determined using a standardized test, such as ASTM D737. The wind resistant layer 101 may comprise a windproof material having a permeability of 0-4, 0-2, and/or 3-4 CFM. The wind resistant layer 101 may comprise a wind-resistant material having a permeability of 0-20, and/or 5-20 CFM.

[0010] The wind resistant layer 101 may comprise a waterproof material. The waterproof material may comprise a material treated with a durable water-repellant (DWR) finish. The DWR finish may cause the material to repel water, such as by causing the water to bead up and roll of a surface of the material. Waterproofing may be based on a water column test that measures water permeability under pressure. The water column test may comprise placing a one-inch diameter column of water over the material for a time period of twenty-four hours. Waterproofness may describe the height of a column that may be filled before water permeates the material within the time period. Waterproofness may be determined using a standardized test, such as AATCC 127, AATCC 35, AATCC 22, or ISO 811. The material may comprise a super waterproof material having a water column test rating of greater than 20,000 mm/24 hours. The material may comprise a very waterproof material having a water column test rating of greater than 15,000 mm/24 hours and up to 20,000 mm/24 hours. The material may comprise a waterproof material having a water column test rating of greater than 10,000 mm/24 hours and up to 15,000 mm/24 hours. The material may comprise a somewhat waterproof material having a water column test rating of greater than 5,000 mm/24 hours and up to 10,000 mm/24 hours. The material may comprise a water resistant material having a water column test rating of around 5,000 mm/24 hours.

[0011] The wind resistant layer 101 may comprise a non-breathable material.

Breathability of a material may be described by an amount of water vapor that can pass through a square meter of the material during a time frame of twenty -four hours. Breathability may be determined using a standardized test, such as BS7209 or ASTM E96. The non-breathable material may have a breathability of 5,000 g/m²-9,000 g/m².

[0012] The wind resistant layer 101 may comprise a downproof material.

Downproofness of a material may be described by a rating determined by a standardized test, such as EN 12131-1, EN 12131-2, GB/T 12705.1, GB/T 12705.2, GB/T 14272, or“International Rotating Box” test (TMS or IDFL-20). As measured by the International Rotating Box test, the downproof material may have a number of total particles escaped or protruding of 0-5, 6-11, or 12-22. The wind resistant layer 101 comprising the downproof material may prevent the escape or movement of the insulating material 102, such as to the exterior of the composite material 100.

[0013] The wind resistant layer 101 may comprise a woven material. The wind resistant layer 101 may comprise a synthetic material, such as polyester, polypropylene, nylon, or a blend. The wind resistant layer 101 may comprise a non-synthetic material, such as wool, cotton, or a blend. The wind resistant layer 101 may comprise a blend of fiber types. The wind resistant layer 101 may comprise a material selected based on the appearance of the material.

For example, if the composite material 100 is used to manufacture an article of apparel, the wind resistant layer 101 may comprise an exterior layer of the article of apparel and the material may be selected based on a desired aesthetic effect of the article of apparel. The wind resistant layer 101 may comprise a material selected based on a weight of the material. For example, a lightweight material may be selected to manufacture sporting equipment comprising the composite material 100.

[0014] The insulating material 102 may a natural fiber, such as down or wool. The insulating material 102 may comprise fleece or shelled microfleece. The insulating material may comprise a synthetic material, such as a synthetic microfiber blend (e.g., Primaloft, Thinsulate, Thermolite, or Quallofil). The insulating material may have an insulation value of .1-.8 clo, as measured by the ASHRAE-55 standard test. The insulating material may have an R-value of 1.6-2.9 per inch, as defined by ASTM C168.

[0015] The insulating material 102 may be disposed adjacent the wind resistant layer 101. The insulating material 102 may comprise a continuous layer. The insulating material may be located in one or more discrete regions of the composite material 100.

[0016] The breathable layer 103 may comprise a material having a permeability greater than the permeability of the material of the wind resistant layer 101. The breathable layer 103 may comprise a wind resistant material having a permeability of 5-20 CFM, 21-60 CFM, 21-49 CFM, or 50-60 CFM, as examples.

[0017] The breathable layer 103 may comprise a water resistant material. The water resistant material may be less water resistant than the material of the wind resistant layer 101. The material may comprise a waterproof material having a water column test rating of greater than 10,000 mm/24 hours and up to 15,000 mm/24 hours. The material may comprise a somewhat waterproof material having a water column test rating of greater than 5,000 mm/24 hours and up to 10,000 mm/24 hours. The material may comprise a water resistant material having a water column test rating of around 5,000 mm/24 hours.

[0018] The breathable layer 103 may comprise a breathable material. The breathable layer 103 may comprise a material that is more breathable than the material of the wind resistant layer 101. The breathable material may have a breathability of 10,000 g/m²-25,000g/m².

[0019] The breathable layer 103 may comprise a downproof material. As measured by the International Rotating Box test, the downproof material may have a number of total particles escaped or protruding of 0-5, 6-11, or 12-22. [0020] The breathable layer 103 may comprise a woven material. The breathable layer 103 may comprise a synthetic material, such as polyester, polypropylene, or a blend. The breathable layer 103 may comprise a non-synthetic material, such as wool, cotton, or a blend. The breathable layer 103 may comprise a blend of fiber types.

[0021] The breathable layer 103 may be disposed adjacent the insulating material 102. The insulating material 102 may be disposed between the wind resistant layer 101 and the breathable layer 103. As an example, the wind resistant layer 101 and the breathable layer 103 may each comprise a sheet. The sheets may have perimeters. At least a portion of the perimeter of the wind resistant layer 101 sheet may be joined to at least a portion of the perimeter of the breathable layer 103, such as by sewing, gluing, weaving, or welding. The joining of the sheets may hold the insulating material between the sheets. The wind resistant layer 101 and the breathable layer 103 may be quilted or joined so as to create compartments. The insulating material may be disposed in one or more of the compartments. The compartments may hold or limit movement of the insulating material in the compartments or between the compartments.

[0022] The knit layer 104 may comprise a material having a permeability greater than the permeability of the material of the wind resistant layer 101 and/or the material of the breathable layer 103. The knit layer 104 may comprise a wind resistant material having a permeability of 5-20 CFM, 21-49 CFM, or 50-60 CFM, as examples.

[0023] The knit layer 104 may not comprise a waterproof material. The knit layer 104 may comprise a material that is less waterproof than the material of the wind resistant layer 101 and/or the material of the breathable layer 103. The knit layer 104 may comprise a waterproof material having a water column test rating of greater than 10,000 mm/24 hours and up to 15,000 mm/24 hours. The knit layer 104 may comprise a somewhat waterproof material having a water column test rating of greater than 5,000 mm/24 hours and up to 10,000 mm/24 hours. The knit layer 104 may comprise a water resistant material having a water column test rating of around 5,000 mm/24 hours.

[0024] The knit layer 104 may comprise a breathable material. The knit layer 104 may comprise a material that is more breathable than the material of the wind resistant layer 101 and/or the material of the breathable layer 103. The knit layer may have a breathability of 10,000 g/m²-25,000g/m². [0025] The knit layer 104 may comprise a downproof material. As measured by the International Rotating Box test, the downproof material may have a number of total particles escaped or protruding of 0-5, 6-11, or 12-22.

[0026] The knit layer 104 may comprise a synthetic material, such as polyester, polypropylene, or a blend. The knit layer 104 may comprise a non-synthetic material, such as wool, cotton, or a blend. The knit layer 104 may comprise a blend of fiber types. The knit layer 104 may comprise a material based on the comfort of the material. For example, an article of apparel comprising the composite material 100 may be configured such that the knit layer 104 is disposed adjacent a body of a user of the article when the article is in normal use. As an illustrative example, the knit layer 104 may form a lining of a jacket made of the composite material 100. The wind resistant layer 101 may form an outer shell of the jacket. The material of the knit layer 104 may comprise a material selected to be comfortable when in contact with the body of the user.

[0027] The knit layer 104 may be disposed adjacent the breathable layer 103. The knit layer 104 may be joined to the breathable layer 103 and/or the wind resistant layer 101, such as by sewing, gluing, weaving, or welding.

[0028] FIG. 2 shows an example method 200. At step 210, the wind resistant layer 101, the breathable layer 103, and/or the knit layer 104 may be coupled. Coupling the layers may comprise sewing, gluing, weaving, or welding the layers. The layers may be coupled in different orders. For example, the wind resistant layer 101 and the breathable layer 103 may be coupled to form a first composite material layer. The first composite material layer and the knit layer 104 may be coupled. As another example, the breathable layer 103 and the knit layer 104 may be coupled to for a first composite material layer. The first composite material layer and the wind resistant layer 101 may be coupled. As yet another example, the wind resistant layer 101 and the knit layer 104 may be coupled. The breathable layer 103 may be inserted between the coupled wind resistant layer 101 and knit layer 104.

[0029] The wind resistant layer 101, the breathable layer 103, and/or the knit layer 104 may comprise sheets. Coupling the wind resistant layer 101, the breathable layer 103, and/or the knit layer 104 may comprise joining at least a portion of a perimeter of a sheet of the wind resistant layer 101, the breathable layer 103, and/or the knit layer 104 to at least a portion of a perimeter of a sheet of another of the wind resistant layer 101, the breathable layer 103, and/or the knit layer 104. Coupling the wind resistant layer 101, the breathable layer 103, and/or the knit layer 104 may sewing an interior or central portion of a sheet of the wind resistant layer 101, the breathable layer 103, and/or the knit layer 104 to an interior or central portion of another of the wind resistant layer 101, the breathable layer 103, and/or the knit layer 104.

[0030] At step 220, the insulating material 102 may be disposed between the wind resistant layer 101 and the breathable layer 103 through an opening. The opening may be between the wind resistant layer 101 and the breathable layer 103. For example, edges or perimeters of the wind resistant layer 101 and the breathable layer 103 may be joined. The edges or perimeters may not be joined at the opening, leaving an entryway for the insulating material 102

[0031] Disposing the insulating material 102 may comprise injecting or stuffing the insulating material between the wind resistant layer 101 and the breathable layer 103. If the composite material 100 comprises compartments between the wind resistant layer 101 and the breathable layer 103, such as formed of a quilted stitching of the wind resistant layer 101 and the breathable layer 103, the

[0032] At step 230, the opening may be closed. Closing the opening may comprise sewing, gluing, weaving, or welding a portion of the wind resistant layer 101 and a portion of the breathable layer 103. The opening may be closed so as to prevent the insulating material 102 from escaping the composite material 100.

[0033] The composite material 100 may be used to manufacture articles. The composite material articles may include articles of apparel, such as jackets, pants, hats, gloves, jumpsuits, or other outerwear. An article of apparel comprising the composite material 100 may be configured such that the knit layer 104 is closer to a body of a user of the article than the wind resistant layer 101 when the article is in normal use. The resistant layer 101 may prevent wind or air from entering the article and passing through the article to the body of the user. Air may circulate from the body of the user and through the knit layer 104, the breathable layer 103, and/or the insulating material 102.

[0034] The composite material articles may include blankets. The composite material articles may comprise sporting equipment or outdoor equipment. The composite material articles may comprise sporting equipment lining, such a lining of a helmet. The wind resistant layer 101, the insulating material 102, the breathable layer 103, and/or the knit layer 104 may each comprise a material selected based on an article to be manufactured using the composite material 100. For example, materials with physical properties may be suitable for articles for certain activities. The materials may be selected based on desired physical properties of the composite material 100, such as weight, reflectiveness, thickness, color, strength, or flexibility.

[0035] The present disclosure comprises at least the following aspects:

[0036] Aspect 1. A composite material comprising: a wind resistant layer comprising a material having a permeability of 0-2 cubic feet per minute (CFM); an insulating material disposed adjacent the wind resistant layer; a breathable layer comprising a material having a permeability greater than the permeability of the material of the wind resistant layer and disposed adjacent the insulating material; and a knit layer disposed adjacent the breathable layer; wherein the composite material is configured to permit passage of air through the knit layer, the breathable layer, and the insulating material and restrict passage of air through the wind resistant layer.

[0037] Aspect 2. The composite material of aspect 1, wherein the breathable layer comprises a material having permeability of 50-60 cubic feet per minute (CFM).

[0038] Aspect 3. The composite material of aspect 1, wherein the breathable layer comprises a woven material.

[0039] Aspect 4. The composite material of aspect 1, wherein the wind resistant layer comprises a woven material.

[0040] Aspect 5. The composite material of aspect 1, wherein the wind resistant layer comprises a waterproof material.

[0041] Aspect 6. The composite material of aspect 1, wherein the wind resistant layer comprises a down-proof material.

[0042] Aspect 7. The composite material of aspect 1, wherein the insulating material comprises down.

[0043] Aspect 8. An article of manufacture comprising the composite material of any of aspects 1-7.

[0044] Aspect 9. A method of making a composite material comprising: coupling a wind resistant layer, a knit layer, and a breathable layer, wherein the breathable layer is disposed between the wind resistant layer and the knit layer, wherein the wind resistant layer comprises a material having a permeability of 0-2 cubic feet per minute (CFM), and wherein the breathable layer comprises a material having a permeability greater than the permeability of the material of the wind resistant layer; and disposing an insulating material between the wind resistant layer and the breathable layer.

[0045] Aspect 10. The method of aspect 9, wherein the disposing the insulating material between the wind resistant layer and the breathable layer comprises injecting the insulating material in an opening between the wind resistant layer and the breathable layer.

[0046] Aspect 11. The method of aspect 10, wherein the method further comprises closing.

[0047] Aspect 12. The method of aspect 9, wherein the coupling the coupling the wind resistant layer, the knit layer, and the breathable layer comprises at least one of sewing, gluing, weaving, or welding the wind resistant layer, the knit layer, and the breathable layer.

[0048] Aspect 13. The method of aspect 9, wherein the coupling the coupling the wind resistant layer, the knit layer, and the breathable layer comprises: coupling the wind resistant layer and the breathable layer to form a composite layer; and coupling the composite layer and the knit layer.

[0049] Aspect 14. The method of aspect 9, wherein the breathable layer comprises a material having permeability of 50-60 cubic feet per minute (CFM).

[0050] Aspect 15. The method of aspect 9, wherein the breathable layer comprises a woven material.

[0051] Aspect 16. The method of aspect 9, wherein the wind resistant layer comprises a woven material.

[0052] Aspect 17. The method of aspect 9, wherein the wind resistant layer comprises a waterproof material.

[0053] Aspect 18. The method of aspect 9, wherein the wind resistant layer comprises a down-proof material.

[0054] Aspect 19. The method of aspect 9, wherein the insulating material comprises at least one of down or wool.

[0055] Aspect 20. The method of aspect 9, wherein the method further comprises manufacturing an article using the composite material.

Claims

CLAIMS What is claimed:

1. A composite material comprising:

a wind resistant layer comprising a material exhibiting a permeability of 0-20 cubic feet per minute (CFM);

an insulating material disposed adjacent the wind resistant layer;

a breathable layer comprising a material having a permeability greater than the permeability of the material of the wind resistant layer and disposed adjacent the insulating material; and

a knit layer disposed adjacent the breathable layer;

wherein the composite material is configured to permit passage of air through the knit layer, the breathable layer, and the insulating material and restrict passage of air through the wind resistant layer.

2. The composite material of claim 1, wherein the wind resistant layer exhibits a

permeability of 0-4 CFM.

3. The composite material of claim 1, wherein the wind resistant layer exhibits a

permeability of 0-2 CFM.

4. The composite material of claim 1, wherein the breathable layer comprises a material exhibiting permeability of 21-60 cubic feet per minute (CFM).

5. The composite material of claim 1, wherein the breathable layer comprises a material exhibiting permeability of 50-60 cubic feet per minute (CFM).

6. The composite material of any one of claims 1-5, wherein the breathable layer comprises a woven material.

7. The composite material of any one of claims 1-6, wherein the wind resistant layer

comprises a woven material.

8. The composite material of any one of claims 1-7, wherein the wind resistant layer

comprises a waterproof material exhibiting a water column test rating of greater than 5,000 mm/24 hours.

9. The composite material of any one of claims 1-7, wherein the wind resistant layer comprises a waterproof material exhibiting a water column test rating of greater than 10,000 mm/24 hours.

10. The composite material of any one of claims 1-7, wherein the wind resistant layer comprises a waterproof material exhibiting a water column test rating of greater than 20,000 mm/24 hours.

11. The composite material of any one of claims 1-10, wherein the wind resistant layer comprises a down-proof material exhibiting a number of total particles escaped or protruding of 0-22 as measured by the International Rotating Box test.

12. The composite material of any one of claims 1-10, wherein the wind resistant layer comprises a down-proof material exhibiting a number of total particles escaped or protruding of 0-11 as measured by the International Rotating Box test.

13. The composite material of any one of claims 1-10, wherein the wind resistant layer comprises a down-proof material exhibiting a number of total particles escaped or protruding of 0-5 as measured by the International Rotating Box test.

14. An article of manufacture comprising the composite material of any of claims 1-13.

15. A method of making the composite material of any of claims 1-13.