CN112400044A - Air-permeable anti-hydrostatic structure - Google Patents
Air-permeable anti-hydrostatic structure Download PDFInfo
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- CN112400044A CN112400044A CN201980044279.4A CN201980044279A CN112400044A CN 112400044 A CN112400044 A CN 112400044A CN 201980044279 A CN201980044279 A CN 201980044279A CN 112400044 A CN112400044 A CN 112400044A
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- breathable structure
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
- D06M23/16—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
- A41D31/10—Impermeable to liquids, e.g. waterproof; Liquid-repellent
- A41D31/102—Waterproof and breathable
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/39—Aldehyde resins; Ketone resins; Polyacetals
- D06M15/423—Amino-aldehyde resins
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/16—Synthetic fibres, other than mineral fibres
- D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M2101/32—Polyesters
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
- D06M2200/10—Repellency against liquids
- D06M2200/12—Hydrophobic properties
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2400/00—Specific information on the treatment or the process itself not provided in D06M23/00-D06M23/18
- D06M2400/01—Creating covalent bondings between the treating agent and the fibre
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Nonwoven Fabrics (AREA)
Abstract
The present invention provides a breathable structure comprising a fibrous substrate and a crosslinked polymer comprising hydrophobic moieties. The fibrous base material comprises a plurality of fibers, and the crosslinked polymer coats a portion of the plurality of fibers.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. provisional application No. 62/700/020 filed on 7/18/2018, the entire contents of which are incorporated herein by reference.
Technical Field
The present disclosure relates generally to breathable structures (e.g., textile materials) having desirable hydrostatic resistance.
Background
Outdoor enthusiasts and others have long needed functional articles, such as waterproof garments, to protect them from the elements. Typically, this need has been met by structures such as fabrics or insulation having a waterproof or drainage membrane or film laminated thereto. The films/membranes impart improved hydrostatic resistance to the structure such that they effectively prevent or reduce the ability of water to penetrate through the structure to the wearer. However, to maintain comfort, in addition to inhibiting water from reaching the body from outside the garment, the drain or waterproof article should also be able to remove vapors generated by the body (e.g., during physical activity). Unfortunately, while such articles are generally classified as breathable, they do not actually provide significant moisture vapor transport. Exceptions include certain monolithic films that are used as air-permeable barriers in textile structures such as outerwear. Such monolithic membranes facilitate the permeation of water vapor from the interior of the structure through the use of a hydrophilic polymer layer that absorbs water vapor and transports it to the external environment. However, monolithic films typically undergo significant swelling of the hydrophilic layer, which significantly alters the vapor removal characteristics of the film and user comfort.
Thus, in general, there is an inverse relationship between the degree of hydrostatic resistance of the article and its ability to allow vapor to escape from the interior. Therefore, the trade-off of waterproof articles is impaired performance properties, such as comfort and breathability. In addition, many breathable articles tend to have very limited barrier properties. Still further, fibrous substrates (e.g., fabrics) laminated to certain film types tend to be inflexible and/or generate noise when in use. Thus, many water repellent and drainage articles tend to suffer from less than desirable attributes, including limited barrier properties, and undesirable moisture vapor transmission rates and breathability, however, it is claimed.
Thus, there remains a need for a breathable structure suitable for use in, for example, outerwear articles that provides desirable hydrostatic resistance without unduly compromising other properties, such as moisture vapor transmission rate and breathability.
While certain aspects of conventional technology have been discussed to facilitate the disclosure of the present invention, applicants do not forego these aspects of technology and it is contemplated that the claimed disclosure may encompass one or more aspects of conventional technology discussed herein.
In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge, or any combination thereof, was at the priority date publicly available, was publicly known, was part of the common general knowledge, or otherwise constituted the prior art under applicable statutory terms; or known to be associated with an attempt to solve any problems associated with the present specification.
Disclosure of Invention
In short, the present invention satisfies the need for a breathable structure that provides desirable hydrostatic resistance without unduly compromising other properties, such as moisture vapor transmission rate and breathability. The present disclosure may address one or more of the technical problems and deficiencies discussed above. However, it is contemplated that the present invention may prove useful to address other problems and deficiencies in many areas of technology. Thus, the claimed invention should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.
Certain embodiments of the disclosed breathable structures, articles comprising the breathable structures, and methods of making the breathable structures have several features, of which not a single feature alone is responsible for their desirable attributes. Without limiting the scope of the structures, articles, and methods as defined by the following claims, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled "detailed description of certain embodiments" one will understand how the features of the various embodiments disclosed herein provide many advantages over the prior art. For example, embodiments of the breathable structures of the present invention provide desirable hydrostatic resistance while maintaining desirable moisture vapor transmission rates and/or breathability.
In a first aspect, the present invention provides a breathable structure comprising a fibrous substrate and a crosslinked polymer comprising a hydrophobic portion, wherein the fibrous substrate comprises a plurality of fibers, and wherein the crosslinked polymer coats a portion of the plurality of fibers.
In a second aspect, the present invention provides an article comprising a breathable structure according to the first aspect of the invention.
In a third aspect, the present invention provides a method of manufacturing a breathable structure according to the first aspect of the invention or an article according to the second aspect of the invention.
These and other features and advantages of the present invention will be apparent from the following detailed description of the various aspects of the invention, taken in conjunction with the appended claims and the accompanying drawings.
Drawings
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, aspects, and advantages of the present invention will become readily apparent from the following detailed description, when taken in conjunction with the accompanying drawings, wherein like numerals designate like components, which are not necessarily drawn to scale, and wherein:
fig. 1 depicts a portion of a nonwoven web comprising polyester fibers.
Fig. 2 is an enlarged view of fibers in an embodiment of a nonwoven web.
Detailed Description
Aspects of the present invention and certain features, advantages and details thereof are explained more fully below. Descriptions of well-known materials, manufacturing tools, processing techniques, etc., are omitted so as not to unnecessarily obscure the detailed disclosure of the present invention. It should be understood, however, that the description and specific examples, while indicating embodiments of the invention, are given by way of illustration only and not limitation. Various substitutions, modifications, additions and/or configurations within the spirit and/or scope of the following inventive concept will become apparent to those skilled in the art from this disclosure.
Embodiments of the invention provide structures having hydrostatic resistance similar to that provided by films, but without breathability or the attendant loss of breathability.
In a first aspect, the present invention provides a breathable structure comprising a fibrous substrate and a crosslinked polymer comprising a hydrophobic portion, wherein the fibrous substrate comprises a plurality of fibers, and wherein the crosslinked polymer coats a portion of the plurality of fibers.
As used herein, a fibrous substrate is a substrate comprising a plurality of fibers. For example, in some embodiments, the fibrous substrate is a fabric, flannel, denim, nonwoven, woven, or knitted structure.
In some embodiments, the fibrous substrate is or comprises one or more nonwovens such as spunbond webs (e.g., comprising filaments), meltblown webs, multi-directional, single or multi-layer carded webs, air-laid webs, wet-laid webs, spunlaced webs, high loft nonwoven insulation, low loft nonwoven insulation, needle punched nonwovens (e.g., high density needle punched nonwovens), pile, and/or composite webs comprising more than one nonwoven layer.
In some embodiments, the fibrous substrate is or comprises one or more woven fabrics, such as: a woven structure, a twill woven structure, a satin woven structure (the foregoing optionally being a reinforcing structure, e.g. having two or more warp and/or weft yarns); knit, felt, fleece and/or needled construction.
In some embodiments, the fibrous substrate is flannel. In some embodiments, the fibrous substrate is denim.
In some embodiments, the thickness of the air-permeable structure and/or fibrous substrate is 0.9 to 50mm (e.g., 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5.5, 5.5, 5.5.5, 5.5.5.5, 5.5, 5.5.5, 5.5, 5.5.5, 5, 5.6, 5, 5.6, 5, 6, 7, 6, 7.6, 6, 7.6, 6, 7.6, 6, 7.6, 6, 7.6, 7.0, 6, 7.6, 6, 8, 7.6, 6, 7.6, 8, 8.6, 8, 6, 8.6, 7.6, 8, 6, 7, 8, 8.6, 8, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9, 15.0, 15.1, 15.2, 15.3, 15.4, 15.5, 15.6, 15.7, 15.8, 15.9, 16.0, 16.1, 16.2, 16.3, 16.4, 16.5, 16.6, 16.7, 16.8, 16.9, 17.0, 17.1, 17.2, 17.3, 17.4, 17.5, 17.6, 6, 7.4, 23.5, 23.20, 23.1, 23.6, 23.2, 23.1, 23.20, 23.2, 23.5, 23.20, 23.0, 23.6, 23.20, 23.1, 23.6, 23.5, 23.0, 23.6, 23.20, 23.0, 23.5, 23.6, 23.0, 23.2, 23.5, 23.2, 23.9.1, 23.2, 23.1.1.2, 23.1, 23.1.2, 23.1.1.1.6, 23.6, 23.2, 22.0, 23.6, 23.0, 23.1, 23.2, 23.1, 23.1.2, 22.1.1, 23.1.1, 1, 1.1, 23.6, 23.1.1.2, 23.9.1, 23.1, 1, 24.6, 23.1, 24.1, 23.1, 1, 24, 25.0, 25.1, 25.2, 25.3, 25.4, 25.5, 25.6, 25.7, 25.8, 25.9, 26.0, 26.1, 26.2, 26.3, 26.4, 26.5, 26.6, 26.7, 26.8, 26.9, 27.0, 27.1, 27.2, 27.3, 27.4, 27.5, 27.6, 27.7, 27.8, 27.9, 28.0, 28.1, 28.2, 28.3, 28.4, 28.5, 28.6, 28.7, 28.8, 28.9, 29.0, 29.1, 29.2, 29.3, 29.4, 29.5, 29.6, 29.7, 29.8, 29.9, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 43, 44, 45, 47, 48, or any subrange therein, including subranges therein.
In some embodiments, the air permeable structure and/or fibrous substrate has a density of 0.9 to 50kg/m3(e.g., 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.6, 6, 6.1, 6.2, 7.3, 7.6, 6, 7.6, 7.8, 7, 7.6, 7, 8, 7.6, 7, 6, 7.6, 7, 8.6, 7, 7.6, 7, 6, 7.6, 7, 8.6, 7.6, 7, 7.6, 8.6, 7.6, 7, 8.0, 7, 7.9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.6, 14.7, 15.8, 15.9, 15.0, 19.9, 19.1, 19.0, 19.1, 19.6, 19.0, 19.6, 1, 15.6, 1, 19.0, 1, 19.6, 1, 19.2, 1, 1.6, 19.2, 1, 19.2, 1, 1.6, 1.2, 1, 1.2, 19.2, 1.2, 1.6, 1.2, 6, 19.2, 1.2, 19.2, 1, 19.2, 1.2, 19.6, 1, 1.2, 19.6, 19.2, 1.6, 19.6, 1.6, 19.6, 1.9, 1.6, 1, 1.9.9.9.9, 19.9, 19, 1.6, 19.6, 19, 1, 19, 19.9.9, 1, 22.3, 22.4, 22.5, 22.6, 22.7, 22.8, 22.9, 23.0, 23.1, 23.2, 23.3, 23.4, 23.5, 23.6, 23.7, 23.8, 23.9, 24.0, 24.1, 24.2, 24.3, 24.4, 24.5, 24.6, 24.7, 24.8, 24.9, 25.0, 25.1, 25.2, 25.3, 25.4, 25.5, 25.6, 25.7, 25.8, 25.9, 26.0, 26.1, 26.2, 26.3, 26.4, 26.5, 26.6, 26.7, 26.8, 26.9, 27.0, 27.1, 27.2, 27.3, 27.4, 27.5, 27.6, 29.7, 29.8, 29.9, 29.0, 29.6, 29.9, 29.6, 29.42, 29.8, 29.9, 29.6, 29.9, 29.8, 29.9, 29.1, 29.6, 29.9, 29.8, 29.9, 29.6, 29.9, 29.8, 29.93) Including any and all ranges and subranges therein.
In some embodiments, the weight of the air permeable structure and/or fibrous substrate is from 25 to 600gsm (g/m)2) (e.g., 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 37, 55, 56, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58,85、86、87、88、89、90、91、92、93、94、95、96、97、98、99、100、101、102、103、104、105、106、107、108、109、110、111、112、113、114、115、116、117、118、119、120、121、122、123、124、125、126、127、128、129、130、131、132、133、134、135、136、137、138、139、140、141、142、143、144、145、146、147、148、149、150、151、152、153、154、155、156、157、158、159、160、161、162、163、164、165、166、167、168、169、170、171、172、173、174、175、176、177、178、179、180、181、182、183、184、185、186、187、188、189、190、191、192、193、194、195、196、197、198、199、200、201、202、203、204、205、206、207、208、209、210、211、212、213、214、215、216、217、218、219、220、221、222、223、224、225、226、227、228、229、230、231、232、233、234、235、236、237、238、239、240、241、242、243、244、245、246、247、248、249、250、251、252、253、254、255、256、257、258、259、260、261、262、263、264、265、266、267、268、269、270、271、272、273、274、275、276、277、278、279、280、281、282、283、284、285、286、287、288、289、290、291、292、293、294、295、296、297、298、299、300、301、302、303、304、305、306、307、308、309、310、311、312、313、314、315、316、317、318、319、320、321、322、323、324、325、326、327、328、329、330、331、332、333、334、335、336、337、338、339、340、341、342、343、344、345、346、347、348、349、350、351、352、353、354、355、356、357、358、359、360、361、362、363、364、365、366、367、368、369、370、371、372、373、374、375、376、377、378、379、380、381、382、383、384、385、386、387、388、389、390、391、392、393、394、395、396、397、398、399、400、401、402、403、404、405、406、407、408、409、410、411、412、413、414、415、416、417、418、419、420、421、422、423、424、425、426、427、428、429. 430, 431, 432, 433, 434, 435, 436, 437, 438, 439, 440, 441, 442, 443, 444, 445, 446, 447, 448, 449, 450, 451, 452, 453, 454, 455, 456, 457, 458, 459, 460, 461, 462, 463, 464, 465, 466, 467, 468, 469, 470, 471, 472, 473, 474, 475, 476, 477, 478, 479, 480, 481, 482, 483, 484, 485, 486, 487, 488, 489, 490, 491, 492, 493, 494, 495, 496, 497, 498, 499, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, or 600gsm), including any and all ranges and subranges therein.
In some embodiments, the air permeable structure comprises a low density high loft fibrous substrate (e.g., a high loft nonwoven) having a thickness of at least about 20mm (e.g., at least 30mm, or such as about 28-48mm) at a weight of 200gsm and a density of less than 10kg/m3(e.g., less than about 7 kg/m)3)。
In some embodiments, the air permeable structure comprises a high density (e.g., high density needled) fibrous substrate having a thickness of less than about 15mm (e.g., less than 10mm, or such as about 1-10mm) and a density of greater than about 20kg/m at a weight of 200gsm3(e.g., greater than about 30 kg/m)3E.g. about 35 to 45kg/m3)。
In some embodiments, the air permeable structure and/or fibrous substrate has an overhang of less than or equal to 3.5cm, e.g., 1.0cm to 3.5cm (e.g., 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, or 3.5cm), as measured according to method ASTM D1388, including any and all ranges and subranges therein.
The fibrous substrate of the air-permeable structure comprises one or more filaments, or a plurality of fibers, of infinite length.
In some embodiments, the plurality of fibers comprises staple fibers (i.e., fibers having a standardized length). For example, in some embodiments, the plurality of fibers comprises staple fibers having a length of 5 to 120mm (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 105, 106, 107, 108, 102, 110, 111, 112, 114, 111, 114, 112, 116. 117, 118, 119, or 120mm), including any and all ranges and subranges therein (e.g., 12 to 90mm, 40 to 60mm, etc.).
Generally, the fibers may be crimped or unbent. Various crimps are known in the art, including spiral crimps and standard (e.g., planar) crimps.
Although the fibers may be linear, optionally with crimp, in some embodiments, the fibrous substrate comprises fibers having a desired shape that is not linear or has a crimped linear shape. While those skilled in the art are familiar with the various desired shapes selected for the fibers that are contemplated for use in embodiments of the present invention, some non-limiting examples include Y-shaped fibers, bow-tie shaped fibers, and the like.
In some embodiments, the plurality of fibers is actually one or more filaments. The filaments are single-length filamentous continuous textile fibers/strands. Unlike staple fibers, which have a finite length, filaments have an infinite length and can be as long as digital or miles. In some embodiments, the filaments have a length ranging from 5 inches to miles, including any and all ranges and subranges therein. For example, in some embodiments, the length of a filament can be at least 5 inches (e.g., a length of at least 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 inches, or any subrange therein). In some embodiments, the length of the filament can be at least 1 foot (e.g., at least 1, 2, 3,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 120, 110, 100, 180, 170, 140, 220, 230, 140, 220, 180, 220, 250. 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, or 1000 feet, or any range or subrange therein).
In some embodiments, the plurality of fibers in the fibrous base material comprise synthetic fibers. Many synthetic fibers are known in the art, and any desired synthetic fiber may be used in the present invention. In fact, different fibers have different properties and lend themselves to advantageous use in different applications. This information is well within the purview of those skilled in the art. Although a wide array of synthetic fibers may be used in the present invention, in some embodiments, non-exclusive synthetic fibers useful in the present invention are selected from the group consisting of nylon, polyester, polypropylene, polylactic acid (PLA), poly (butyl acrylate) (PBA), polyamide, acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, and combinations thereof. In a particular embodiment, the synthetic fibers comprise polyester fibers. For example, in some embodiments, the polyester is selected from the group consisting of poly (ethylene terephthalate), poly (hexahydro-p-xylylene terephthalate), poly (butylene terephthalate), poly-1, 4-cyclohexylenedimethylene (PCDT), polytrimethylene terephthalate (PTT), and terephthalate copolyesters in which at least 85 mole% of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In a particular embodiment, the polyester is polyethylene terephthalate. In some embodiments, the synthetic fibers comprise virgin fibers. In some embodiments, the synthetic fibers comprise recycled fibers (e.g., recycled polyester fibers).
The plurality of fibers comprises 0 to 100% synthetic fibers by weight, such as 0, 1, 2, 3,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100% by weight, including any and all ranges including 100 to 100% by weight (e.g., 100 to 100% by weight, 30, and all ranges including 100 to 100% by weight (e.g., 100 to 100, and all ranges including 100% by weight, 51 to 100 wt.%, 40 to 90 wt.%, 20 to 80 wt.%, etc.). In some embodiments, the fiber mixture comprises more than 50, 55, 60, 65, 70, or 75 weight percent synthetic fibers.
Denier is a measure defined as the weight in grams of 9000 meters of a fiber or yarn. Which is a common way to specify the weight (or size) of a fiber or yarn. For example, polyester fibers of 1.0 denier are typically about 10 microns in diameter. Micro denier fibers are fibers having a denier of 1.0 or less, while macro denier fibers have a denier of greater than 1.0.
In some embodiments, the synthetic fibers have a denier of 0.7 to 8.0 denier, including any and all ranges and subranges therein. For example, in some embodiments, the synthetic fibers have a denier of 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5.5, 5.6, 7.6, 6.6, 7.6, 7, 7.6, 7, 6, 7, 7.6, 7, 6, 7, 6, 7, 7.6, 6, 7, 6, 7.
In some embodiments, the synthetic fibers comprise micro-denier fibers (e.g., fibers having a denier of 0.7 to 1.0). In some embodiments, the synthetic fibers comprise macrodenier fibers (e.g., fibers having a denier of 1.1 to 8.0). In some embodiments, the synthetic fibers comprise micro denier fibers and macro denier fibers.
In some embodiments, the plurality of fibers comprises siliconized synthetic fibers.
The term "siliconized" means that the fibers are coated with a composition comprising silicon (e.g., silicone). Silicidation techniques are well known in the art and are described, for example, in U.S. patent No. 3,454,422. The composition comprising silicon may be applied using any method known in the art, e.g., spraying, mixing, dipping, padding, etc. A silicon-containing (e.g., silicone) composition, which may include an organosiloxane or polysiloxane, is bonded to the outer portion of the fibers. In some embodiments, the silicone coating is a polysiloxane such as methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino-modified dimethylpolysiloxane. As is known in the art, the composition comprising silicon may be applied directly to the fibres, or may be diluted with a solvent as a solution or emulsion prior to application, for example an aqueous emulsion of the polysiloxane. After treatment, the coating may be dried and/or cured. As is known in the art, catalysts may be used to promote the curing of the silicon-containing composition (e.g. a polysiloxane containing Si-H bonds) and may, for convenience, be added to an emulsion of the silicon-containing composition, wherein the resulting combination is used to treat synthetic fibres. Suitable catalysts include iron, cobalt, manganese, lead, zinc and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, after siliconization, the fibers may be dried to remove residual solvent and then optionally heated to between 65 ℃ and 200 ℃ to cure.
From 0 to 100 wt.% (e.g., 0, 1, 2, 3,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt.%, inclusive, and any subrange, inclusive of the synthetic fibers and subranges thereof are present in the plurality of the fibers, if any, inclusive.
In some embodiments, the plurality of fibers comprises natural fibers. For example, in some embodiments, the plurality of fibers comprises one or more members selected from the group consisting of: wool, cotton, tencel (tencel), kapok (cotton-like staple fibers obtained from kapok seeds, which may optionally be further treated prior to use), flax, animal hair, silk and down (e.g., duck or goose down).
The plurality of fibers comprises 0 to 100 wt.% natural fibers, e.g., 0, 1, 2, 3,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt.%, including any and all ranges including 0 to 50 wt.% (e.g., 0 to 100 wt.%) and all ranges including any range from 0 to 40 wt.% (e.g., 0 to 40, and all ranges including ranges from 0 to 100 wt.%) 5 to 25 wt%, 30 to 60 wt%, etc.). In some embodiments, the fiber mixture comprises less than 50, 40, 30, 20, or 10 weight percent natural fibers.
In some embodiments, the fiber mixture comprises only synthetic fibers. In some embodiments, the fiber mixture comprises only natural fibers. In some embodiments, the fiber mixture comprises synthetic fibers and natural fibers.
In some embodiments, the plurality of fibers comprises 0 to 25 weight percent synthetic binder fibers having a bonding temperature lower than the softening temperature of the synthetic fibers present in the plurality of fibers.
In some embodiments, the synthetic binder fibers comprise, for example, 0, 1, 2, 3,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 weight percent of a plurality of fibers, including any and all ranges and subranges therein.
In some embodiments, the synthetic binder fibers have a denier of 1.0 to 6.0 (e.g., 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5.5, 5.6, 5.7, 5.8, 5.6, 5.5.0, 5.2, 5.3, 5.4, 5.5.5, 5, 5.6, 5.8, 5.6, 5, and the like, and any range including, 0, and any range.
In some embodiments, the binder fibers have a staple fiber cut length of 38 to 105mm, including any and all ranges and subranges therein. For example, in some embodiments, the length is 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, or 105mm, including any and all ranges/subranges (e.g., 38-51mm) therein.
As indicated above, the bonding temperature of the binder fibers is lower than the softening temperature of any synthetic fibers present in the plurality of fibers. In some embodiments, the binder fibers have a bonding temperature of less than or equal to 200 ℃. In some embodiments, the binder fibers have a bonding temperature of 50 to 200 ℃, including any and all ranges and subranges therein. In some embodiments, the bonding temperature of the binder fibers is from 80 ℃ to 150 ℃. In some embodiments, the bonding temperature of the binder fibers is from 100 ℃ to 125 ℃.
In some embodiments, the binder fibers comprise low melting polyester fibers.
In some embodiments, the binder fiber is a bicomponent fiber comprising a sheath and a core, wherein the sheath comprises a material having a lower melting point than the core.
In some embodiments, the fibrous substrate comprises binder fibers and has been heat treated to melt all or a portion of the binder fibers. It will be understood by those skilled in the art that in this embodiment, although "binder fibers" may be recited in the fibrous base material, the fibers may be fully or partially fused fibers, as opposed to binder fibers in their original, pre-heat treated form.
In some embodiments of the fibrous substrate, the fiber members of the plurality of fibers are homogeneously mixed, meaning that the fiber mixture of the plurality of fibers has a substantially uniform (i.e., 90-100% homogeneous) composition.
The breathable structure comprises a crosslinked polymer comprising hydrophobic moieties.
In some embodiments, the crosslinked polymer is free of fluorine.
In some embodiments, the crosslinked polymer does not comprise a fluorocarbon.
In some embodiments, the crosslinked polymer comprises a cationic moiety.
In some embodiments, the crosslinked polymer comprises a hydrocarbon group (e.g., an aliphatic hydrocarbon group) that imparts water repellency to the polymer. In some embodiments, the crosslinked polymer comprises chemically reactive groups for bonding to the surface of the fibrous substrate.
In some embodiments, the polymer is formed from a polymer composition comprising one or more self-crosslinking water-dispersible polymers (including copolymers) that can be crosslinked by the application of heat and/or light-induced stimulation. Examples of non-limiting polymers include acrylic (co) polymers described in U.S. patent application No. 20170030010. In some embodiments, the self-crosslinking water dispersible polymer comprises a hydrocarbon group (e.g., an aliphatic hydrocarbon group). In some embodiments, the self-crosslinking water-dispersible polymer comprises chemically reactive groups for bonding to the fiber surface upon exposure to an external stimulus such as heat and/or for crosslinking the polymer.
In some embodiments, the polymer is formed from a polymer composition comprising one or more polymers and/or prepolymers (e.g., monomers) having a weight average molecular weight (Mw) of 1,000 to 2,500 daltons (e.g., 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 2300, 2400, or 2500Da, including any and all ranges and subranges therein, such as 1400-2000Da, 1500-1800Da, and the like), as measured using Gel Permeation Chromatography (GPC) using polystyrene standards.
In some embodiments, the polymer is selected from the group consisting of hydrocarbons (e.g., having alkyl chains (e.g., C)4-C20Alkyl radicals, e.g. C4、C5、C6、C7、C8、C9、C10、C11、C12、C13、C14、C15、C16、C17、C18、C19Or C20Or any range therein, e.g. C6-C14、C8-C12Etc.), hydrocarbon waxes, etc.). In some embodiments, the composition comprises a component having an alkyl chain with a terminal CH3。
In some embodiments, the polymer is formed from a polymer composition comprising one or more melamine rings.
In some embodiments, the polymer is formed from a polymer composition comprising formaldehyde.
In some embodiments, the polymer is formed from a polymer composition comprising a melamine formaldehyde resin.
In some embodiments, the polymer is prepared from a polymer comprising a functionalized melamine prepolymer, such as an alkyl (e.g., C)8-C12Alkyl) functionalized melamine compound.
In some embodiments, the polymer is formed from a polymer composition comprising less than 1 wt% formaldehyde (e.g., less than 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99 wt%).
In some embodiments, the polymer is formed from a relatively monodisperse polymer composition. In some embodiments, the polymer composition has a dispersibility (Mw/Mn) from GPC of 0.90 to 1.50. For example, in some embodiments, the PDI is 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.0, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, 1.20, 1.21, 1.22, 1.23, 1.24, 1.25, 1.26, 1.27, 1.28, 1.29, 1.30, 1.31, 1.32, 1.33, 1.34, 1.35, 1.36, 1.37, 1.38, 1.39, 1.40, 1.41, 1.42, 1.45, 1.48, etc. including any subrange therein, and any subrange therein, including any subrange therein.
In some embodiments, the polymer is formed from a polymer composition that does not contain any free (unpolymerized) formaldehyde.
In some embodiments, the polymer is selected from the group consisting of Altopel F3(by Bolger)&O' heart, inc., commercial, fluorine-free hydrophobe-reinforced, self-crosslinking polymer sold as a drainage agent).
In some embodiments, the polymer composition is contained within a polymer solution (e.g., an aqueous-based solution) that includes one or more additional components, such as an emulsifier or surfactant. Various additional components are described, for example, in U.S. application No. 20120114928. Emulsifiers and surfactants are well known in the art. In some embodiments, the solution comprises a cationic and/or nonionic emulsifier or surfactant.
In some embodiments, the polymer solution is applied to the fibrous substrate (e.g., by spraying the polymer solution onto the fibrous substrate, dipping the fibrous substrate into the polymer solution, or kiss-rolling the polymer solution onto the fibrous substrate), thereby coating a portion of the plurality of fibers in the fibrous substrate with the polymer solution. The solution applied fibrous substrate may then be subjected to a stimulus (e.g., heat) that crosslinks the polymer, thereby forming a crosslinked polymer that coats a portion of the plurality of fibers.
Fig. 1 depicts a portion of a fibrous substrate, nonwoven web 10 comprising polyester fibers 12. Fig. 2 is an enlarged view of the nonwoven web 10 and depicts the polyester fibers 12 and binder fibers 16, which have melted after the heat treatment of the web in fig. 2, thus binding the fibers within the web 10 together. In fig. 2, there are various overlap points 14 where the fibers 12 overlap each other and/or the binder fibers 16. Depending on the proximity of the fibers (due to, for example, fiber number, substrate density, etc.), some fiber substrate embodiments will have more overlapping points 14 than others. As will be readily understood by those skilled in the art, where the fibrous substrate has more overlapping points 14, there will generally be less fiber surface area available for polymer coating.
In some embodiments of the breathable structures of the present invention, 40 to 100% (e.g., 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.5, or 100%), including any and all ranges and subranges therein (e.g., 40-100%, 50 to 99%, 60 to 98%, 70 to 97%, 80 to 96%, 90 to 100%, etc.), of the surface area of the fibers in the fibrous substrate is in direct contact with the crosslinked polymer. When the fibers have been treated with other chemicals (e.g., siliconized), the surface area of the chemically treated fibers, regardless of such chemicals (e.g., siliconized), will still be considered to be in direct contact with the crosslinked polymer.
In some embodiments of the breathable structures of the present invention, greater than or equal to 40% (e.g., greater than or equal to 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99%) of the surface area of the fibers in the fibrous substrate is in direct contact with the crosslinked polymer.
In some embodiments, the inventive breathable structures comprise 0.25% to 7% by weight (e.g., 0.25, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.5, 5.0, 5.5, 5.6, 6.6, 6, 6.6, 6% by weight percent of the polymer and any sub-ranges including, e., ranges therein.
The term hydrostatic resistance (which may be used interchangeably herein with the term hydrostatic head) is a measure of the resistance of a structure to liquid water penetration under static pressure. As used herein, the anti-hydrostatic/hydrostatic head is calculated according to AATCC-127, which is incorporated herein by reference, and reported in units of centimeters of water. In some embodiments, the breathable structures of the present invention have a hydrostatic resistance of 30 to 700cm of water (e.g., 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, or 700cm of water), including any and all ranges and subranges therein. In some embodiments, the air permeable structure of the present invention has a hydrostatic resistance of greater than or equal to 50cm of water.
In some embodiments, the air permeable structure has a hydrostatic resistance of HR2 and the fibrous substrate (or air permeable structure in the absence of the cross-linked polymer) has a hydrostatic resistance of HR1, wherein:
(e.g., ≧ 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, or 75%).
In some embodiments, the breathable structures have a Moisture Vapor Transmission Rate (MVTR) (calculated according to ASTM E-96B, which is incorporated herein by reference) of from 200 to 1500g/m2A/day (e.g., 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 1070, 930, 940, 950, 960, 970, 980, 990, 1000, 1010, 1020, 1030, 1040, 1050, 1060, 1100, 1080, 1130, 1140, 1420, 1170, 1180, 1190, 1200, 1210, 1220, 1240, 1270, 1370, 1440, 1370, 1440, 1370, 1440, 1450. 1460, 1470, 1480, 1490 or 1500g/m2Day), including any and all ranges and subranges therein. In some embodiments, the MVTR of the breathable structure is greater thanOr equal to 300g/m2The day is.
In some embodiments, the Air permeable structure has a Frazier Air Permeability (Frazier Air Permeability) (calculated according to ASTM D737, which is herein incorporated by reference) of from 1 to 500cfm (e.g., 1, 2, 3,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 88, 85, 91, 98, 93, 99, 95, 98, 97, 95, 98, 99, 95, 98, 97, 98, 99, 98, 99, 95, 98, 99, and 23, 100. 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 210, 209, 212, 209, 215, 220, 224, 220, 224, 220, 224, 220, 229. 230, 231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 255, 256, 257, 258, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268, 269, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289, 290, 291, 292, 293, 294, 295, 296, 297, 298, 299, 300, 301, 302, 303, 304, 305, 306, 307, 308, 309, 310, 311, 312, 313, 314, 315, 316, 317, 318, 319, 320, 321, 322, 323, 324, 325, 326, 327, 328, 326, 332, 333, 334, 337, 336, 341, 338, 339, 340, 353, 340, 353, 342, 357, 342, 357, 356, 358. 359, 360, 361, 362, 363, 364, 365, 366, 367, 368, 369, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 380, 381, 382, 383, 384, 385, 386, 387, 388, 389, 390, 391, 392, 393, 394, 395, 396, 397, 398, 399, 400, 401, 402, 403, 404, 405, 406, 407, 408, 409, 410, 411, 412, 413, 414, 415, 416, 417, 418, 419, 420, 421, 422, 423, 424, 425, 426, 427, 428, 429, 430, 431, 432, 433, 434, 435, 436, 437, 438, 439, 440, 441, 442, 443, 444, 446, 447, 448, 449, 450, 451, 452, 453, 455, 482, 457, 458, 459, 456, 460, 465, 463, 467, 470, 481, 480, 481, 480, 478, 481, 480, 481, 475, 478, 475, 478, 480, 478, 480, 466, 486, 466, 479, 478, 480, 481, 480, 487. 488, 489, 490, 491, 492, 493, 494, 495, 496, 497, 498, 499, or 500cfm), including any and all ranges and subranges therein.
In some embodiments, the fibrous base material is listed in table I:
TABLE I
| Fibrous substrate | Permeability of Frazier |
| Fabric | 1 to 160cfm |
| High loft nonwoven | 250 to 500cfm |
In some embodiments, the moisture vapor transmission rate of the breathable structure of the present invention is MVTR2, and the moisture vapor transmission rate of the breathable structure in the absence of crosslinked polymer (i.e., the uncoated fibrous substrate) is MVTR1, and:
for example, in some embodiments,
in some embodiments, the air permeable structure of the present invention has a frazier permeability of AP2, and the air permeable structure in the absence of crosslinked polymer (i.e., the uncoated fibrous substrate) has a frazier permeability of AP1, and:
for example, in some embodiments,
in a second aspect, the present invention provides an article comprising a breathable structure according to the first aspect of the invention.
Non-limiting examples of articles of the present invention include, for example, garments (e.g., outerwear garments, such as outerwear, jackets, other rain gear, etc.), clothing, pillows, cushions, sleeping bags, bedding (e.g., bedding, comforters), and the like.
In some embodiments, the article is a fabric or insulation (e.g., batting, lint, flannel, etc.). In some embodiments, the article is a product (e.g., sleeping bag, outerwear, sportswear, household product, etc.) comprising a fabric or insulation.
In a third aspect, the present invention provides a method of manufacturing a breathable structure according to the first aspect of the invention or an article according to the second aspect of the invention.
In some embodiments, the inventive method comprises applying a polymer solution comprising a crosslinkable polymer to a fibrous substrate, thereby forming an intermediate structure, and subsequently heating the intermediate structure, thereby crosslinking the polymer, the crosslinkable polymer comprising a hydrophobic moiety.
Although the polymer solution can be applied in any technically acceptable manner, in some embodiments, applying the polymer solution to the fibrous substrate includes spraying the polymer solution onto the fibrous substrate, dipping the fibrous substrate in the polymer solution, or contact rolling the polymer solution onto the fibrous substrate.
In some embodiments, the polymer solution comprises 0.5 to 10 wt% of the crosslinkable polymer (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.5, 5.6, 7.6, 7.8, 7.6, 7, 8, 5.0, 5.6, 7, 7.6, 7, 8, 6, 7.6, 7, 8, 6.6, 6, 7, 8, 6, 6.6, 7, 8.6.6, 6, 7, 8.6, 6, 7.6, 6, 8.6, 6, 7.6, and 7.6.6.6.6.6.6.6, 7.6, and any of the ranges including any of the foregoing.
In some embodiments, the invention is as described in the following clauses:
1. a breathable structure comprising a fibrous substrate and a crosslinked polymer comprising a hydrophobic portion, wherein the fibrous substrate comprises a plurality of fibers, and wherein the crosslinked polymer coats a portion of the plurality of fibers.
2. The air-permeable structure according to item 1, wherein the plurality of fibers comprises synthetic fibers.
3. The air-permeable structure of clause 1 or clause 2, wherein the plurality of fibers comprise natural fibers.
4. The air-permeable structure of any of the preceding items, wherein greater than or equal to 50% by weight of the fibers in the fibrous substrate are synthetic fibers.
5. The air-permeable structure according to any one of the preceding items, wherein greater than or equal to 40% of the surface area of the fibers in the fibrous substrate is in direct contact with the crosslinked polymer.
6. The air-permeable structure of clause 5, wherein greater than or equal to 60% of the surface area of the fibers in the fibrous substrate are in direct contact with the crosslinked polymer.
7. The breathable structure of any one of the preceding items, comprising 0.25% to 7% by weight of the crosslinked polymer.
8. The breathable structure of clause 7, comprising 1 to 5% by weight of the crosslinked polymer.
9. The breathable structure of any one of the preceding items, wherein the crosslinked polymer does not comprise fluorine.
10. The breathable structure of any one of the preceding items, wherein the structure does not comprise fluorocarbon compounds.
11. The breathable structure of any one of the preceding items, wherein the plurality of fibers comprises polyester fibers.
12. The air permeable structure according to any one of the preceding items, wherein the fibrous substrate is a nonwoven web.
13. The breathable structure of any of items 1-11, wherein the fibrous substrate is plush.
14. The breathable structure of any of items 1-11, wherein the fibrous substrate is a fabric.
15. The air-permeable structure of any of clauses 1-11, wherein the fibrous substrate is a nonwoven insulation (e.g., a high loft nonwoven insulation, a low loft nonwoven insulation, or a needle-punched nonwoven insulation, such as a high density needle-punched nonwoven insulation).
16. The air-permeable structure of any of the preceding items having a hydrostatic resistance greater than or equal to 50 centimeters of water.
17. The air permeable structure according to any of the preceding items having a hydrostatic resistance to HR2, wherein the air permeable structure has a hydrostatic resistance to HR1 in the absence of the cross-linked polymer, and wherein:
18. the breathable structure of any one of the preceding items, having a weight of greater than or equal to 300g/m2Moisture Vapor Transmission Rate (MVTR) per day.
19. The air-permeable structure of any one of the preceding items having a frazier air permeability of 1 to 500 cfm.
20. The air-permeable structure of item 19 having a frazier air permeability of 1 to 160cfm (e.g., 1 to 20cfm), wherein the fibrous substrate is a fabric.
21. The air-permeable structure of item 19 having a frazier air permeability of 250 to 500cfm, wherein the fibrous substrate is a high loft nonwoven.
22. The breathable structure of any of the preceding items, having a moisture vapor transmission rate of MVTR2 and a Frazier permeability of AP2, wherein the breathable structure has a moisture vapor transmission rate of MVTR1 and a Frazier permeability of AP1 in the absence of the crosslinked polymer, and wherein:
-
and/or
-
23. An article comprising the breathable structure according to any one of the preceding items.
24. The article of item 23, wherein the article is a garment.
25. A method of making a breathable structure according to any one of items 1-22, the method comprising applying a polymer solution comprising a cross-linkable polymer to a fibrous substrate, thereby forming an intermediate structure, and subsequently heating the intermediate structure, thereby cross-linking the polymer, the cross-linkable polymer comprising hydrophobic moieties.
26. The method of clause 25, wherein the applying comprises spraying the polymer solution onto the fibrous substrate, immersing the fibrous substrate in the polymer solution, or contact rolling the polymer solution onto the fibrous substrate.
27. The method according to clause 25 or 26, wherein the polymer solution comprises 0.5 to 10% by weight of the crosslinkable polymer.
28. The method of clause 27, wherein the polymer solution comprises 1 to 5 weight percent of the crosslinkable polymer.
Examples
The invention will now be illustrated with reference to, but is not limited to, the specific embodiments described in the following examples.
Example 1: aqueous polymer solution was prepared by mixing Altopel F3(commercially available fluorine-free hydrophobe-enhanced self-crosslinking polymers, produced by Bolger&O' heart, inc. sold as a drainage agent) with water. The polymer solution was applied to the PET fleece via contact roller pressing. Altopel F3The polymer of (a) is crosslinked by heat treating the coated fleece at about 175 ℃ to produce a breathable structure comprising about 2% by weight of the crosslinked polymer. The result is a treated structure having good hydrostatic resistance while surprisingly maintaining breathability and breathability.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" (and any form comprising (comprises) ", such as" comprises "and" comprising) "," has "(and any form having (has)", such as "has" and "has)", "includes" (and any form including (includes), such as "includes" and "includes)", "contains" (and any form including (includes) "," contains "(and any form containing (contains)", such as "contains" and "contains)", and "contains" (contains) "and any other grammatical variations thereof are open-ended linking verbs. As a result, a method or article of manufacture that "comprises," "has," "includes" or "contains" one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that "comprises," "has," "includes" or "contains" one or more features possesses those one or more features, but is not limited to possessing only those one or more features.
As used herein, the terms "comprising," "having," "including," "containing," and other grammatical variations thereof encompass the terms "consisting of … … (the governing of)" and "consisting essentially of … … (the governing of)".
The phrase "consisting essentially of … …" or grammatical variations thereof as used herein is to be taken as specifying the stated features, integers, steps or components but does not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed composition or method.
All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference as if fully set forth.
Subject matter incorporated by reference should not be viewed as an alternative to the limitations of any claim unless explicitly indicated otherwise.
Where reference is made throughout this specification to one or more ranges, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if fully set forth herein.
While several aspects and implementations of the present invention have been described and depicted herein, alternative aspects and implementations may be affected by one skilled in the art to achieve the same objectives. Accordingly, the invention and the appended claims are intended to cover all such additional and alternative aspects and implementations as fall within the true spirit and scope of the invention.
Claims (28)
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
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| US201862700020P | 2018-07-18 | 2018-07-18 | |
| US62/700,020 | 2018-07-18 | ||
| PCT/US2019/042135 WO2020018627A1 (en) | 2018-07-18 | 2019-07-17 | Breathable hydrostatically-resistant structures |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN112400044A true CN112400044A (en) | 2021-02-23 |
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| CN201980044279.4A Pending CN112400044A (en) | 2018-07-18 | 2019-07-17 | Air-permeable anti-hydrostatic structure |
Country Status (5)
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| US (1) | US20210123185A1 (en) |
| CN (1) | CN112400044A (en) |
| DE (1) | DE112019003628T5 (en) |
| TW (1) | TW202006207A (en) |
| WO (1) | WO2020018627A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113756089B (en) * | 2021-10-26 | 2023-05-23 | 成都海蓉特种纺织品有限公司 | Low-air-permeability fabric and preparation method and application thereof |
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Also Published As
| Publication number | Publication date |
|---|---|
| WO2020018627A1 (en) | 2020-01-23 |
| TW202006207A (en) | 2020-02-01 |
| US20210123185A1 (en) | 2021-04-29 |
| DE112019003628T5 (en) | 2021-04-01 |
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