HK1173756B - Textile composite article - Google Patents

Description

Fabric composite article

Technical Field

The present application relates to a fabric composite article comprising at least one fabric made of fibers/filaments, especially in the form of yarns, with a partially internal discontinuous pattern of impregnating material to form an air permeable, water vapor permeable fabric composite that reduces the rate of water absorption and re-drying time. In one embodiment, the fabric composite article exhibits additional enhanced fire resistance.

Background

There is a need for apparel fabrics that have reduced water absorption capacity upon exposure to water. The textile yarns may be comprised of multifilament or staple fibres. These yarns in the form of fiber/tow contain voids between the fibers/filaments. In the event that the yarn contacts a liquid, such as water, most of the liquid wicks into the yarn void. This wicking process results in the fabric being wet, heavy and requiring a long period of drying.

One possible way to overcome this drawback is to provide the fabric with a hydrophobic finish, usually based on fluorocarbon. However, the fabric loses its water repellency after several washes.

Another possibility of how to treat a fabric to make it water repellent is described in EP 2034088a1 of w.l. gore & Associates GmbH. EP 2034088a1 describes fabrics consisting of yarns composed of multiple fibers with voids between the fibers. The fabric has a very open textile structure with the average width of the voids in the yarn being greater than 100 um. The voids are filled with polymeric material while the voids remain open. The filling in the voids between the fibers prevents moisture from being absorbed into the voids, thereby reducing the water absorbency of the fabric. The fabric having the open structure has very limited industrial applications, and although the yarn itself can resist external water, its open and wide voids still allow water to pass therethrough into the garment. In addition to this, the yarn interior is already filled with the polymer material, and it is therefore difficult to add additional functionality to the fabric by other treatments.

US 5,418,051a to tasdeck Applications limited (Nextec Applications, Inc.) relates to a flexible porous mesh comprising an inner coating of a silicone polymer composition. The web may comprise fibers in the form of monofilaments, yarns, staple fibers, and the like. The web material may be a woven or nonwoven fabric comprising fibers of any desired composition. The web comprises a curable silicone polymer impregnant in the form of a film, coating or layer within the web surrounding at least a portion of the fibers of the web. The voids in the inner coating region are mostly filled or plugged with the impregnant. The outer surface of the web is substantially free of impregnant. The silicone polymer substantially completely encapsulating the fibers of the web and forming the inner layer means that the silicone polymer is predominantly located on surface portions of the fibers within the web. Based on the inner coating, the fibers of the outer surface of the web are uncoated and thus are able to wick water into the web. To avoid this phenomenon, the web is impregnated with a fluorine compound before the silicone polymer is applied. Such impregnated webs are known to lose their water repellency after several washes. In addition to this, such a mesh with an inner coating is air impermeable, since its inner layer or membrane is a silicone polymer.

Typically, protective clothing for industrial workers and law enforcement personnel is made of a tight fabric of polycotton. Polycotton fabrics are inexpensive but have very high water absorption and a re-drying time of several hours.

Firefighters, industrial workers, law enforcement personnel, etc., require clothing that protects them not only from weather conditions, but also from hazardous liquids, heat, and flames. In particular, protection against flames requires both self-extinguishing properties of the material and prevention of combustion by heat transferred through the laundry. In addition, liquid and flame protective clothing should have a sufficient level of breathability to reduce the thermal stress burden to extend their performance or to prevent thermal casualty. The fire-blocking material comprises a non-combustible, non-fusible fabric made of, for example: aramid, Polybenzimidazole (PBI), poly-p-phenylene-2, 6-benzobisoxazole (PBO), modacrylic blends, and mixtures thereof. These fibers may have flame retardancy themselves, but may have some limitations. In particular, these fibers can be very expensive, difficult to dye and print to color, and may not have sufficient abrasion resistance. Furthermore, these fibers absorb more water than nylon or polyester based fabrics and the comfort is not satisfactory. In addition, it is difficult to perform additional hydrophobic, oleophobic, etc. treatments based on the unique chemical structure of the fire-blocking material.

The present invention overcomes the above-mentioned deficiencies.

It is an object of the present invention to provide an improved fabric composite having low water absorbency, fast re-drying time and yet being air permeable.

It is another object of the present invention to provide a fabric composite having low water absorption, high air permeability and flame retardancy.

It is another object of the present invention to provide a fabric composite comprising a fusible, flammable outer fabric which is flame retardant, air permeable, waterproof, while having low water absorption and fast re-drying times.

In addition, to optimize performance in environments that are occasionally exposed to open flame (flash fire), there is a need for garments that are lightweight, permeable to water vapor, and waterproof, and have enhanced fire protection.

Disclosure of Invention

The present invention provides a textile composite article according to claim 1, the dependent claims relating to embodiments of the textile composite article. The present invention also includes a garment made from the fabric composite article of claim 1.

A fabric composite article is described comprising a first fabric having an inner surface and an outer surface. The first fabric comprises a plurality of fibers/filaments having voids between the fibers. In one embodiment, the first fabric comprises yarns having multiple fibers/filaments with interstices between the yarns. The first fabric includes a discontinuous pattern of impregnated material that forms impregnated areas and non-impregnated areas conforming to the discontinuous pattern across at least a portion of a cross-section between the inner and outer surfaces of the first fabric. At least a part of the cavities in the impregnation zone is filled with the impregnating material, the water absorption of the textile composite being less than or equal to 70% according to DIN EN29865 (1991). In one embodiment, the yarns in the impregnation zone have voids between them, while at least a portion of the voids between the yarns are filled with the impregnating material. At least a portion of the impregnating material penetrates to form a partially internal discontinuous pattern of impregnating material.

In one embodiment, the first fabric has a tight fabric structure. This tight first fabric means any densely manufactured fabric structure made of yarns, e.g. knitted or woven structures, or fibers/filaments, e.g. non-woven. The interstices between yarns in the tightly-woven fabric structure are significantly smaller or the non-woven fibers/filaments are void-free. The small voids between the multiple fibers/filaments and the yarns that may be present result in air permeability and/or water vapor permeability of the tight fabric.

The first fabric comprises a tightly woven fabric structure made from yarns with voids between them according to one embodiment. The tight fabric is characterized by 1cm²The average size of the inter-yarn voids measured therein is less than 100 um.

The first fabric is an outer fabric, which means that it may be used to form the outermost layer of a garment or garment.

In one embodiment, the first fabric may be made of polycotton.

In another embodiment, the first fabric may be made of at least one fusible material, which may be combustible. Fabrics considered to be fusible include, but are not limited to, polyamides such as nylon 6 or nylon 6, polyesters, polypropylene. The use of meltable materials is very beneficial because the materials are inexpensive, easy to dye and print and have sufficient abrasion resistance.

In another embodiment, the first fabric may be made of at least one of an infusible material or a thermally stable fabric such as: aramid, Flame Retardant (FR) cotton, PBI, PBO, FR rayon (rayon), modacrylic (modacrylic) blends, polyamine, carbon (carbon), fiberglass (fiberglass), PAN, Polytetrafluoroethylene (PTFE), and blends and mixtures thereof.

The impregnated material filled in the voids between the fibres/filaments prevents liquid from being absorbed into the voids. The impregnating material is located substantially only within the voids between the fibres/filaments in the impregnated areas defined by the discontinuous pattern. The at least partial penetration of the impregnating material into the cross-section means that the impregnation zone is divided into non-impregnation zones according to a discontinuous pattern. The impregnated areas are discrete individual units of impregnated impregnating material that are completely disconnected from adjacent impregnated areas.

At least a portion of the voids in the impregnated area are filled, indicating that there may be voids in the impregnated area that are not filled by the impregnating material.

In one embodiment containing yarn-to-yarn voids, the voids in the impregnated region are also at least partially filled. Generally, the impregnating material is able to penetrate into the cross-section and fill any spaces and volumes (voids/interstices) within the textile structure (fibers/filaments/yarns), thereby preventing the liquid from completely filling the spaces/volumes. This forms an internally discontinuous pattern of impregnated areas and non-impregnated areas.

The level or depth of penetration or filling is different according to the present invention for deploying material within surface pores or surface cavities of the fabric.

In one embodiment, the amount of impregnating material is at least 10% by weight of the first fabric. In another embodiment, the amount of impregnating material is at least 30% by weight of the first fabric. In another embodiment, the amount of impregnating material is at least 50% by weight of the first fabric.

In one embodiment, the impregnating material fills most of the voids in the impregnated region. Most voids indicate that more than half of the voids in the impregnated area are filled. By majority of voids is meant voids that are filled in the impregnated region greater than or equal to 50%, greater than or equal to 60%, greater than or equal to 70%, greater than or equal to 80%, greater than or equal to 90%. Substantially all of the voids in the impregnated area may be filled. The level of filling the voids depends on the amount of impregnating material and the pattern of discontinuity. The more the voids are filled, the more the water absorption of the fabric composite decreases. On the other hand, the air permeability and/or water vapor permeability may decrease and may increase the weight and stiffness of the fabric composite. The distance between the impregnated areas and the non-impregnated areas, which depends on the discontinuous pattern, also affects the water absorption, air permeability and water vapor permeability of the textile composite.

In another embodiment, the inner and outer surfaces of the first tight fabric remain substantially unchanged and are at least partially free of impregnating material even in the impregnated areas. The impregnated area is located primarily within the middle of the first fabric section. At least partially free of impregnating material means that a small portion of the impregnating material may remain as a very thin layer on part of the outer and/or inner surface of the fabric after the impregnation process. This leaves the fabric feel of the fabric substantially unchanged, meaning that the fabric properties/characteristics of the fabric are retained, and the fabric itself is soft, feels good, is securely wired, and has no sticky touch.

The treated textile composite with the filled voids prevents liquid from wicking into the yarns in the impregnation zone. The liquid in the impregnated areas of the fabric only adheres to the outer surface of the yarn but does not wet the void volume within the yarn. Thus, the water absorption of the textile composite is reduced relative to untreated textiles. The water absorption of the textile composite is less than or equal to 70%, less than or equal to 50%, less than or equal to 40%, less than or equal to 30%, less than or equal to 20%, less than or equal to 10%, according to the Bundesmann test (DIN EN29865, 1991).

In addition, the treated fabric compound exhibits enhanced re-drying properties, the re-drying time of the treated fabric composite being less than the re-drying time of a fabric composite not treated by the present invention.

To ensure the air-permeability and/or water vapor permeability of the textile composite, an impregnating material is applied to the textile in a discontinuous pattern to form a discontinuous pattern of impregnated and non-impregnated regions.

The non-impregnated areas provide the air and/or water vapor permeability of the fabric composite article of the present invention. In one embodiment, the air permeability is greater than 300l/m²And s. In another embodiment, the air permeability is greater than 150l/m²S, even more than 20l/m²S, even more than 5l/m²/s。

In one embodiment, the discontinuous pattern is in the form of discrete discontinuities and/or lines. The dots may be circular, square, rectangular, square (square shape), or a combination thereof. The lines may be straight lines, wavy lines, curved lines, or a combination thereof. The dots and lines may be arranged closer to or farther from each other depending on the pattern.

The impregnating material may be selected from: silicone, polyurethane, amorphous perfluoropolymer, or mixtures thereof. A known commercially available amorphous perfluoropolymer is TeflonAF (DuPont), HyflonAD (Solvay Solexis) and Cytop(Asahi glass Co., Ltd.). TeflonAF is a member of the amorphous fluoropolymer family available from DuPont and is prepared by copolymerizing 2, 2-bis-trifluoromethyl-4, 5-difluoro-1, 3-dioxole (PDD) with other fluoromonomers. Currently, Teflon is commercially availableAF grades are copolymers of PDD and Tetrafluoroethylene (TFE) known as TeflonAF 1600 and TeflonAF 2400. In a particular embodiment, the impregnating material contains at least one silicone or silicone rubber.

The impregnating material requires a very low viscosity to wick into the voids in the fibres/filaments, especially in the yarn, by capillary forces.

The viscosity of the impregnating material that can be used before filling the cavities is less than 5000 mPa/s. In another embodiment, the viscosity of the impregnating material is about 2000mPa/s or less. Furthermore, the impregnating material has substantially no swelling and/or dissolving properties in a liquid. The impregnating material may or may not be crosslinked.

In another embodiment, the impregnating material contains one or several additives. In another embodiment, the impregnating material contains at least one expandable graphite-containing additive. The expandable graphite acts as a flame retardant upon thermal contact. The expandable nature of the expandable graphite blocks heat and prevents burning of the fabric composite. Thus, the use of expandable graphite enhances the heat and/or fire resistant properties of the substrate where it is exposed.

In another embodiment of the present invention, the non-impregnated areas of the first fabric at least partially comprise at least one functional coating material to form coated areas. Coated areas refer to non-impregnated areas of the outer surface of the yarn covered by the functional coating material with the voids substantially free of the functional coating material. The coated areas are still air and/or water vapor permeable. The functional coating material may additionally add to the good function of the fabric. For example, the functional coating material may be selected from: hydrophilic materials, hydrophobic materials, oleophobic materials, insect repellent materials and mixtures thereof. An example of an insect repellent material may be pyrethrin.

A second fabric may be disposed adjacent the first fabric adjacent the inner surface of the first fabric. In one embodiment, the second fabric may comprise a tight fabric structure as described for the first fabric. The second fabric has a first surface and a second surface and comprises a plurality of fibers/filaments having voids between the fibers/filaments. In one embodiment, the second fabric comprises yarns having multiple fibers/filaments with interstices between the yarns.

In another embodiment, the second fabric is bonded to the first fabric by an impregnating material. In this case, the impregnating material also penetrates at least part of the cross-section of said second fabric, from the first surface to the second surface, forming a discontinuous pattern of impregnated areas and non-impregnated areas, in correspondence with the discontinuous pattern of impregnating material, wherein at least part of the cavities in the impregnated areas are filled with said impregnating material. In one embodiment using yarns, at least a portion of the voids between the yarns are also filled with the impregnating material.

In one embodiment, the impregnating material fills a majority of the voids in the second fabric within the impregnated region. By majority of voids is meant that the voids in the impregnated region are filled to greater than or equal to 50%, greater than or equal to 60%, greater than or equal to 70%, greater than or equal to 80%, greater than or equal to 90%. Substantially all of the voids in the impregnated area may be filled.

The filling value of the voids in the second fabric depends on the discontinuous pattern and the amount of impregnating material applied to the first fabric. The more the voids in the second fabric are filled, the lower the water absorbency of the second fabric.

In another embodiment, a discontinuous pattern of impregnating material is applied to the inner surface of the first fabric and then the first surface side of the second fabric is bonded to the inner side of the first fabric, thereby encapsulating the discontinuous pattern between the first and second fabrics. The impregnating material is placed in the voids between the first and second fabrics using pressure and heat, and simultaneously fills some of the voids in the impregnated areas of the first and second fabrics. The outer surface of the first fabric remains substantially unchanged from the second surface side of the second fabric and is at least partially free of impregnating material in the impregnated areas. At least partially free of impregnating material means that a small portion of the impregnating material may remain as a very thin layer on part of the outer surface and/or the second surface of the fabric after the impregnation process. This leaves the textile composite with a substantially unchanged textile hand, meaning that the textile properties/characteristics of the textile are retained, and the textile composite itself is soft, feels good, is securely wired, and has no sticky touch.

In one embodiment, a fabric composite article comprises a first fabric and a second fabric. The first fabric is made from a tightly fabricated fabric made from multifilament polyamide or polyester yarns, which are fusible and thermally unstable. The second fabric is made of a flame retardant material. The first and second fabrics are bonded together by an impregnating material comprising expandable graphite (an impregnating material blend). The impregnating material blend is at least partially cross-sectioned through the first dense fabric and the second fabric in a discontinuous pattern to form impregnated areas and non-impregnated areas in both fabrics that conform to the discontinuous pattern. At least a portion of the voids in the impregnated areas are filled with the impregnating material blend, wherein the water absorption of the fabric composite is less than or equal to 70% according to DIN EN29865 (1991). According to this embodiment, a fabric composite is provided that is easy to dye and print, has low water absorption, and provides fire resistance.

In another embodiment, a barrier layer is adjacent to one side of the first or second fabric to form a fabric composite article. The barrier layer may be water vapor permeable. The barrier layer may also be liquid and/or air impermeable. In most embodiments, the barrier layer is a film or membrane and is bonded to at least one backing fabric layer.

The term "permeable to water vapor" means a layer that ensures the transmission of water vapor through the layer. The barrier layer has a water vapour permeability, measured as the water vapour permeability resistance (Ret), of less than 20m²Pa/W。

The term "barrier layer" as used herein is defined as a film, film or coating that is minimally impervious to the penetration of air, and ideally impervious to the attack of many other gases, such as gaseous chemicals. The barrier layer is air impermeable and/or gas impermeable. If the air permeability of the barrier layer is less than 5l/m²(EN ISO 9237, 1995), it is considered to be air impermeable.

In another embodiment, the barrier layer is also minimally impervious to liquid water penetration, and ideally impervious to many liquid chemical attacks. A layer is considered liquid impermeable if it is capable of preventing the transmission of liquid water under a pressure of at least 0.13 bar. The water permeation pressure was determined on a sample of the barrier layer described herein based on the same conditions described according to ISO 811.

In one embodiment, the barrier layer comprises at least one water vapor permeable, air impermeable film to provide air impermeable, water vapor permeable (breathable) properties. Preferably, the film is also liquid impermeable, at least water impermeable. The use of an air impermeable, water vapor permeable film in a fabric composite article also forms an air impermeable, water vapor permeable fabric composite article.

Suitable water impermeable and water vapor permeable flexible membranes for use herein are described, for example, in U.S. patent 3,953,566, which discloses a porous expanded Polytetrafluoroethylene (PTFE) material. The microstructure of expanded porous PTFE is characterized by interconnected nodes of fibrils. Expanded PTFE can be coated with a hydrophobic and/or oleophobic coating material to enhance water impermeability, if desired.

The water impermeable, water vapor permeable membrane may also be a microporous material, such as: high molecular weight microporous polyethylene or polypropylene, microporous polyurethane or polyester, or hydrophilic monolithic polymers such as polyurethane.

The combination of the barrier layer with the fabric composite of the present invention provides superior comfort to the garment and facilitates waterproofing. "garment" means any article of manufacture suitable for wearing, including footwear, hats, gloves, shirts, coats, pants, and the like.

In one embodiment, a fabric composite article according to the present invention comprises a first fabric and a water vapor permeable, liquid water impermeable film comprising porous expanded Polytetrafluoroethylene (PTFE) bonded to the inside of the first fabric by an impregnating material. In another embodiment, the film is laminated to at least one backing fabric layer using at least one discontinuous adhesive or the same impregnating material.

An improved fabric composite article having improved comfort and protection is described. Based on the filled voids and interstices in the impregnated areas and the non-impregnated areas that are permeable to water vapor, the fabric composite exhibits limited wicking and low water absorption, a faster re-drying process, reduced evaporative heat loss, and a small increase in weight after rain.

According to the present invention, the impregnated fabric composite of the impregnated material and the expandable graphite blend is simultaneously flame retardant. Especially in the case of a fabric composite comprising a first fabric using an impregnating material blended with expandable graphite and a second fabric containing a flame retardant material and bonded to the inner surface of the first fabric by the impregnating material blend, the fabric composite is flame retardant according to ISO15025 (2003).

Brief description of the drawings

Fig. 1 shows a cross-sectional view of an untreated multifilament yarn.

Figure 2 shows a cross-sectional view of an untreated multi-fiber yarn after contact with a liquid.

Figure 3 shows a fabric composite article made from a multi-fiber yarn with a discontinuous pattern of impregnating material.

FIG. 4 shows a schematic representation of a fabric composite article having a discontinuous pattern of impregnated material in another embodiment.

Figure 5 shows a schematic representation of a cross-section of a first fabric in one embodiment herein.

Fig. 6 shows a schematic representation of a cross-section of a first fabric and a second fabric bonded to each other by an impregnating material in another embodiment herein.

FIG. 7 shows a schematic representation of a cross-section of a first fabric having an impregnated region made of an impregnating material in one embodiment.

Fig. 8 shows a schematic representation of a cross-section of a fabric having impregnated areas made of an impregnating material and non-impregnated areas containing a functional coating material in another embodiment.

Fig. 9 shows a schematic representation of a cross section of a first fabric and a second fabric bonded to each other by an impregnating material blend containing expandable graphite.

FIG. 10 shows a schematic diagram of a cross-section of a first fabric and a second fabric and a barrier layer therebetween in one embodiment; the first fabric is bonded to the barrier layer by a blend of impregnating materials containing expandable graphite, and the second fabric is bonded to the barrier layer by a blend of impregnating materials containing expandable graphite.

Fig. 11 shows a Scanning Electron Micrograph (SEM) of a cross section of the impregnated area in the fabric composite.

Fig. 12 shows, on an enlarged scale, an SEM of a cross-section of the same impregnated area shown in fig. 11.

Figure 13 shows a SEM of a cross section of a fabric composite with impregnated and non-impregnated areas.

Fig. 14 shows, on an enlarged scale, an SEM of a cross-section of the same impregnated fabric shown in fig. 13.

FIG. 15 is a graphical representation of the re-drying time of samples described herein.

Detailed Description

"Fabric" means a woven material comprised of yarns containing fibers/filaments. In particular, the term "fabric" as used herein means a tightly manufactured sheet-like structure (e.g., knitted or woven) containing yarns.

As used herein, the term "yarn" means a continuous strand of multi-bundle fibers, filaments, or the like, such as may be suitable for knitting, weaving, or otherwise forming a fabric. The yarn may be a plurality of fibers twisted together (spun yarn), or a plurality of filaments arranged together without twist (zero-twist stretch yarn) or twisted filaments. Yarns include a plurality of fibers/filaments that are associated or inter-engaged with one another and define voids therebetween. The yarn may also comprise a single monofilament.

The term "void" as used herein means the void space/volume between fibers or filaments, particularly within a yarn. Void space may also be expressed as capillary space between fibers/filaments within a yarn. Typically, the cavity is filled with air. The average size of the voids may be 0-50um depending on how tightly the fibers/filaments are arranged within the yarn.

The term "fiber" as used herein means a flexible, natural or man-made thread-like article. The fibers can be regarded as a unit form formed by a method of a known technique or the like.

The term "filament" as used herein means a synthetic thread of indefinite length.

The term "void" as used herein means the space/opening between yarns in a fabric structure containing spun fibers or filaments. In a tight fabric, 1cm²The average size of the voids measured therein is less than 100 um. In woven fabrics, a void is formed at the intersection of two parallel warp yarns with two parallel weft yarns (see FIG. 3). In a tightly woven fabric, 1cm²The average size of the voids measured therein is less than 100um, preferably at 1cm²Less than 50um measured inside, and preferably the value of the void size is zero.

The term "laminate" as used herein means at least two separate layers, the layers being bonded together by adhesive or other means.

The present invention is directed to a fabric composite having reduced absorbency, wherein a multifilament/fibril containing yarn is used. In particular, the present invention describes a treated textile composite that reduces and prevents the storage of liquid in the open cavities between the yarns of the multi-fiber/filament. The invention particularly prevents capillary wetting of the yarns used in the textile composite. In one embodiment, the treatment of the yarns may provide the fabric composite with additional enhanced flame retardancy.

Figure 1 shows a schematic cross-section of a typical yarn 2 for a fabric, which itself is made up of bundles of fibres or filaments 5. The yarn 2 is well known in the art. Yarn 2 shown in fig. 1 comprises multiple fibers/filaments 5 with some voids 6 between the individual fibers/filaments 5 of yarn 2. When yarn 2 is contacted with a liquid, such as water, the liquid first stays on the outer surface 7 of yarn 2 and then permeates between fibers/filaments 5 and fills the void volume of yarn 2.

Fig. 2 shows such a liquid-filled yarn 2. Yarn 2 comprises multiple fibers/filaments 5 and the void volume in yarn 2 is completely filled with a liquid 8 such as water. ResultsThe yarn 2 is weighted more than before, and the fabric formed by the yarn 2 obtains an unwanted weight. In many cases, the water absorption capacity may exceed 100g/m². It is almost impossible to remove the liquid 8 from the cavity 6 quickly. The re-drying time is therefore long.

Fig. 3 shows a fabric composite article 10 according to the present invention. The fabric composite article 10 comprises a first fabric 12 comprised of yarns 2 woven with the yarns 2 in the warp and weft directions. It may consist of 10-50 yarns/cm of warp 3 and weft 4 yarns.

The first fabric 12 is a tightly woven fabric structure, and small gaps 9 are formed at the intersections of two parallel warp yarns 3 and two parallel weft yarns 4 of the first fabric, and are 1cm in length²The average size of the voids measured therein is less than 100 um. At 1cm²The size of the inner measured partial gap 9 is less than 100um, and the partial gap 9 is very small and has zero size. The first fabric 12 includes an inner surface 16 and an outer surface 18. The inner surface 16 of the fabric 12 faces a person or away from the environment. The outer surface 18 of the fabric 12 is remote from the person and in one embodiment, the outer surface 18 is the outermost side of the garment that is in direct contact with the environment (e.g., rain). Based on manufacturing, both surfaces are dense, tight and compact and have only small voids 9. In any event, the first fabric 12 is at least permeable to water vapor, which can be comfortable to the wearer as moisture can transfer from the body through the fabric structure to the exterior. Preferably, the first fabric 12 is air permeable.

In this embodiment, all yarns 2 are bundles of fibers or filaments 5. The cross-section of the yarns 2 in fig. 3 shows that each yarn 2 comprises a plurality of fibers or filaments 5, the fibers 5 having voids 6 therebetween as shown in fig. 1. A void 9 may be formed at the intersection between two parallel warp yarns 3 and two parallel weft yarns 4.

The inner surface 16 of the fabric 12 schematically shows a discontinuous pattern 20 of impregnating material 60. The pattern 20 in this embodiment is in the form of a similar dot. The discontinuous pattern 20 of impregnating material 60 forms impregnated areas 22 (dots) and non-impregnated areas 24 (areas around dots). The non-impregnated areas 24 are air permeable and water vapor permeable. A discontinuous pattern means a pattern that may be formed by discrete discontinuous points and/or interrupted lines in the impregnating material. The dots may be circular, square, rectangular, square (quadratithereby), or a combination thereof. The lines may be straight lines, wavy lines, curved lines, or a combination thereof.

The dots or lines are arranged at a distance from each other such that the discontinuous pattern 20 of impregnating material 60 forms a non-impregnated region 24 adjacent to the impregnated region 22.

The non-impregnated areas 24 are areas in which the voids, voids and fibers/filaments are free of the impregnating material 60. Thus, the discontinuously impregnated fabric is still permeable to air, at least to water vapor.

In the impregnated areas 22, the impregnating material 60 penetrates the cross-section of the fabric so that the impregnating material 60 fills at least a portion of the voids 6 between the fibres 5. Impregnating material 60 also at least partially fills voids 9 in impregnated areas 22. The impregnated area 22 is impermeable to air and/or water vapor.

Yarn 2 is selected from: polyolefins, polyamides, polyesters, regenerated cellulose, cellulose acetate, rayon, acetate, aramid, glass, modacrylic, cotton, polycotton, wool, silk, flax, jute and mixtures thereof. Yarn 2 comprises continuous multifilament or staple fibres or a combination thereof. The fibers used to form the fabric are not pretreated. In one embodiment of the invention, yarn 2 comprises filaments composed of polyamide. In another embodiment, yarn 2 comprises a blend of polyester staple fibers and cotton. The yarns 2 used to form the first fabric 12 can be prepared using a number of known techniques. For example, the yarn comprises a polyester or polyamide that has not been pre-treated.

The fabric may also comprise yarns composed of a single monofilament. Such yarns, which are composed of a single monofilament, have no voids and cannot be filled. The fabric may comprise a mixture of yarns composed of multiple fibers and yarns composed of a single monofilament.

In a particular embodiment, all yarns 2 of the fabric 12 comprise multiple fibers/filaments.

The first fabric 12 may be made of a knitted fabric structure, a woven fabric structure, a non-woven fabric structure, or a felt material.

The first fabric 12 may have a fabric weight of 50-200g/m². In one embodiment, the first fabric 12 has a weight of 90-110g/m². In another embodiment, the untreated fabric has a weight of about 180g/m²。

In one embodiment, the first fabric is an outer fabric, the material of which may be fusible, combustible, non-fusible or non-combustible, or a combination thereof. This fabric is suitable for use as an outer layer fabric, including but not limited to nylon 6, polyester, and polypropylene.

The impregnating material 60 comprises a polymeric material selected from the group consisting of: silicones, polyurethanes, amorphous perfluoropolymers, and mixtures thereof. The impregnating material 60 is composed of at least one silicone or silicone rubber. In another embodiment, the impregnating material 60 contains a non-swelling polyurethane. In another embodiment, the impregnating material 60 is made of an amorphous perfluoropolymer such as Teflon AFAnd (4) forming.

In one embodiment, silicone is used as the impregnating material 60. The silicone used may be of the RTV-type, LSR-type or mixtures thereof. This silicone consists of two parts that are mixed together just prior to use.

The curing process of RTV (room temperature vulcanizing) silicones starts when mixed at room temperature, but accelerates as the temperature increases. The good curing temperature is 120-180 ℃.

LSR (liquid silicone rubber) silicones require high temperatures, i.e. curing between 160 ℃ and 200 ℃.

The curing time depends on the amount of silicone in the yarn, the line speed, the length of the heating zone, and the selected temperature of the heating zone.

The impregnating material 60, in particular silicone, may contain one or more additives. The additives used may be: reflecting agents, mold inhibitors, hand changing agents, viscosity agents, rheology agents, flexibilizing agents, ultraviolet agents, fillers, electrically conductive agents, thermally conductive agents, flame retardants, and radiation reflectivity agents.

The flame retardant may be a boron compound, aluminum trihydrate, antimony oxide with a halogen-containing compound, magnesium hydroxide, and organic and inorganic compounds with a phosphorus-containing compound.

In one embodiment, the impregnating material may contain expandable graphite. In another preferred embodiment, the impregnating material comprises a blend or mixture of silicone and expandable graphite.

Fig. 4 shows another embodiment of the fabric composite article (10) as described in fig. 3. The impregnating material 60 of the discontinuous pattern 20 is applied to the first fabric 12 in a pattern of discrete points and lines. The discontinuous pattern 20 forms a plurality of impregnated areas 22 and non-impregnated areas 24 at a cross-section 23 of the first fabric 12.

The discontinuous pattern 20 may be in the configuration of any discrete dots and/or discrete lines to ensure permeability to air and water vapor. The amount of impregnating material 60 applied may be at least 10% by weight of the first fabric, in another embodiment at least 30% by weight of the first fabric, and in another embodiment at least 50% by weight of the first fabric.

The impregnating material 60 is applied in a manner that causes the material to firmly bond in the voids and interstices within the impregnated area 60 of the first fabric 12, thereby forming a discontinuous pattern 20. The application technique is chosen so that the impregnating material 60 is uniformly dispersed throughout the cross-section 23 of the fabric, but is confined to the impregnated area 22.

The impregnating material 60 may be applied to one surface of the first fabric 12 using any known impregnation technique. In one embodiment, the impregnating material is applied using a gravure application method. The depth of penetration can be controlled by the viscosity of the impregnating material. Preferably, the viscosity is about 2000 mPa/s.

In a particular embodiment, the impregnating material is applied according to well-known screen printing techniques.

In one embodiment, a continuous roll screen printing process is used. In this screen printing process, the impregnating material is pressed onto the first fabric by means of a screen roll. The laying is mainly adjusted by the silk screen rolling mode and the silk screen thickness, but can also be slightly changed by the angle/shape of a blade in the silk screen rolling and the rolling speed.

The cured was then cured in an oven at a temperature of 120-.

Other methods of applying the impregnating material may include: screen printing, or spraying or dispersion coating or knife coating.

FIG. 5 illustrates a cross-sectional view of the fabric composite 10 shown in FIG. 3 according to one embodiment. The woven first fabric 12 comprises warp yarns 3 and weft yarns 4. The section 23 shown in figure 5 shows a section of several warp yarns 3 and a section of one weft yarn 4, which weft yarn 4 passes from one side of the first fabric 12 to the other. Warp yarns 3 and weft yarns 4 comprise bundles of fibres/filaments 5. The cross-section of the warp yarn 3 shows that each warp yarn 3 comprising multiple fibres/filaments 5 has voids 6 between the fibres 5. At the crossing points of the yarns 3 and 4, in particular between two parallel warp yarns 3 and two parallel weft yarns 4, small interstices 9 are formed.

The fabric 12 includes an inner surface 16 and an outer surface 18. According to an embodiment, the discontinuous pattern 20 of impregnating material 60 is applied to the inner surface 16 of the fabric 12 using, for example, a rotary screen printer.

Fig. 5 shows an impregnated area 22 formed by impregnating material 60 into a section 23 of the first fabric 12. The portion of this section 23 that does not contain any impregnating material 60 forms a non-impregnated region 24. The void volume of the yarns 3, 4 or portions of the yarns 3, 4 in the impregnated region 22 and the interstices 9 between the yarns are at least partially filled with the impregnating material 60. This results in the fibres/filaments 5 being partially embedded in the cross-section 23 of the impregnating material 60. In some embodiments, the infusion pattern 20 penetrates into the cross-section 23 of the first fabric 12 such that the inner surface 18 (or the outer surface) is free of the infusion material 60. This is beneficial because the fabric hand of the first fabric 12 remains unchanged. In an optional embodiment, it is also possible that the outer surface 16 is at least partially covered by a thin layer of impregnating material 60.

Non-impregnated areas 24 are those areas where the void volume of the fibers/filaments 5 and the interstices 9 between the intersections of the yarns 3, 4 are free of the impregnating material 60. Thus, the discontinuously impregnated fabric 12 remains permeable to air, at least water vapor.

In the impregnated region 22, the impregnating material 60 penetrates the cross-section 23 of the fabric 12 such that the impregnating material 60 fills at least a portion of the voids 6 between the fibers 5 and the interstices 9 at the intersections of the yarns 3, 4. The impregnated area 22 is air impermeable. In some embodiments, the impregnated region is air and water vapor impermeable.

In one embodiment, most of the voids 6 in the impregnated region 22 are filled. Furthermore, in an embodiment using yarns, the voids 9 in the impregnated areas 22 are also filled. The majority of voids 6/voids 9 represents more than 50% of the voids 6/voids 9 in the impregnated region 22, or more than 80% of the voids 6/voids 9 in the impregnated region 22, or more than 90% of the voids 6/voids 9 in the impregnated region 22. There are embodiments where about all of the voids/interstices (100%) in the impregnated region 22 are filled.

The impregnated area 22 is at least air impermeable. The filled voids 6/voids 9 in the impregnated area 22 of the first fabric 22 reduce and prevent liquid from penetrating into the void volume in the yarn 2, which significantly reduces the water absorbency of the fabric composite 10. Water absorbency refers to the amount of water absorbed by the fabric composite 10 after the fabric composite 10 has been submerged in water for a predetermined period of time. The ratio of the weight of water absorbed by the fabric 10 to the weight of the dry fabric is the water absorption or percent water absorption.

Thus, the water absorbency of the fabric composite article 10 of the present invention is less than or equal to about 70% according to DIN EN29865 (1991). In other embodiments, the water absorption value is less than or equal to about 50%, or less than or equal to about 40%, or less than or equal to about 30%, or less than or equal to about 20%, or less than or equal to about 10%, according to DIN EN29865 (1991).

In addition, the impregnated fabric composite 10 of the present invention provides a reduced re-drying time compared to non-impregnated fabrics.

The re-drying time of the fabric is the time required to evaporate the total amount of water from the fabric. The re-drying time is also related to the ambient temperature and the ambient humidity. Lower temperatures and higher humidity increase drying time. Total water amount (g/m)²) The re-drying time is determined depending on the climatic conditions.

The impregnating material 60 penetrates into the void volume between the inner surface 16 and the outer surface 18 of the yarn 2, forming an impregnated region 22 in the cross-section 23 of the first fabric 12. Preferably, said impregnated area 22 fills only part of the section 23 between the inner surface 16 and the outer surface 18. The impregnated area 22 may be located in the middle region of the cross-section 23 of the first fabric 12, at a distance from the outer surface 18 and the inner surface 16. In another embodiment, the impregnated areas 22 range from the inner surface 16 to the cross-section 23. In another embodiment, the impregnated areas 22 range from the outer surface 18 to the cross-section 23. In another embodiment, the impregnated areas 22 range from the inner surface 16 to the outer surface 18. The size and location of the impregnated areas depends on the amount of impregnating material 60 applied to one surface, on the viscosity of the impregnating material 60, on the pressure and technique used to form the impregnated areas 60 in the first fabric 12.

In a particular embodiment, at least the fibers/filaments 5 within the outer surface 7 (see fig. 1) of yarn 2 are embedded in the impregnating material 60. In this embodiment, the surface 7 of the yarn 20 is substantially free of the impregnating material 60.

In another embodiment, impregnating material 60 forms a thin outer layer at least partially around at least a portion of outer surface 7 of yarn 20.

Thus, the fabric characteristics of the fabric 12 remain unchanged compared to the untreated fabric.

The non-impregnated areas are free of the impregnating material, thereby allowing at least water vapor and air to pass through the first fabric 12.

Fig. 6 shows a fabric composite article 10 according to another embodiment of the present invention. The first fabric 12 may be adjacent to another layer to form a multi-layer fabric composite on the side opposite the side forming the outer surface 18 of the future garment. In the illustrated embodiment, the second fabric layer 14 is arranged adjacent to the inner surface 16 of the first fabric 12. In another embodiment, the first fabric 12 and the second fabric 14 are bonded to each other by a discontinuous pattern 20 of impregnating material 60. The second fabric 14 may be a fabric backing, preferably a thermally stable fabric backing.

The second fabric 14 may be woven, non-woven, or braided and may be constructed of various materials such as polyesters, polyamides, polyolefins, and the like. In another embodiment, the second fabric 14 may be made of at least one thermally stable fabric such as: aramid, Flame Retardant (FR) cotton, PBI, PBO, FR rayon (rayon), modacrylic (modacrylic) blends, polyamine, carbon, fiberglass (fiberglass), PAN, Polytetrafluoroethylene (PTFE), and blends and mixtures thereof.

The first fabric 12 may have a fabric construction as shown in fig. 1-5, but may be other fabric constructions. The second fabric 14 may comprise yarns 2 that are bundles of fibers or filaments 5. Cross-section 23 of yarn 2 in fig. 6 shows that each yarn 2 comprises a plurality of fibers or filaments 5, with voids 6 between fibers 5 as shown in fig. 1. Voids 9 are also formed at the intersections of the yarns 2.

The second fabric 14 is bonded to the first fabric by the impregnating material 60. The impregnating material 60 penetrates into the fabric structure of the second fabric 14 and forms impregnated areas 22 'and non-impregnated areas 24' in the second fabric 14 that are consistent with the discontinuous pattern 20. Thus, at least part of the voids 6 between the fibres/filaments 5 in the second fabric 14 are filled with the impregnating material 60, depending on the penetration level of the impregnating material 60. At least part of the voids 9 in the impregnation zone 22' are also filled with the impregnation material 60.

The impregnating material 60 fulfills two main functions, as a bonding material between the two fabric layers 12, 14 and as a filling material for the cavities 6 and voids 9 in the impregnated areas 22, 22'.

A method of constructing a fabric composite article by bonding two fabric layers together is also provided. The method includes providing a first fabric and a second fabric. The inner surface of the first fabric with the discontinuous pattern of impregnating material is provided by, for example, a gravure printing technique or a roll screen printing technique. One side of the second fabric is brought into contact with the inner surface of the first fabric. The first and second fabrics pass through the nip of the two moving rolls and are compacted prior to the impregnating material entering the voids in the fibers and, if present, the interstices between the yarns. The size of the gap, the speed of the rollers and the pressure between the two cylinders determine the depth of penetration of the impregnating material into the first and second fabric sections.

The cured was then cured in an oven at a temperature of 120-.

Preferably, the outer surface of the first fabric and the second surface of the second fabric remain free of the impregnating material to maintain the textile feel of the textile composite.

The method further includes constructing the garment from the fabric composite, wherein the outer surface of the first fabric faces away from the body of the wearer of the garment.

Figure 7 shows another embodiment of the fabric composite of the present invention. The first fabric 12 as described in fig. 1-5 is illustrated in detail. As previously described, the first fabric 12 includes a discontinuous pattern 20 of impregnated material 60 that penetrates a cross-section 23 between the outer surface 18 and the inner surface 16 of the first fabric 12 to form impregnated areas 22 and non-impregnated areas 24. As illustrated in fig. 7, impregnating material 60 fills most of voids 6 between fibers 5 and most of voids 9 between yarns 3, 4, so that impregnated area 22 reaches from outer surface 18 to inner surface 16. Thus, a discontinuous pattern is visible on the outer surface 18 and the inner surface 16 of the first web 12.

Fig. 8 shows another embodiment of the present invention. The impregnated first fabric 12 is schematically illustrated in fig. 7. In this embodiment, the non-impregnated region 24 partially contains at least one functional coating material 40. The functional coating material 40 may impart additional features to the textile composite, such as: flame protection, oil and/or water repellency or insect repellent protection. The non-impregnated areas 24 are treated with a functional material 40 to form coated areas 42. The coating 42 covers only the outer surface 7 of the yarn 2 (see fig. 1), while the voids 6 and interstices 9 remain substantially free of the functional coating material 40. The coated non-impregnated areas 24 are still permeable to air and water vapor. The functional coating material 40 may be a hydrophilic material, a hydrophobic material, an oleophobic material, a flame retardant, an insect repellent material, and mixtures thereof. The functional coating material 40 may be applied in the non-impregnated areas 24 after the impregnated areas 22 are formed.

The method suitable for applying the functional coating material 40 may be selected from a minimum coating technique such as a friedel (cult) application. In one embodiment, the functional coating material 40 is a hydrophobic material available from Clariant under the tradename Nuva TTC or HPU or Nuva 2110.

In another embodiment, illustrated in FIG. 9, the first fabric 12 and the second fabric 14 are bonded to each other as shown in FIG. 6. The impregnating material 60 in this embodiment contains expandable graphite 30 as an additive. The blend of impregnating material 62 fills the voids 5 between the fibers/filaments 5 and the interstices 9 at the intersections of the yarns 2 in the first fabric 12 and the second fabric 14 and bonds the two fabric layers to one another.

Preferably, the impregnating material 60 contains expandable graphite 30. The blend of impregnating materials 62 includes less than or equal to about 50 wt%, or less than or equal to about 40 wt%, or less than or equal to about 30 wt% expandable graphite, based on the total weight of the impregnating material with graphite. In other embodiments, the expandable graphite contains less than or equal to about 20 wt%, or less than or equal to about 10 wt%, or less than or equal to about 5 wt% of the impregnating material. Generally, from about 5% to about 50% by weight of expandable graphite based on the total weight of the impregnated material containing graphite is desirable. Other levels of expandable graphite may be suitable for other embodiments depending on the desired properties and the resulting construction of the fabric composite. Other additives, such as pigments, fillers, biocides, processing aids and stabilizers, may also be added to the impregnating material. The particle size of the expandable graphite suitable for use in the present invention should be selected so that the impregnating material blend can be applied using the selected application method. For example, when the impregnating material blend is applied by a rolling screen printing technique, the particle size of the expandable graphite should be small enough to match the screen.

One type of expandable graphite suitable for use in the present invention is an expandable graphite available from NRC Nordmann (Nordmann) corporation (germany), Rassmann (rassman): Nord-Min 251, Commodity #102148 or Nord-Min 250, Commodity # 102147. The expanded volume of Nord-Min 251 type expandable graphite is 250 ml/g. The particle size of a minimum of 80% of the particles is >0.3 mm. The expansion starts when the contact temperature is >180 ℃.

Preferably, the impregnating material blend 62 comprises silicone and expandable graphite 30.

The impregnated material blend 62 containing graphite 30 may be prepared by a process that provides an intimate blend of polymeric material and expandable graphite (intercylate blend) without causing significant expansion of the expandable graphite. Suitable mixing methods include, but are not limited to, paddle mixer mixing, blending, and other low shear mixing techniques. In one method, an intimate blend of the polymeric material and expandable graphite particles is formed by mixing expandable graphite into a pre-mixed silicone polymer (e.g., Wacker Elastosil LR 7665 at a 1: 1 mixing ratio or Wacker Elastosil at a 1: 1 mixing ratio). In a method of providing an intimate admixture of a polymeric material and expandable graphite particles or agglomerates of expandable graphite, the expandable graphite is coated or encapsulated by the polymeric material prior to expansion of the graphite.

The fabric composite prepared according to this embodiment (using the impregnating material in combination with expandable graphite) has the ability to suppress afterflame after exposure to flame according to the horizontal burn test of ISO15025 (2003). Treatment of the first and second fabrics with an impregnating material incorporating expandable graphite forms a fabric composite having enhanced flame retardancy. Enhanced flame retardancy means that the fabric composite 10 has an after flame time of 10 seconds or less after exposure to a flame according to the vertical flame test of ISO15025 (2003). Samples having an afterflame time of 10 seconds or less after exposure to a flame were considered non-flammable according to the vertical burning test of ISO15025 (2003). Preferred samples have an afterflame time of 3 seconds or less. Most preferred samples are completely flameless.

Samples with an after flame time of more than 10 seconds were considered flammable.

In one embodiment, the inner surface of the outer fabric of the fabric composite having a fusible outer fabric is bonded to the impregnating material blend, the fabric composite providing a discontinuous pattern of impregnating material incorporating expandable graphite and a thermally stable fabric backing, the outer surface of the outer fabric being oriented to contact a flame in use. The fabric composite does not exhibit a flame-holding time when the outer surface of the outer layer fabric is exposed to a flame, as tested according to the horizontal burn test of ISO15025 (2003). Upon contact with a flame, the meltable outer fabric melts towards the impregnating material incorporating the expandable graphite. As the expandable graphite expands, it is believed that the thermally stable fabric backing holds the impregnating material in place to facilitate the absorption of the melt of the meltable outer fabric.

In addition, the non-impregnated area 24 portion of the first fabric 12 of the fabric composite 10 shown in fig. 9 comprises at least one functional coating material 40. The functional coating material 40 may impart additional features to the textile composite, such as: flame protection, oil and/or water repellency or insect repellent protection. The treatment of the non-impregnated areas 24 with the functional material 40 to form the coated areas 42 is explained in more detail in fig. 8. In another embodiment, the non-impregnated areas 24 of the second fabric 14 may also contain at least one functional coating material to form coated areas 42.

Figure 10 shows another embodiment of the present invention wherein the fabric composite 10 comprises a barrier layer 50. In one embodiment of the present invention, the barrier layer 50 is water vapor permeable.

The barrier layer may be a film, membrane or laminate comprising Polytetrafluoroethylene (PTFE), expanded PTFE, polyurethane or other suitable substrate.

First fabric 12 may be adjacent to barrier layer 50 on the side opposite that forming the outer surface 18 of the future garment to form multi-layer fabric composite 10. In one embodiment, first fabric 12 is laminated to barrier layer 50 using impregnating material 62 as an adhesive. Second fabric 14 is also bonded to barrier layer 50 using an impregnating material 62 or a conventional adhesive. When the impregnating material 62 is used as an adhesive, a discontinuous pattern of impregnated areas 22 and non-impregnated areas 24 is formed at the cross-section of the first fabric 12 and the second fabric 14.

For example, the inner surface 16 of the first fabric 12 may be attached or adhered to a barrier layer 50, such as a water impermeable, water vapor permeable film or membrane, for example a monolithic breathable polyurethane or polyester polyether film or a porous, especially microporous, polyethylene or polypropylene, or polyurethane. One embodiment of the membrane or membrane is comprised of an expanded polytetrafluoroethylene (ePTFE) membrane as described in U.S.3,953,566, having a porous microstructure characterized by interconnected nodes of fibrils. The membrane resists the passage of liquid water but is permeable to water vapor. The film may have a weight of 1 to 100g/m²。

In a film or membrane comprising ePTFE, the ePTFE may be impregnated with a hydrophobic impregnant. The ePTFE may have a continuous layer of waterproof, water vapor permeable material such as a film or coating of water vapor permeable polyurethane of the type described in U.S.4,194,041. The continuous water vapor permeable polymer layer is a hydrophilic polymer, referred to herein as a hydrophilic polymer, in terms of transporting water molecules. The hydrophilic layer selectively transports water by diffusion, but does not support pressure driven liquid or gas flow. Thus, moisture, such as water vapor, may be transported, but the continuous layer of polymer blocks the passage of liquid water and substances, such as airborne particles, microorganisms, oil, or other contaminants.

In one embodiment of the present invention, the barrier layer 50 is at least air impermeable. The term "air impermeable" means that the air permeability of the barrier layer or the fabric composite 10 with the barrier layer 50 is less than 5l/m²。

In another embodiment, barrier layer 50 is liquid impermeable. The term "liquid-impermeable" means that the water entry pressure of the barrier layer, or the fabric composite 10 with the barrier layer, is > 0.13 bar (ISO 20811).

In another embodiment, the first fabric 12 is attached to a barrier layer that is impermeable to air, liquid, and water vapor.

In the embodiment shown in figure 10, which is a fabric composite 10 according to the present invention, a barrier layer 50 is placed between the first fabric 12 and the second fabric 14 in the fabric composite to form a laminate. Barrier layer 50 is bonded to the two fabric layers by impregnating material blend 62 as previously described.

Figure 11 shows an SEM of a cross section of a fabric composite 10 according to the invention having two fabric layers. The woven first fabric 12 and the knitted second fabric 14 are bonded with a discontinuous pattern of impregnating material blend 62 (silicone with expandable graphite). The SEM shows a discontinuous pattern of dots. The dot impregnated material blend 62 is impregnated into the first fabric 12 and the second fabric 14 and partially fills the voids 6 and interstices between the yarns 2 in the fabrics 12, 14 to form the impregnated areas 22. The impregnated areas 22 terminate near the middle of the two fabric sections so that the outer surface 18 of the first fabric 12 and the second surface 19 of the second fabric 14 are substantially free of the impregnating material 62.

Fig. 12 shows an SEM of a cross-section of a fabric composite 10 on an enlarged scale having two fabric layers bonded to each other by a blend 62 of impregnating material. The voids 6 and voids 9 in the impregnated region 22 are partially filled with the impregnating material blend 62. The SEM shows a discontinuous pattern of dots. The filled cavities 6 and voids 9 in the impregnated areas 22 prevent liquid from being absorbed into these spaces of the fabric.

Fig. 13 shows another SEM of a cross-section of the fabric composite 10. The fabric composite 10 comprises a discontinuous pattern of first and second fabrics 12, 14 bonded to one another with a blend 62 of an impregnating material to form impregnated areas 22 and non-impregnated areas 24. The SEM shows three impregnated areas 22 and two non-impregnated areas 24, where the impregnated area 22 has impregnated the blend 62 of the impregnating material into the fabric structure of the first fabric 12 and the second fabric 14. The non-impregnated areas 24 are completely free of the impregnating material 62 and are permeable to air and water vapor. In the impregnated region 62, most of the voids and interstices are filled with the impregnating material blend 62. The outer surface 18 of the first fabric 12 and the second surface 19 of the second fabric 14 are substantially free of the impregnating material 62 so that there is a substantially constant textile hand.

Fig. 14 shows an SEM of a cross section of the textile composite 10 shown in fig. 13 on an enlarged scale. The SEM shows a non-impregnated region 24 between two impregnated regions 22.

Examples

Impregnating material 1(IM 1):

the mixing ratio is 1: 1 silicone Wacker Elastosil LR 7665 (from Wacker Chemie AG) was mixed to prepare a silicon solution to prepare an impregnating material. The viscosity of the impregnating material was 20000 mPa/s.

Impregnating material 2(IM 2):

the mixing ratio is 1: 1 mixing silicone Wacker Elastosil silica gel (Silgel), available from Wacker Chemie AG, to prepare a silicon solution to prepare an impregnating material. The viscosity of the impregnated material was 2000 mPa/s.

Infusion material blend 1(IMB 1):

a blend of impregnating material and expandable graphite was prepared by mixing expandable graphite (NRC Nordmann, Germany, commercially available from Rassmann: Nord-Min 251, commercially available # 102148) into the impregnating material IM 1. The amount of expandable graphite incorporated into IM1 ranged from 10 to 45%. Particle size is at least 80% of the particles >0.3 mm.

Infusion material blend 2(IMB 2):

a blend of the impregnating material and expandable graphite was prepared by mixing 10-45% expandable graphite (NRC Nordmann, Germany, commercially available from Rassmann: Nord-Min 250/commercially available # 102147) into the impregnating material IM 1. The particle size of the expandable graphite is about 250-300 um.

Example 1 of a Fabric composite

A first outer layer tight fabric made of 65% Polyester (PES) yarn and 35% cotton yarn was used. The tight fabric is a woven fabric made of spun yarn Nm 64/2. The yarn was not pretreated. The weight of the fabric was 180g/m². Measured 1cm²The average size of the interstices between the yarns within is about 50 um. Such tightly woven fabrics are commercially available from Ibena textilecke GmbH, germany.

The inner surface of the tight fabric was impregnated with impregnating material IM2 by means of a continuous roll screen printing technique to provide a discontinuous cross (cross) pattern (cured at about 150 c for about 1 minute). The screen has a pattern of spaced discrete intersections of 120um thickness.

The weight of the treated fabric was 245g/m²Thus, the amount of IM2 is about 65g/m²It is about 36.1% by weight of the fabric.

The samples of example 1 were tested for air and water vapor permeability and water absorption and the results are shown in table 1.

Example 2 of a Fabric composite

A first outer layer tight fabric made of 50% aramid/50% viscose FR yarn was used. The tight fabric is a woven fabric made of spun yarn Nm 60/2. The yarn was not pretreated. The weight of the fabric was 190g/m². The average size of the voids is about 60 um. Such tightly woven fabrics are commercially available from udesbel corporation of belgium (Utexbel, Belguim).

The inner surface of the tight woven fabric was impregnated with impregnating material IM2 by means of a continuous roll screen printing technique to provide a discontinuous stripe pattern (cured at about 150 c for about 1 minute). The screen has a pattern of spaced discrete lines.

The weight of the treated fabric was 215g/m²Therefore, the amount of IM2 is about 25g/m²It represents about 13.15% of the fabric weight.

The samples of example 2 were tested for air and water vapor permeability and water absorption and the results are shown in table 1.

TABLE 1

As shown in table 1, the treated samples of examples 1 and 2 were air and water vapor permeable after treatment with the impregnating material. This means that the non-impregnated areas are still open for the exchange of air and water vapour. The treated samples had reduced air and water vapor permeability but were still higher. The reason for this is that the voids and interstices in the impregnated area can no longer transport air and water vapor because they are filled with the impregnating material. In the water absorption test, the treated sample had a reduced water absorption of less than 70%. The water absorption is less than 70% even after several domestic washing cycles and air drying.

Table 1 also shows the re-drying properties of example 2 subjected to the permeability test (permest). Figure 15 shows the re-drying curves for untreated and treated samples of example 2. The sample of example 2 was wetted under specific conditions: exposure to bond raman (Bundesmann) rain for 10 minutes and an additional 15 seconds of rotation according to DIN EN29865 (1991). The re-drying time of the sample and the total heat loss when the sample was dried were determined by the permeability test. All heat losses (W/m) from the wetted sample when placed on the instrument were recorded under specific climatic conditions (15 ℃, 65% relative humidity, wind speed 2.5 m/s)²). The area under the curve when dry is all heat loss over that time. The flat tail of the curve represents the time for re-drying of the fabric.

Example 3 of a Fabric composite

Made using 100% Polyamide (PA) Tystile (Taslite) twill yarnThe first closed face fabric of (a) to make a fabric composite. The first fabric is a woven fabric made of yarn (dtex 78f 34). The yarn was not pretreated. The weight of the first fabric was 100g/m². Measured 1cm²The average size of the interstices between the yarns within is about 40 um. Such woven tight fabrics are commercially available from Ibena Textilwerke GmbH, germany. The first dense fabric is bonded to the second backing fabric. The first fabric forms the front side and the second fabric forms the back side. A second backing fabric made of 65% Polyester (PES) yarn and 35% cotton yarn was used. The second fabric is a knitted fabric made of spun yarns Nm. The yarn was not pretreated. The weight of the second fabric was 95g/m². Such a knitted fabric can be obtained from Riedel + Tietz textile GmbH (Riedel + Tietz textile GmbH)&Co) was purchased. The second fabric is placed on the inside of the first fabric to form a double layer fabric composite. The samples were tested for air and water vapor permeability, water absorption, and horizontal burn test method and the results are shown in table 2.

Example 4 of the Fabric composite

A two-layer fabric composite was prepared essentially according to example 3, but adhered to each other by the impregnating material blend IMB 1. A discontinuous pattern of the infusion material blend IMB1 was printed onto the inside surface of the first face fabric and then a second backing fabric was adhered to the first face fabric between two rolls spaced 0.4mm apart to make a two-layer fabric composite laminate. The discontinuous pattern of IMB1 is printed by means of a continuous roll screen printing technique to provide a pattern of discontinuous dots. The pattern of the screen is a pattern of spaced discrete dots of 2.3mm diameter and 120um thickness. The resulting fabric composite was a two-layer fabric laminate with an outer fusible polyamide dense fabric bonded to a thermally stable backing fabric by a discontinuous pattern of point IMB1 and a laminate weight of 261g/m². The mass of the IMB1 was approximately 79g, so the amount of impregnating material applied was 60% of the first fabric weight. The laminate was cured at a temperature of 150 ℃ for about 1 minute. The samples were tested for air and water vapor permeability, water absorption, and horizontal burn test method and the results are shown in table 2.

Example 5 of a Fabric composite

A fabric composite was prepared using a first tight face fabric made from 100% Polyamide (PA) Taslite twill yarn. The first fabric is a woven fabric made of yarn (dtex 78f 34). The yarn was not pretreated. The weight of the first fabric was 100g/m². Measured 1cm²The average size of the interstices between the yarns within is about 40 um. Such woven tight fabrics are commercially available from Ibena Textilwerke GmbH, germany. The first dense fabric is bonded to the second backing fabric. The first fabric forms the front side and the second fabric forms the back side. The second backing fabric is a knitted fabric made of 100% Nomex (aramid) staple fiber spun yarn Nm 80/1. The yarn was not pretreated. The weight of the second fabric was 58g/m². Such knitted Nomex backing fabrics are commercially available from tabril (Estambril s.a.) from spain. The second fabric is placed on the inside of the first fabric to form a double layer fabric composite. The samples were tested for air and water vapor permeability, water absorption, and horizontal burn test method and the results are shown in table 2.

Example 6 of a Fabric composite

A two-layer fabric composite was prepared essentially according to example 5, but adhered to each other by the impregnating material blend IMB 1. A discontinuous pattern of the infusion material blend IMB1 was printed onto the inside surface of the first face fabric and then a second backing fabric was adhered to the first face fabric between two rolls spaced 0.5mm apart to make a two-layer fabric composite laminate. The discontinuous pattern of IMB1 is printed by means of a continuous roll screen printing technique to provide a pattern of discontinuous dots. The pattern of the screen is a pattern of spaced discrete dots of 2.3mm diameter and 120um thickness. The resulting fabric composite was a two-layer fabric laminate with an outer fusible polyamide tight fabric bonded to a thermally stable backing fabric by a discontinuous pattern of dot IMB1 and a laminate weight of 230g/m². The amount of IMB1 was about 72g, so the amount of impregnating material applied was 72% of the first fabric weight. At a temperature of 150 deg.CThe laminate was cured at c for about 1 minute. The non-impregnated areas of the first face fabric in the laminate were treated with a hydrophobic fluorocarbon (Clariant) NuvaTTC). The samples were tested for air and water vapor permeability, water absorption, and horizontal burn test method and the results are shown in table 2.

Example 7 of a Fabric composite

A two-layer fabric composite was prepared essentially according to example 3, but adhered to each other by the impregnating material blend IMB 2. A discontinuous pattern of impregnating material, IMB2, was printed onto the inside surface of the first face fabric and a second backing fabric was adhered to the first face fabric between two rolls spaced 0.4mm apart to produce a two-layer fabric composite laminate. The discontinuous pattern of IMB2 is printed by means of a continuous roll screen printing technique to provide a pattern of discontinuous dots. The pattern of the screen is a pattern of spaced discrete dots of 2mm diameter and 200um thickness. The resulting fabric composite was a two-layer fabric laminate with an outer fusible polyamide tight fabric bonded to a thermally stable backing fabric by a discontinuous pattern of point IMB2 and a laminate weight of 364g/m². The amount of IMB1 was about 168g, so the amount of impregnating material applied was 165% of the first fabric weight. The laminate was cured at a temperature of 150 ℃ for about 1 minute. The samples were tested for air and water vapor permeability, water absorption, and horizontal burn test method and the results are shown in table 2.

Example 8 of a Fabric composite

A two-layer fabric composite was prepared essentially according to example 3, but adhered to each other by the impregnating material blend IMB 2. A discontinuous pattern of the infusion material blend IMB2 was printed onto the inside surface of the first face fabric and then a second backing fabric was adhered to the first face fabric between two rolls spaced 0.4mm apart to make a two-layer fabric composite laminate. The discontinuous pattern of IMB2 is printed by means of a continuous roll screen printing technique to provide a pattern of discontinuous dots. The pattern of the screen is a pattern of spaced discrete dots of 2mm diameter and 200um thickness. Obtained (a)The textile composite was a double layer textile laminate with an outer fusible polyamide scrim bonded to a thermally stable backing fabric by a discontinuous pattern of point IBM2 and a laminate weight of 364g/m². The amount of IMB1 was about 172g, so the impregnating material was applied at 165% by weight of the first fabric. The laminate was cured at a temperature of 150 ℃ for about 1 minute. The non-impregnated areas of the first face fabric and the second backing fabric in the laminate were treated with a hydrophobic fluorocarbon (clariant nuva TTC). The samples were tested for air and water vapor permeability, water absorption, and horizontal burn test method and the results are shown in table 2.

TABLE 2

As shown in table 2, the treated samples of examples 4, 6, 7 and 8 were air and water vapor permeable after treatment with the impregnating material. This means that the non-impregnated areas are still open for the exchange of air and water vapour. The air and water vapor permeability of the treated samples of examples 4 and 6 was reduced but still higher. The reason for this is that the voids and interstices in the impregnated area can no longer transport air and water vapor because they are filled with the impregnating material. In the water absorption test, the treated sample had a reduced water absorption of less than 70%. Even after several household washing cycles and tumble drying, the water absorption is almost less than 70%.

Further, table 2 shows that the treated samples of examples 4, 6, 7, 8 were subjected to flame retardancy testing according to the flame retardancy test as described herein. As reported in table 2, all treated samples had no afterflame after 10 seconds of flame exposure.

Test method

Air permeability:

for determining the air permeability of fabrics (fabrics), use is made of measurable air flowsPass through the fabric test instrument. The sample was placed between two rings and the test area was 100cm². Air was absorbed through the sample at a constant pressure of 100 Pa. Thereby measuring the amount of air passing through the sample in l/m²And calculating the/s. The test method is described in ENISO 9237.

Water vapor transmission rate:

RET test method for fabric layers, fabric composite articles and barrier layers:

water vapor transmission resistance (Ret) is a specific material property of a sheet structure or composite that allows the latent heat evaporation flux through a given area to be measured at a constant partial pressure gradient. If the fabric layer, fabric composite fabric or barrier layer according to the invention has a water vapor transmission resistance Ret of less than 150 (m)²xPa)/W, it is water vapor permeable. Preferably, the Ret of the barrier layer is less than 20 (m)²X Pa)/W. The water vapour permeability is determined according to the skin model of ISO11092 (2005).

Water impermeability:

the water impermeability is determined according to international standard ISO 811. In one embodiment, the barrier layer has a water pressure resistance of up to 0.13 bar.

Water absorption:

one method of determining the water absorbency of a textile structure is to use a rain test according to the Bundesmann test (DIN EN29865) (1991). The rain device produces rain water defined by the water volume, droplet size, and distance between the rain device and the test sample. The test was run for 10 minutes. The water absorption of the fabrics and fabric composite articles was determined according to the following method:

1. determination of the weight of the sample (Fabric/Fabric composite)

2. Bundesmann rain test was performed for 10 minutes

3. Sample was inverted for 15 seconds

4. Determining the weight of the sample

5. The weight gain relative to the sample before the Bundesmann rain test was calculated and expressed as%.

The water absorbency measurements (air or tumble drying) were performed on untreated fabrics and fabric composite articles, samples of the impregnated fabrics and fabric composite articles of the present invention, and samples of the treated fabrics and fabric composite articles of the present invention after 10 cycles of home laundering at 60 ℃.

Household washing:

washing was carried out according to the international standard ISO6330/2A (1984) and subsequent air drying (ISO 6330/2A-A) or tumble drying (ISO 6330/2A-E) at 60 ℃ in a domestic washing cycle.

Viscosity of the impregnating material:

the viscosity of the polymer material is measured with a rotational measuring device (viscometer), for example a viscometer from the company Rotek (Rheotec) or Brookfield (Brookfield).

Flame retardancy

Flame retardancy was measured according to international standard ISO15025(2003) with a surface exposed to the flame for 10 seconds. The outer fabric side of the sample was exposed to the flame for 10 seconds. The flame time was recorded. Samples with an after flame time of more than 10 seconds were considered flammable. Samples having an after flame time of less than or equal to 10 seconds were considered non-flammable. The preferred sample has an afterflame time of 3 seconds or less. Most preferred samples have no afterflame.

Average size of voids:

1cm²the average size of the interstices between the yarns in the internally measured tightly manufactured fabric is less than 100 um. In woven fabrics, voids 9 are formed at the intersections of two parallel warp yarns with two parallel weft yarns (see FIG. 3).

The average size of the voids is determined using an optical microscope (e.g., zeiss microscope). The dimensions of each void and all voids (i.e., the dimensions of all intersections) in a predetermined 1cm x 1cm area of fabric were determined by light microscopy. The measurement was performed in a plan view of a fabric region of 1cm x 1 cm. The average size of the voids is calculated from all voids in the intended fabric area (even if their size may be zero). Preferably, the microscope is at a magnification of 50x and the distance is determined in conjunction with an electrical measurement program. Any other useful magnification may be used.

Permeability test (permest):

the permeability test (permest) is a fast response test instrument (skin model) for determining the heat and water vapor resistance or permeability of woven fabrics, non-woven fabrics, foils and paper sheets. The instrument provides tests very similar to all types in ISO standard 11092(2005) and the results are evaluated according to the same procedure as required by ISO11092 (2005). For the smaller samples, there was a difference with respect to the standard.

The Permetest method is of particular interest in determining the change in heat loss during rewetting of wet fabric. If the temperature of the heating plate of the permeability test (permest) is set to 35 ℃ as the surface temperature and the ambient conditions are set to 15 ℃, 65% relative humidity, 2.5m/s as the wind speed, the re-drying process is simulated when the wet fabric is worn under these conditions.

Without wishing to limit the scope of the invention, the above disclosure sets forth the preparation and use of the invention.

While specific embodiments of the invention have been illustrated and described herein, the invention is not to be limited to these illustrations and descriptions. It is apparent that changes and modifications may be included within the invention, as embodied in part, within the scope of the appended claims.

Claims (20)

1. A garment comprising a fabric composite article (10), the fabric composite article (10) comprising a first fabric (12) having an inner surface (16) and an outer surface (18), the first fabric (12) comprising:

yarns (2) made of multiple fibers (5), wherein the multiple fibers (5) contain voids (6) between them and there are voids between the yarns; and

a discontinuous pattern (20) of impregnating material (60) which penetrates at least part of the cross-section between the inner surface (16) and the outer surface (18) of said first fabric (12) to form impregnated areas (22) and non-impregnated areas (24) in correspondence with the discontinuous pattern (20) of impregnating material (60) to reduce the water absorption of the fabric composite, wherein at least part of the voids (6) and at least part of the interstices in said impregnated areas (22) are filled with said impregnating material (60);

wherein the water absorption of the textile composite is less than or equal to 70% according to DIN EN29865 (1991), and the non-impregnated areas (24) are such that the air permeability of the article is greater than 20l/m²/s。

2. The garment according to claim 1, characterized in that a majority of the voids (6) in the impregnated area (22) are filled with the impregnating material (60).

3. The garment as claimed in claim 1, characterized in that the amount of impregnating material (60) is at least 10% by weight of the first fabric.

4. The garment according to claim 1, characterized in that said impregnation material (60) is selected from: silicones, polyurethanes, amorphous perfluoropolymers, and mixtures thereof.

5. The garment as claimed in claim 1, characterized in that the impregnating material (60) contains one or more additives.

6. The garment according to claim 5, wherein at least one of the additives comprises expandable graphite (30).

7. The garment as recited in claim 1, wherein the non-impregnated areas (24) at least partially comprise at least one functional coating material (40) to form coated areas (42).

8. The garment as claimed in claim 1, characterized in that said first fabric (12) comprises a fusible material.

9. The garment as recited in claim 1, wherein the article further comprises a second fabric (14) adjacent the inner surface (16) of the first fabric (12).

10. The garment as claimed in claim 9, characterized in that said second fabric (14) is bonded to said first fabric (12) by means of an impregnating material (60).

11. The garment as claimed in claim 10, characterized in that said second fabric (14) comprises:

fibres (5) containing voids (6) therebetween, and an impregnating material (60) penetrating at least part of the cross-section of the second fabric (14) from the first surface (17) to the second surface (19) of the second fabric (14), forming impregnated areas (22 ') and non-impregnated areas (24') coinciding with the discontinuous pattern (20) of the impregnating material (60); wherein at least part of the cavities (6) in the impregnated region (22') are filled with the impregnating material (60).

12. The garment according to claim 11, characterized in that a majority of the voids (6) in the impregnated area (22') of the second fabric (14) are filled with the impregnating material (60).

13. The garment according to any of claims 9 to 11, characterized in that the second fabric (14) comprises a non-meltable and/or flame retardant material.

14. The garment of claim 1, wherein the article comprises at least one water vapor permeable barrier layer (50).

15. The garment as claimed in claim 9, wherein an air impermeable, liquid impermeable, water vapor permeable barrier layer (50) is attached to one surface of said first fabric (12) or said second fabric (14).

16. The garment according to claim 14 or 15, wherein the barrier layer (50) comprises a porous membrane made of expanded polytetrafluoroethylene (ePTFE).

17. The garment according to any of claims 9 to 12, wherein the first fabric (12) and the second fabric (14) are bonded to each other by an impregnated material comprising expandable graphite, said article being free of afterflame after 10 seconds of exposure to a flame according to the horizontal flame resistance test of ISO15025 (2003).

18. The garment according to any of claims 1-12, wherein the first fabric (12) comprises a tight fabric structure.

19. The garment according to claim 18, characterized in that said first fabric (12) is made of yarns (2) having interstices (9) between them, at 1cm²The average size of the voids between the inner yarns is less than 100 um.

20. The garment of claim 1 or 11, wherein said fibers comprise filaments.