Trilobal Waterproof Breathable Laminated Stretch Fabric

Abstract

A woven polyester fabric with a trilobal construction and a 5% elastane content, and an outer laminated layer of polyurethane, with 250 GSM insulation. The fabric and clothing made from the fabric is waterproof, breathable, stretchable in 4 directions, and insulating to −50 degrees Celsius. The fabric meets the standards defined by the testing standards ASTM D2034-2009; ASTM D1424-2009: ASTM D434-1995; ASTM D4970/D4970M-2010c1, ASTM D3107-07(R2011), AATCC 127, and JIS L1099 Method B-1:2006.

Claims

1. A woven polyester fabric wherein the fabric has a trilobal woven construction and a 5% elastane content.

2. The fabric of claim 1, further comprising an outer laminated layer of polyurethane.

3. The fabric of claim 2, wherein the fabric has 250 GSM insulation.

4. The fabric of claim 2, wherein the fabric meets the standards defined by the testing standards ASTM D2034-2009; ASTM D1424-2009: ASTM D434-1995; ASTM D4970/D4970M-2010c1, ASTM D3107-07(R2011), AATCC 127, and JIS L1099 Method B-1:2006.

5. A woven polyester fabric which has a trilobal woven construction and is laminated in polyurethane.

6. The fabric of claim 5, further comprising 5% elastane woven into the fabric.

7. The fabric of claim 6, wherein the fabric has 250 GSM insulation.

8. The fabric of claim 6, wherein the fabric meets the standards defined by the testing standards ASTM D2034-2009; ASTM D1424-2009: ASTM D434-1995; ASTM D4970/D4970M-2010c1, ASTM D3107-07(R2011), AATCC 127, and JIS L1099 Method B-1:2006.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A detailed description of the preferred embodiment is provided by way of example only and with reference to the following drawing, in which:

[0009] FIG. 1 is an exploded view of the fabric of the invention, depicting the trilobal construction checkerboard pattern, according to the invention.

[0010] In the drawing, one embodiment of the invention is illustrated by way of example. It is to be expressly understood that the description and drawing are only for illustrative purposes and as an aid to understanding, and other embodiments are also within the scope of the invention.

SUMMARY OF THE INVENTION

[0011] There is provided a woven polyester fabric having a trilobal woven construction and a 5% elastane content. The fabric may have an outer laminated layer of polyurethane, and 250 GSM insulation. The fabric meets the standards defined by the testing standards ASTM D2034-2009; ASTM D1424-2009: ASTM D434-1995; ASTM D4970/D4970M-2010c1, ASTM D3107-07(R2011), AATCC 127, and JIS L1099 Method B-1:2006. There is further provided a polyester fabric which is waterproof, breathable, stretchable in 4 directions, and insulating to −50 degrees Celsius.

DETAILED DESCRIPTION OF THE INVENTION

[0012] The fabric of the present invention is manufactured of polyester, nylon, or other thread materials in a trilobal construction. In this specification, “trilobal construction” is defined to be “the weaving together of three threads which are then inserted on the horizontal (weft) and vertical (warp) every 1 cm. The result is a checkerboard construction of repeating squares of thread as depicted in FIG. 1.

[0013] This construction increases the tensile strength of the fabric and reduces the incidence of tearing by incorporating the increased strength of three threads woven together into the core fabric. Early attempts to improve the polyester fabric comprised a stronger 600 Denier polyester fabric that has slightly lower tensile and tear resistance than a 420 Denier Nylon. Although this increase in Denier value resolves the strength and dye issue with the garments, the early versions of the product were heavy, stiff and inflexible, creating fatigue with the wearers.

[0014] To address this issue, the next fabrics developed incorporated trilobal construction, which is the weaving of three threads together and inserted into the woven fabrics every 1 cm in a checkerboard construction. The result of this new trilobal design was a garment in 300 Denier polyester with equal tensile, tear and puncture resistance as a non-trilobal 420 Denier Nylon. The garment was lighter and looser hanging, but still lacked any flexibility in the fabric.

[0015] The present invention further incorporates an elastane (Elastamor) filament within the woven threads that gives the fabric the ability to stretch 10% to 15% in all 4 directions. This technology has been used in the prior art with woven cottons, poly/cotton blends and other organic fibers, but these other materials would not stand up to the rigors of the industrial application of our market. Generally a fabric will stretch on its “bias” (the diagonal cross section of the woven fabric), but on the warp and weft polyester fibers are not flexible and have no stretch capacity. The present invention will stretch on the warp, weft, and both biases.

[0016] To meet the requirements of the industry, the fabric meets the critical tensile, tear, seam slippage and pilling resistance requirements of ASTM D2034-2009; ASTM D1424-2009: ASTM D434-1995; and ASTM D4970/D4970M-2010c1, and the fabric can stretch and recover, meeting the requirements of ASTM D3107-07(R2011). Prior art stretch fabrics can stretch out, but many have poor recovery resulting in bagging or sagging regions of the fabric around the buttocks, elbows and knees, unlike the present invention. The fabric also meets the AATCC 127 waterproof requirement of average 5000 (mmH2O) as well as the JIS L1099 Method B-1:2006 test with a minimum of 15,000 g/m2/24 hours.

[0017] The fabric of the invention further incorporates intertwining approximately 5% elastane into the fabric, and uses a laminate coating of PU instead of a spray coating.

[0018] The present invention comprises a novel fabric of stretchy woven polyester coated in a waterproof/breathable PU laminate. The invention uses trilobal construction with a laminated PU coating, as well as integrated Elastane to provide a fabric of greater strength than standard stretch fabrics, and more resistant to wear and washing than conventional stretch fabrics.

[0019] The present invention is a fully tested and functional waterproof and breathable, trilobal woven polyester industrial strength 4-way stretch fabric. In one embodiment, it may be manufactured into a coverall. Other items of clothing and other items requiring the features of stretch, durability, waterproofing, breathability and flexibility are also within the scope of the invention.

[0020] Fabric Testing Results

[0021] 300D Fabric Tests

[0022] A fabric sample comprising Woven 300D fabric, 95% polyester 5% spandex, was tested for water resistance, water vapour permeability, water vapour transmission, tensile strength, tearing strength, seam slippage, pilling resistance, and stretch properties.

[0023] Tensile Strength (ASTM D5034-2009; Instron CRE—1″ Grab)

TABLE-US-00001 Warp (lbf) 214.0 Weft (Ibf) 212.0

[0024] Tearing Strength (ASTM D1424-2009; Elmendorf)

TABLE-US-00002 Warp yarns torn (lbf) >14.1 Weft yarns torn (lbf) >14.1

[0025] Seam Slippage (ASTM D434-1995; Instron CRE)

[0026] Seam Slippage at ¼ Inch

TABLE-US-00003 Seam/Warp (lbf) 53.1 (Sewing Thread Breaks (S.T.B.) Seam/Weft (lbf) 51.0 (S.T.B.)

[0027] Pilling Resistance (ASTM D 49700 D4970M-201e1; Martindale Tester)

TABLE-US-00004 After 100 movements Rating 4.5 Remarks: Pilling Rating 5 No pilling 4 Slight pilling 3 Moderate pilling 2 Severe pilling 1 Very severe pilling

[0028] Stretch Properties of Fabrics Woven from Stretch Yarns

[0029] (ASTM D3107-07(R2011)) Gauge Length=250 mm

TABLE-US-00005 Warp A. Fabric stretch after applying a specified tension at 4 lb load (I) Within 10 s (%) 13.2 (II) After 30 min. (%) 14.4 B. Fabric growth after applying to specified tension and relaxation (I) Within 10 s (%) 2.8 (II) After 30 s (%) 2.4 C. Fabric growth after stretching to a specified extension of 280 mm and relaxation (I) After 30 s (%) 2.0 (II) After 30 min. (%) 0.8 The maximum allowable stretch requirement is 7%. D. Fabric recovery after stretching to a specified extension of 280 mm and relaxation (I) After 30 min. (%) 93.3 The minimum recovery requirement is 75%.

[0030] Stretch Properties of Fabrics Woven from Stretch Yarns

[0031] (ASTM D3107-07(R2011)) Gauge Length=250 mm

TABLE-US-00006 Weft A. Fabric stretch after applying a specified tension at 4 lb load (I) Within 10 s (%) 15.2 (II) After 30 min. (%) 17.2 B. Fabric growth after applying to specified tension and relaxation (I) Within 10 s (%) 4.0 (II) After 30 s (%) 3.2 C. Fabric growth after stretching to a specified extension of 286 mm and relaxation (I) After 30 s (%) 2.8 (II) After 30 min. (%) 1.2 The maximum allowable stretch requirement is 7%. D. Fabric recovery after stretching to a specified extension of 286 mm and relaxation (I) After 30 min. (%) 91.7 The minimum recovery requirement is 75%.

[0032] Water Resistance: Hydrostatic Pressure Test

[0033] (AATCC 127-2008; Hydrostatic Head; Rate of Increase of Water Pressure: 60 cm H.sub.20/Min Temp. of Distilled Water: 20° C., Face Side Facing Water)

TABLE-US-00007 Specimen #1 2# 3# Average After 5 washes Water Column 5161 4641 4457 4753 (mmH.sub.20)

[0034] Wash procedure (AATCC 135-2010; Test No. (1) IIIB; Machine wash at 105 degree F. with 4 lb loading, normal cycle & line dry).

[0035] Water Vapour Permeability of Textiles (J IS Li 099 Method B-1:2006)

[0036] Temperature of oven: 30° C.

[0037] Test Method: Potassium Acetate

[0038] Test Duration: 15 minutes.

[0039] Orientation: Back side Facing Water

[0040] After 5 washes

TABLE-US-00008 (g/m.sup.2/hour) 950 (g/m.sup.2/24 hours) 22800

[0041] Wash procedure (AATCC 135-2010; Test No. (1) IIIB; Machine wash at 105 degree F. with 4 lb loading, normal cycle & line dry).

[0042] Water Vapour Transmission of Textile Fabrics* (ASTM E96:1995)

[0043] Procedure BW—Inverted Water Method at 73.4° F. (23° C.) & 50±2% RH

[0044] Tested Area: 0.003117 square metre

[0045] Orientation: Back Facing Water

[0046] After 5 washes

[0047] Gram per square metre per 24 hours 8461

[0048] Wash procedure: (AATCC 135-2004; Test No. (1) IIIB; Machine wash at 105 degree F. with 41b total loading, normal cycle & line dry)

[0049] 600D Fabric Tests

[0050] A fabric sample comprising Woven 600D*600D/78t polyester oxford four ways stitch+TPU film 5 k/5 k was tested for water resistance, water vapour permeability, water vapour transmission, strength, tearing strength, seam slippage, pilling resistance, and stretch properties.

[0051] Water Resistance: Hydrostatic Pressure Test

[0052] AATCC 135-2012: Test No. (2) JIB: machine wash at 85 degree F. with 41b loading, without detergent, gentle cycle & line dry

[0053] (AATCC 127-2008; Hydrostatic Head; Rate of increase of water pressure: 60 cm H.sub.2O/min temp. of distilled water: 200 C, face side facing water)

TABLE-US-00009 Specimen 1 2 3 Average As Received Water Column 13444 13097 12985 13175 (mmH.sub.20)

[0054] After 5 washes

TABLE-US-00010 Water Column 12913 12434 12597 12648 (mmH.sub.20)

[0055] Water Vapour Permeability of Textiles (JIS L1099 Method B-1:2006)

[0056] Temperature of oven: 30° C.

[0057] Test Method: Potassium Acetate

[0058] Test Duration: 15 min.

[0059] Orientation: Back side Facing Water

TABLE-US-00011 As Received After 5 washes (g/m.sup.2/hour) 442 567 (g/m.sup.2/24 hours) 10608 13608

[0060] Water Vapour Transmission of Textile Fabrics* (ASTM E96:1995)

[0061] Procedure BW—Inverted Water Method at 73.4° F. (23° C.) & 50±2% RH Tested Area: 0.003117 square metre

[0062] Orientation: Back side Facing Water

TABLE-US-00012 As Received After 5 washes G/m.sup.2 per 24 hours 6736 6606

[0063] Washing procedure (AATCC 135-2012: Test No. (2) IIB: machine wash at 85 degree F. with 41b loading, without detergent, gentle cycle & line dry).

[0064] Tensile Strength (ASTM D5034-2009; Instron CRE-1″ Grab)

TABLE-US-00013 Warp (lbf) 291.8 Weft (lbf) 260.8

[0065] Tearing Strength (ASTM D1424-2009; Elmendorf Tear)

TABLE-US-00014 Warp yarns torn (lbf) >14.1 Weft yarns torn (lbf) >14.1

[0066] Seam Slippage (ASTM D434-1995)

TABLE-US-00015 Seam Slippage at ¼ inch #: Before ¼ inch opening Seam/Warp (lbf) 59.4# (S.T.B) Seam/Weft (lbf) 63.8# (S.T.B)

[0067] Pilling Resistance (ASTM D4970/D4970M-10e1; Martindale Abrasion & Pilling Tester After 100 Cycles, Using Viewing Cabinet 45° Viewing Angle)

TABLE-US-00016 After 100 revs 4.0 Pilling Rating 5 No pilling 4 Slight pitting 3 Moderate pitting 2 Severe pitting 1 Very severe pitting

[0068] Stretch Properties of Fabrics Woven from Stretch Yarns

[0069] (ASTM D3107-07(R201 1) Gauge Length=250 mm

TABLE-US-00017 Warp A. Fabric stretch after applying a specified tension at 4 lbf load (I) Within 10 s (%) 11.6 (II) After 30 min. (%) 12.0 B. Fabric growth after applying to specified tension and relaxation (I) Within 10 s (%) 2.0 (II) After 30 s (%) 1.6 C. Fabric growth after stretching to a specified extension of 276 mm and relaxation (I) After 30 s (%) 2.0 (II) After 30 min. (%) 0.8 D. Fabric recovery after stretching to a specified extension of 276 mm and relaxation (I) After 30 min. (%) 92.3

[0070] Stretch Properties of Fabrics Woven from Stretch Yarns (ASTM D3107-07(R2011) Gauge length=250 mm

TABLE-US-00018 Weft A. Fabric stretch after applying a specified tension at 4 lbf load (I) Within 10 s (%) 20.8 (II) After 30 min. (%) 22.8 B. Fabric growth after applying to specified tension and relaxation (I) Within 10 s (%) 4.8 (II) After 30 s (%) 4.0 C. Fabric growth after stretching to a specified extension of 276 mm and relaxation (I) After 30 s (%) 3.6 (II) After 30 min. (%) 1.6 D. Fabric recovery after stretching to a specified extension of 276 mm and relaxation (I) After 30 min. (%) 91.7

[0071] The coverall of the present invention is an extreme cold climate coverall. Typically such coveralls are made with heavy duty cotton fabrics, are insulated with poly-fill to a cold rating of −50 degrees C. In such prior art cold weather coveralls, the consumer cannot move in them as they are so restrictive to body movement due to the bulk of the garment. In contrast, the 4-way fabric of the present invention is a −50 degree C. insulated coverall that is waterproof, and breathable, with 250 GSM insulation. This coverall is also extremely flexible to provide almost no restriction to movement.

[0072] The present invention combines several known technologies, including trilobal weaving construction, laminated PU coatings for high level breathability, as well as waterproofing, and stretch fabric technology using elastane, to form a unique fabric.

[0073] As many possible embodiments may be made of the invention without departing from the scope of the claims, it is to be understood that all matter herein set forth or shown in the accompanying drawings is illustrative and not limiting. It will be appreciated by those skilled in the art that other variations of the preferred embodiment may also be practised without departing from the scope of the invention.