COMPOSITE MATERIALS WITH MEMBRANE

Abstract

Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer.

Claims

1. A composite material comprising: a shell fiber layer comprising between 58 wt % and 72 wt % nylon and between 28 wt % and 37 wt % polyester without exceeding 100 wt %; and a breathable electrospun fiber membrane disposed adjacent the shell fiber layer, wherein the composite material exhibits a low range hydrostatic water resistance of at least 5,000 millimeter (mm) as measured using American Association of Textile Chemists and Colorists (AATCC) 127; wherein the composite material exhibits an air permeability of at least 0.25 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737; and wherein the composite material exhibits a moisture vapor transmission rate (MVTR) of at least 30 kilogram per square meter per 24 hour (kg/sqm/24 hr) as measured using Japanese Industry Standards (JIS) L1099-B1.

2. The composite material of claim 1, wherein the shell fiber layer comprises 58 wt % nylon and 37 wt % polyester.

3. The composite material of claim 1, wherein the shell fiber layer comprises 62 wt % nylon and 33 wt % polyester.

4. The composite material of claim 1, wherein the shell fiber layer comprises 72 wt % nylon and 28 wt % polyester.

5. The composite material of claim 1, wherein an overall composite fabric weight associated with the composite material is between 102 gsm and 136 gsm.

6. The composite material of claim 1, wherein the membrane is coupled to the shell fiber layer.

7. The composite material of claim 1, wherein the membrane is glued to the shell fiber layer.

8. An article comprising the composite material of claim 1, wherein the article comprises a garment, gloves, footwear, headwear, bib pants, pants, a jacket, a tent, a sleeping bag, and a backpack.

9. A composite material comprising: a shell fiber layer comprising between 23 wt % and 31 wt % nylon and between 69 wt % and 77 wt % polyester without exceeding 100 wt %; and a breathable electrospun fiber membrane disposed adjacent the shell fiber layer, wherein the composite material exhibits a low range hydrostatic water resistance of at least 5,000 millimeter (mm) as measured using American Association of Textile Chemists and Colorists (AATCC) 127; wherein the composite material exhibits an air permeability of at least 0.25 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737; and wherein the composite material exhibits a moisture vapor transmission rate (MVTR) of at least 30 kilogram per square meter per 24 hour (kg/sqm/24 hr) as measured using Japanese Industry Standards (JIS) L1099-B1.

10. The composite material of claim 7, wherein the shell fiber layer comprises 25 wt % nylon and 75 wt % polyester.

11. The composite material of claim 7, wherein the shell fiber layer comprises 23 wt % nylon and 77 wt % polyester.

12. The composite material of claim 7, wherein the shell fiber layer comprises 31 wt % nylon and 69 wt % polyester.

13. The composite material of claim 1, wherein an overall composite fabric weight associated with the composite material is between 102 gsm and 165 gsm.

14. The composite material of claim 7, wherein the membrane is coupled to the shell fiber layer.

15. The composite material of claim 7, wherein the membrane is glued to the shell fiber layer.

16. An article comprising the composite material of claim 9, wherein the article comprises a garment, gloves, footwear, headwear, bib pants, pants, a jacket, a tent, a sleeping bag, and a backpack.

Description

DETAILED DESCRIPTION

[0008] Composite materials are described herein. The composite materials may be or comprise laminate materials having a plurality of layers. An example composite material may comprise a shell and a membrane. The shell may comprise a shell fiber layer. The shell may comprise various materials such as polymers. The shell may comprise polyester, nylon, recycled polyester, elastane, or combinations thereof. Other materials may be used. The membrane may be or comprise a breathable membrane. The membrane may be or comprise a water proof or water repellant membrane. The membrane may be formed from various process such as fiber spinning (e.g., electrospinning). Together, the shell and membrane may have a fabric weight. Various combinations of shell and membrane weight may be used. The membrane may have a weight of less than 9 gsm, less than 8 gsm, less than 7 gsm, less than 6 gsm, less than 5 gsm, less than 4 gsm, or less than 3 gsm. Other weight membranes may be used. The shell and the membrane may be disposed adjacent each other and may be coupled together, for example using adhesive.

[0009] The composites of the present disclosure show improved performance over comparative conventional materials. As shown more clearly in Tables 1-3, the composite materials of the present disclosure are identified using ID's: LV6W, LV6Z, LV74, LWEN, LV71, LWEQ, LV75, LWEP, LV7B, LV7D, and LWEO. The comparative examples are identified as A-L. The Appendix, which is hereby incorporate herein by reference in its entirety shows improved performance of the composite materials after 20 launderings.

[0010] Table 1 matches High, Medium, and Low labels for example value ranges for various measurements:

TABLE-US-00001 Low Range Air Hydrostatic Permeability (AATCC 127) - (ASTM D737) - MVTR (JIS KEY As Received As Received L1099-B1) High 10,000 mm+ .75 cfm+ 45K g/sqm/24 hr+ Medium 5,000-10,000 mm .25-.75 cfm 30K-45K g/sqm/24 hr Low 0-5,000 mm 0-0.25 cfm 0-30K g/sqm/24 hr

[0011] Table 2 shows attributes of various jackets:

TABLE-US-00002 Shell Fiber Fabric ID Content Weight A 72% 132 gsm Polyester, 28% Nylon B 100% Nylon 82 gsm C 100% Nylon 182 gsm D 100% Nylon 84 gsm with 100% Polyester Backer E 100% Nylon 83 gsm F 100% Body: Recycled 150 Polyester gsm; Hood; 153 gsm G 100% Nylon Body: 105 gsm; Hood: 115 gsm H 100% Nylon 161 gsm I 100% Nylon 120 gsm J 100% Nylon 54 gsm K 100% Nylon 64 gsm L 100% 114 gsm Recycled Polyester LV6W 58% Nylon, 102 gsm 37% Polyester, 5% Elastane LV6Z 100% 177 gsm Polyester LV74 100% 173 gsm Polyester LWEN 93% Nylon, 160 gsm 7% Elastane LV71 100% 91 gsm Polyester LWEQ 93% Nylon, 168 gsm 7% Elastane LV75 62% Nylon, 136 gsm 33% Polyester, 5% Elastane LWEP 93% Nylon, 158 gsm 7% Elastane LV7B 75% 163 gsm Polyester, 25% Nylon LV7D 75% 165 gsm Polyester, 25% Nylon LWEO 96% Nylon, 164 gsm 4% Elastane

[0012] Table 3 shows attributes of various articles:

TABLE-US-00003 ID Shell Fiber Content Fabric Weight LMTU 100% Polyester 118 LNWU 82% Nylon, 14% Polyester, 4% Elastane 230 LUS0 100% Polyester 62 LV6W 58% Nylon, 37% Polyester, 5% Elastane 102 LV71 100% Polyester 91 LVAZ 91% Polyester, 9% Elastane 207 LVB0 93% Polyester, 7% Elastane 237 LVB1 100% Nylon 53 LVRX 100% Nylon 83 LWEN 93% Nylon, 7% Elastane 160 LWEO 96% Nylon, 4% Elastane 164 LWEP 93% Nylon, 7% Elastane 158 LWEQ 93% Polyester, 7% Elastane 168 LWQY 77% Polyester, 23% Nylon 124 LWQZ 72% Nylon, 28% Polyester 115 LYMC 100% Nylon 218 LYMD 100% Nylon 177 LYMG 69% Polyester, 31% Nylon 102 LYMP 100% Nylon 99 LYON 100% Polyester 112 LZ6I 100% Nylon 108 LMTU 100% Polyester 118 LUS0 100% Polyester 62 LV6W 58% Nylon, 37% Polyester, 5% Elastane 102 LV6Z 100% Polyester 177 LV71 100% Polyester 91 LV73 100% Polyester 100 LV74 100% Polyester 173 LV92 100% Polyester 155 LVAZ 91% Polyester, 9% Elastane 207 LVB0 93% Polyester, 7% Elastane 237 LVB1 100% Nylon 53 LVRX 100% Nylon 83 LVZ2 64% Polyester, 27% Wool, 9% Nylon 332 LWEN 93% Nylon, 7% Elastane 160 LWEO 96% Nylon, 4% Elastane 164 LWEP 93% Nylon, 7% Elastane 158 LWEQ 93% Polyester, 7% Elastane 168 LWQY 77% Polyester, 23% Nylon 124 LWQZ 72% Nylon, 28% Polyester 115 LXO2 100% Polyester 160 LXVP 100% Polyester 186 LXVX 100% Nylon 246 LY15 100% Polyester 108 LYMC 100% Nylon 218 LYMD 100% Nylon 177 LYOM 100% Nylon 153 LYON 100% Polyester 112 LYOP 89% Polyester, 11% Elastane 157 LYOQ 100% Polyester 198 LYOR 51% Polyester, 49% Nylon 140 LYOT 100% Polyester 110 LYOU 100% Nylon 135 LYOV 100% Nylon 95 LYOV 100% Nylon 95 LYOW 100% Nylon 154 LZIM 91% Polyester, 9% Elastane 178 M1T5 97% Polyester, 3% Elastane 218 LV6Z 100% Polyester 177 LVRX 100% Nylon 83 LYMC 100% Nylon 218 LYON 100% Polyester 112 LZ6I 100% Nylon 108 LV92 100% Polyester 155 LWQY 77% Polyester, 23% Nylon 124 LWQZ 72% Nylon, 28% Polyester 115 M4IP 100% Polyester 98 M4RW 79% Polyester, 21% Nylon 158 LYMC 100% Nylon 218 LYON 100% Polyester 112 LYOU 100% Nylon 135 LYOW 100% Nylon 154 M1T5 97% Polyester, 3% Elastane 218 M4IM 100% Nylon 106 M4RX 100% Polyester 116 M4SY 100% Nylon 254 M4TF 63% Polyester, 29% Nylon, 8% Polyethylene 136 M4TG 72% Polyester, 21% Nylon, 7% Polyethylene 142 M4TI 75% Polyester, 25% Nylon 121 M4TJ 100% Polyester 177 M4WO 100% Polyester 161 M52J 94% Polyester, 6% Polyethylene 175 M59R 68% Polyester, 32% Nylon 94 M5KD 100% Polyester 163 M5LR 100% Polyester 110 M6AO 100% Polyester 128 M6JU 90% Nylon, 10% Polyethylene 74 M6JW 72% Polyester, 21% Nylon, 7% Polyethylene 142

[0013] Table 4 matches labels shows in Table 1 with jackets identified in Table 2.

TABLE-US-00004 Low Range Air Hydrostatic (AATCC Permeability (ASTM MVTR (JIS ID 127) - As Received D737) - As Received L1099-B1) A High Medium Low B Low Medium High C High Low Low D Low High Medium E Medium Low Low F High Low Medium G High Low High H High Low Low I High Low Medium J Medium Low Medium K Low Low Low L High Low Low LV6W Medium Medium Medium LV6Z High Medium Medium LV74 High Medium Medium LWEN Medium Medium Low LV71 Medium High High LWEQ Medium Medium Medium LV75 Medium Medium Medium LWEP Medium Medium Low LV7B High Medium Medium LV7D Medium Medium Medium LWEO Medium High Low

[0014] Table 5 matches labels shows in Table 1 with articles identified in Table 3.

TABLE-US-00005 Low Range Hydrostatic (AATCC Air Permeability (ASTM MVTR (JIS ID 127) - As Received D737) - As Received L1099-B1) LMTU High Medium Medium LNWU High Medium Low LUS0 Low Medium High LV6W Medium Medium Medium LV71 Medium High High LVAZ High Medium Low LVB0 High Medium Low LVB1 Low High High LVRX Medium Low Low LWEN Medium Medium Low LWEO Medium High Low LWEP Medium Medium Low LWEQ Medium Medium Medium LWQY High Medium Medium LWQZ Medium Medium Medium LYMC Medium Medium Low LYMD Low High Low LYMG Medium Medium Medium LYMP Medium Medium Medium LYON Medium High High LZ6I Medium Medium Low LMTU High Medium Medium LUS0 Low Medium High LV6W Medium Medium Medium LV6Z High Medium Medium LV71 Medium High High LV73 Medium Medium High LV74 High Medium Medium LV92 High Medium High LVAZ High Medium Low LVB0 High Medium Low LVB1 Low High High LVRX Medium Low Low LVZ2 Low Medium Low LWEN Medium Medium Low LWEO Medium High Low LWEP Medium Medium Low LWEQ Medium Medium Medium LWQY High Medium Medium LWQZ Medium Medium Medium LXO2 High Medium Medium LXVP High Medium Medium LXVX Medium Medium Low LY15 High Medium High LYMC Medium Medium Low LYMD Low High Low LYOM Medium Medium Low LYON Medium High High LYOP Medium Medium Medium LYOQ High High High LYOR Medium Medium Medium LYOT Medium High High LYOU Medium Medium Low LYOV Medium Medium High LYOV Medium Medium High LYOW Medium Medium Low LZIM Medium Medium Low M1T5 High High Low LV6Z High Medium Medium LVRX Medium Low Low LYMC Medium Medium Low LYON Medium High High LZ6I Medium Medium Low LV92 High Medium High LWQY High Medium Medium LWQZ Medium Medium Medium M4IP High Medium Medium M4RW High Medium Low LYMC Medium Medium Low LYON Medium High High LYOU Medium Medium Low LYOW Medium Medium Low M1T5 High High Low M4IM Medium Medium Medium M4RX High Medium Medium M4SY High Medium Low M4TF High Medium Low M4TG Medium Medium Low M4TI High Medium Low M4TJ High Medium Low M4WO High Medium Low M52J High Medium Low M59R Medium Medium Medium M5KD High Medium Medium M5LR Medium Medium Low M6AO Medium Medium Medium M6JU Low Medium Medium M6JW Medium Medium Low

[0015] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The shell fiber layer may comprise one or more of nylon, polyester, or elastane. The shell fiber layer may consist essentially of one or more of nylon, polyester, or elastane. The shell fiber layer may comprise about 100 weight percent (wt %) polyester from a total of 100 wt % of the shell fiber layer. The shell fiber layer may comprise greater than 90 wt % polyester from a total of 100 wt %. The shell fiber layer may comprise about 90 wt %, 91 wt %, 92 wt %, 93 wt %, 94 wt %, 95 wt %, 96 wt %, 97 wt %, 98 wt %, 99 wt %. Other loadings may be used. The shell fiber layer may comprise about 58 wt % nylon, about 37 wt % polyester, and about 5 wt % elastane. The shell fiber layer may comprise about 93 wt % nylon and about 7 wt % elastane. The shell fiber layer may comprise between 50 wt % and 100 wt % nylon. The shell fiber layer may comprise nylon by weight percent wt % as 51 wt %, 52 wt %, 53 wt %, 54 wt %, 55 wt %, 56 wt %, 57 wt %, 58 wt %, 59 wt %, 60 wt %, 61 wt %, 62 wt %, 63 wt %, 64 wt %, 65 wt %, 66 wt %, 67 wt %, 68 wt %, 69 wt %, 70 wt %, 71 wt %, 72 wt %, 73 wt %, 74 wt %, 75 wt %, 76 wt %, 77 wt %, 78 wt %, 79 wt %, 80 wt %, 81 wt %, 82 wt %, 83 wt %, 84 wt %, 85 wt %, 86 wt %, 87 wt %, 88 wt %, 89 wt %, 90 wt %, 91 wt %, 92 wt %, 93 wt %, 94 wt %, 95 wt %, 96 wt %, 97 wt %, 98 wt %, 99 wt % based on 100 wt % of the composite material. Other loadings may be used. The shell fiber layer may comprise about 62 wt % nylon, about 33 wt % polyester, and about 5 wt % elastane. The shell fiber layer may comprise about 93 wt % nylon and about 7 wt % elastane. The shell fiber layer may comprise about 75 wt % polyester and about 25 wt % nylon. The shell fiber layer may comprise 96% nylon, 4% elastane.

[0016] The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The membrane may be coupled to the shell fiber layer. The membrane may be glued to the shell fiber layer.

[0017] Composite materials are described herein. An example composite material may comprise a shell fiber layer. The example composite material may comprise a membrane disposed adjacent the shell fiber layer. The example composite material may exhibit a low range hydrostatic water resistance of above 5000 millimeter (mm) as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of above 0.25 as measured using American Society for Testing and Materials (ASTM) D737. The example composite material may exhibit a moisture vapor transmission rate (MVTR) of above 30 kilogram per square meter per 24 hour (kg/sqm/24 hr) as measured using Japanese Industry Standards (JIS) L1099-B1.

[0018] The example composite material may exhibit a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000 mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of between 0.25 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737. The example composite material may exhibit a moisture vapor transmission rate (MVTR) of between 30 kilogram per square meter per 24 hour (kg/sqm/24 hr) and 55 Kg/sqm/24 hr as measured using Japanese Industry Standards (JIS) L1099-B1.

[0019] A fabric weight associated with the example composite material may be between 90 grams per square meter (gsm) and 200 gsm. A fabric weight associated with the example composite material may be between 90 gsm and 180 gsm. A fabric weight associated with the example composite material may be between 91 gsm and 177 gsm. Other fabric weights and component weights may be used.

[0020] The example composite material may exhibit a low range hydrostatic water resistance of between 5000 millimeter (mm) and 25,000 mm as measured using American Association of Textile Chemists and Colorists (AATCC) 127. The example composite material may exhibit an air permeability of between 0.75 and 1 cubic feet per minute (cfm) as measured using American Society for Testing and Materials (ASTM) D737.

[0021] A fabric weight associated with the example composite material may be between 90 grams per square meter (gsm) and 200 gsm. A fabric weight associated with the example composite material may be between 90 gsm and 180 gsm. A fabric weight associated with the example composite material may be between 91 gsm and 177 gsm.

[0022] Articles are described herein. An example article may comprise composite material described herein. The example article may comprise a garment, gloves, footwear, headwear, bib pants, pants, a jacket, a tent, a sleeping bag, and a backpack.