GB2528904A

GB2528904A - An insulating material

Info

Publication number: GB2528904A
Application number: GB1413759.0A
Authority: GB
Inventors: Rolf Lyon
Original assignee: RLEPL Ltd
Current assignee: RLEPL Ltd
Priority date: 2014-08-04
Filing date: 2014-08-04
Publication date: 2016-02-10
Also published as: GB201413759D0

Abstract

A fabric material 30 comprises an outer, translucent, water resistant fabric 11 bonded to an insulating, fibrous matting 12, and an inner, water resistant fabric 13. The preferred fabric material 30 also includes additional layers of insulating material 24 and low bulk density fibres 31. The preferred outer 11 and inner 13 fibrous layers comprise polypropylene or nylon, and have density = 10-50 (30) g/m2. The preferred insulating material 12 comprises red, needle-punch felt comprising polyester, especially polyethylene terephthalate (PET), fibres of mean length 50-70 (64) mm, and has density = 80-170 (100-150) g/m2. Preferably, the layers are thermally bonded. The preferred insulating layers 24 and 31 are similar to layer 12 but include hollow fibres and have lower density. The, preferably breathable, material can be used in clothing, soft furnishing and roofing felt, but most preferably cold weather garments.

Description

MÜNLABNGMATaJAL The present nventon relates to a ttexble nsulatng matcual The mater al s a eibnc whch is particularly suitable for use in clothing, soft fumishing bedware or the like. Certain embodnents are also swtable for use r the nsulaton of buddngs, for example as roofing felt, Bacfvention Materials which can be used as fabrics for garments, soft furnishings etc. (and also ncludng certarn matenals whch are also suaable for use w the nsulaton of btnldrngs against heat loss, for exampLe as roofing felt), and which have low heat transfer properties across their surfaces are well known. Usually such materials are utmsed to retain heat inside a volume and are typically used for coldweather clothing. With respect to the latter usage, the materials used usually comprise multiple layers in which at least an outer layer is water resistant allowing the wearer to use the clothing in showery weather.

In order to retain heat within the garments an insulating layer is provided. The insulating layer typcally relies on a fibrous network to obtain air wfthin its bulk material and so restrict heat transfer between the wearer and the environment, A third layer can often be fl utilised, the third layer hacking on to the insulating layer and in effect sandwichirig the insulating Layer between the outer Layer and the third layer.

One problem with conventional fabrics is that although many are designed to be waterproof, or at least showerproof, in the event that water does penetrate the water resistant layer, the insulating material beneath this layer easily absorbs the water and loses its insuiating properties and at the same time becomes significantly heavier due to the absorbed water, The ability of the garment to protect the wearer from the cold environment is thereby significantly reduced. Moreover, the breathabilfty of the fabric, to enabling water to escape from the inside of the garment is also compromised.

in addition, prior art cold weather garments, particular for use in extreme environments such as industrial cold stores or the like are coloured white, Although this may have certain advantages in some situations, the white coloration does not provide the wearer with the feeling of warmth as white is inherently viewed as a cold colour, It is an object of the current invention to provide a material which when incorporated or utilised to make a garment addresses the above problems. fthon

According to the invention there is provided a fabric material, suitable for use in the manufacture of clothing, soft furnishings or the like, said material comprising: * a first layer comprising an at least water resistant fabric the first layer being translucent to visible Light: * a second layer bonded to said first layer and consisting of an insulating fibrous matting; * a third layer comprising an at least wateNresistant fabric, the first and third Layers providing the outer and inner layers respectively.

Preferably the first and third layers comprise a breathable fabric which ailows moisture from the wearer to escape from the garment so that a wearer's clothing beneath a garment made of the fabric material does riot become damp.

OptionalLy, the fabric materiaL includes a fourth Layer between the iirst and third layers, said fourth Layer being further optionally bonded to one or both of the first or second Layers and the third laye.r and yet further optionally comprising insulating fibres, the fourth Layer having a Lower hulk density than the second layer.

The two insulating layers combine together to reduce heat Loss to a greater extent than the indMduai Layers atone, io Advantageously, at Least one of the insulating [ayers is red in colour and especiaLly advantageously the second Layer is red. The use of the red colour provides the psychological effect on the user of the perception of warmth. Further advantageously, the colour is selected from Pantone colours of reference 1795c, 1797c, 18Cc, 1805c or 180/c.

is Preferably the second Layer lies between the first and fourth Layers. Further preferably, the second Layer is presern at a Level from 15 to 25 % w/w of the fabric material yet further preferabLy 18 to 2? % w/w and especially preferabLy 20% w/w.

The second Layer advantageously has a density of from 80 to 170gm-2 and especially advantageously of from 100 to 150 g rn-2 and is optionally formed of a needle punch felt The second and fourth Layers are conveniently formed of a synthetic fibre and in particular a poLyester polymer material.

The second and fourth Layers are optonaLly trmed of fibres whch have a mean length of from 50 -70mm, and especially 64mm. The fibres from which the fourth layer is formed are further optionally hollow and the internal lumen of the further optional hollow fibres is approximately 20% of the overall diameter of a fibre, The fourth layer advantageousLy has a density of 100 to 300g rn'2.

The first and third Layers are preferably iorrned of a polypropylene or a nylon plastics material The first and third layers preferably have a density of from 10 to 50 g m and especially preferably 10 to 30gm2 and further especially preferably 30 g m2.

The invention now described with reference to the accompanying drawings which show by way of example only, three embodiments of a fabric materiaL In the drawings: Figure 1 illustrates a section through a first embodiment of a fabric material; Figure 2 illustrates a section through a second embodiment of a fabric material; Figure 3 iLlustrates a section through a third embodiment of a fabric material; and Figure 4 is an image of material in accordance with the second embodiment.

QSI&d.Lcj1gtionofth1tjnxn' The following illustrates material for use as a coLd weather garment such as a jacket, although the material is suitable for use in soft furnishings and related technical areas, Referring initlly to Figure 1, this illustrates a first embodiment of the invention. The fabric materiaL generally referenced 10 consists of three layers. The first layer 11 is formed of a material such as a polypropylene or a nylon plastics materiaL The first layer 11 is preferably water-resistant, but not necessarily completeLy waterproof. In addition, the first Layer 11 is further preferably a breathable material enabling moisture from the wearer to evaporate to atmosphere. Additionally, the first layer ills translucent to allow the colour of the inner layer to show through.

The material from which the first layer 11 is formed preferably has a density of 10 to 50 g m4 and especially preferabLy 10 to 30 g m4, In the illustrated embodiment the Layer 11 has a density of 30 g m4, The second layer i2 is an msulatng layer, also referred to herein as a heat crust layer having a density of from 80 to 170gm4 and preferably of from 100 to 150 g m2, In the illustrated embodiment the layer 12 is formed of a polyester, such as a terephthalate (including alkylterephthatates) ester having a density of 32 dtex.

The heat crust layer 12 is a fibrous matting or a needle-punch felt to provide insulation to a wearer. The fibres typically have a mean Length of from 50 70 mm, and preferably around 64 mm, In addition, the heat crust layer 12 appears red in colour, The red colour, o although providing no insulating properties over and above those ocher colours has the effect on the wearer to provide the psychological feeling of warmth. The red colour therefore results in the wearer feeling warm, even though the temperature in which they are Located is cold. As non-limiting examples of suitable colours can be listed Pantone references 1795c, 1797c, 180c, 1805c and 1807c, The third layer 13 is of the same or similar composition to the first layer 11 and creates a sandwich structure forming material 10 which is thereby both water resistant and heat insulating, enabling the material to be formed into garments for use in outdoor actMties or also in controlled, cold environments such as refrigeration units, The layers 11 to 13 are bonded together, in a process which also bonds the heat crust layer 12 to the layers 11, 13, using a thermal bonding or welding method known in the art. Due to the relatively low melting point of the poLypropylene in particular, heat and pressure is applied to firstly press the layers 11, 13 together, and also to soften the polymers where they touch. The layers 11, 13 are therefore welded together, and when the heat and pressure is removed the layers remain bound to each other. Heat energy can be applied either by a thermal or ultrasonic transfer. An example of a machine suitable for this use is the Pfaff Seamsonic TM Range.

The resulting patterned effect produced on the material, can be chosen to suit the particular techncal affect reqwred or also the aesthetc effect An example of a pattern ntroduced nto a section of rnate,al 40 s shown in Figure 4, in whch the weldrng seams 41 are introduced by means of a cog-type anvil wheel and ultrasound as the Source of heat energy, In relation to Figure 2, this shows a second embodiment of a materiaL In this figure (and also Figure 3) features common to those referenced in Figure 1 are given the same reference number, In addition to the layers 11 to 13 of the first embodiment, a second insulating layer 24 is included, The density of the Layer 24 relative to the layer 12 is typically 50% and the relative thickness 700%. Where a second insulating layer (or subsequent insulating layer) is included in the material, any additional Layer can be bonded along with the others by the thermal bonding method described above. However a preferred method is to bLow the layer 24 together with the other layers and subsequently heat treat in an oven, The layers then stick together without the need for compression.

The second insulating layer 24 is also composed of fibres which together form a mesh. The fibres from which the second insulating layer 24 is formed are, like those in the heat crust Layer 12, synthetic man..made polymeric fibres which allow thermal and in particular ultrasonic bonding of the layers. A preferred polymeric material is also a polyester.

Similarly to the fibres in the heat crust layer 12, the fibres from which the second insulating Layer 24 is formed, typically have a mean Length of from 50 70 mm and preferably around 64 mm, A mixture of fibres of different polymeric material and fibre type can be used, Although the densi of the fibres ci the material forming the second insulating layer 24 can be the same as that of the heat crust layer 12, the bulk density of the second insulating layer 24 is preferably less than that of the heat crust layer 12 and is typically within the range of 100 to 300 g m2. The Lower bulk densfty can arise for two reasons, Firstly, the material forming the second insulating Layer 24 is uncompressed during manufacture Second, a proporuon of the fibres of the second nsuLatng Layer 24 can be hollow, with the lumen comprising up to 20% of the volume of the fibre, As an exampLe of a fibre mixture for use in the second insulating layer is the foLlowing "-65% w/w holLow conjugated silconeised fibres of density 10 dtex and mean length 64mm: 15% W1W bicomponent (bico) fibres of density 4.4 dtex and mean Length Simm: 20% solid fibres of density 6.7 dtex and mean length 64mm.

Without being hound by theory the difference in density between the two layers enhances the overall insulating properties of the fabric materiaL 20. The heat crust Layer 12 traps the so warm air between the heat crust layer 12 and the second insulating layer 24 and so retains heat within a garment.

In use it is expected that the first Layer 11 will be the outer layer of the garment. This will provide that the denser, heat crust layer 12 is also facing outwards. As the fibres of the / heat crust Layer are closer together than those in the second insulating Layer 24, the heat crust layer 12 [s more resistant to penetration by water, This improves the water resistant properties of the material and hence the garment formed from said material. In order for the heat crust 12 to be effective it is present at a Level of around 15 25 %w/w of the overall fabric materiaL These values enable the heat crust Layer 12 to provide sufficient insulation and ako colour to the fabric material without the fabric material becoming too heavy to be worn comfortably. Especially preferably, the heat crust Layer 12 is at a level of from 18-22 %wtw and in the embodiment shown is at 20%w/w.

to In order to reinforce the colour effect, the second insulating layer 24 can also be colcured, although given the lower density of the Layer 24, the colour may be weaker, The weaker colour can he acimevea through the use of a mncture of fibres As an example of such a mixture, the second insulating layer can comprise 65 96 wiw of a hollow fibre to provide further air spaces within the Layer, 15% w/w of a bicomponent fibre and 20% wlw of the red fibre used for the heat crust layer 12 (which Layer 12 aLso functions as a first insulating Layer), thus imparting the colour. Bicomponent fibres are well known in the art comprised at theft most basic, a mixture of two polymer fibres of different melting point. When heat is applied at a level between the melting points, the Lower melting point polymer becomes more fluid and flows around the other fibres. On cooling, the Lower melting point polymer solidifies producing a bonded bundle of fibres. As a typical example, mixtures of polyethylene/potypropylene fibres are known, with the polyethylene having a tower melting point.

Regarding the third embodiment the fabric material 30 shown in Figure 3, the material 30 has an additional layer 31 of low bulk density fibre. The fibre in the layer 31 can be the same as that used in the layer 24 or different to provide additional insulating properties.

It will be recognised that the invention has not alluded to the specific details described heron,, whch are gven by way of example amy, and that vancus mothhcanons a"d alteratois are possthle wtthn the scope of tno nventon

Claims

S1. A fabric material comprising a flrst Layer comprising an at least water resistant fabric, the first layer being translucent to visible Light; a second layer bonded to said first layer and consisting of an insulating fibrous matting; a third Layer comprising an at Least water-resistant labric, the first and third layers providing the cuter and inner Layers respectively.
A fabric material according to cLaim 1, wherein the first and third layers comprise a breathable fabric which allows moisture from the wearer to escape from the garment.
3 A fabnc material according to cLam 1 o dawn r cluding a fourth layer between the first and third layers.
4. A fabric material according to claim 3, wherein said fourth Layer is bonded to one or both of the first or second layers and the third layer.
5. A fabric material according to claim 3 or cLaim 4 comprising insulating fibres, the fourth layer having a lower bulk density than the second layer.
6 A fabric material ?ccording to any preceding dawn wheren at Least one of the insulating Layers is red in colour.
7. A fabric material according to cLaim 6 wherein the second layer is red.
8. A fabric material according to claim 7, wherein the colour is selected from Pantone reference 1795c, iYSlc. 181k, iSOSc or 180k,
9. A fabric material according to claims 3 to 8, wherein the second layer Lies between the first and fourth layers.
10, A fabric material according to daim 9, wherein the second layer is present at a level from 15 to 25% wlw of the fabric rnatehaL
11. A fabric material according to ctaim 10, whereLn the leveL is from 18 to 22 96 wlw,
12. A fabric material according to claim 11 wherein the level is 20% w/w,
13. A fabric material according to any preceding cLaim wherein the second layer has a density of from 80 to 170 g rrr2, U) 14 A fabnc mater at dccord ng to clann 14 wherem the lev& s from 100 to 150gm' 15. A fabric material according to claim 13 or cLaim 14 wherein the material is formed of a needle punch left, 16. A fabric material according to cLaims 3 to 15, wherein the second and fourth layers are formed of a synthetic poymeric fibre.7 A fabnc maena accordmgto clam 16 wherem the syntletrn pa ymenc fibre sa p&yester polymer materiaL 18. A fabric material according to claims 3 to 17, wherein the second and fourth layers are formed of fibres which have a mean length of from 50 70mm, 19. A fabric material according to claim 18, wherein the Length is 64mm.A faboc matenat accordmg to clam 18 or clam 19, wherern at least a porbon of the fibres from which the fourth layer is formed are hollow and the internal lumen of the hollow fibres is approximately 20% of the overall diameter of a fibre, 21 A fabnc matenat accordmg to darns 3 to 20, wherem the fourth layer has a densLy of 100 to 300 g rn-2.22. A fabric materiaL according to any preceding claim wherein the first and third layers are formed of a polypropylene or a nylon plastics material.23. A fabric material according to any preceding claim wherein the first and third Layers have a density of from 10 to 50 g rn-a, 24. A fabric material according to dairn 23, wherein the density is from 10 to 30gm2.25. A fabric material according to claim 24, wherein the density is 30 g rrr2.26. A fabric material substantially as herein described with reference to and as iUustrated by the accompanying drawings.