Breathable, wicking nonwoven material

Patent metadata

Field	Value
Publication number	US-11510447-B2
Application number	US-202117552598-A
Country	US
Kind code	B2
Filing date	Dec 16, 2021
Priority date	Dec 20, 2017
Publication date	Nov 29, 2022
Grant date	Nov 29, 2022

Abstract

An article including one or more moisture wicking layers and one or more fibrous layers. The fibrous layers may have generally vertically oriented fibers, which may be oriented generally perpendicularly to a surface having or producing moisture. The article may be adapted to remove moisture form the surface having or producing moisture. The article may be breathable. The article may be quick drying. The article may provide cushioning. The article may be a wearable item.

First claim

What is claimed is:

1. A wearable article for transferring perspiration away from an outer surface of a user consisting of:
a. a first layer that is permeable and is configured to contact the perspiration on the outer surface of the user while being worn; and
b. a second layer being disposed opposite the first layer and including fibers that have been processed for alignment in a substantially parallel orientation relative to each other, the second layer configured to include a plurality of undulations having a crest and a trough defined from being vertically lapped and thereby resulting in a plurality of fibers oriented generally perpendicularly to the first layer and a plurality of interstitial spaces between and among the fibers for at least partially defining a fluid transport path for transporting the perspiration away from the first layer and through the second layer;
wherein the second layer has a thickness defined between a first side and a second side, the first side being in opposing contacting relation with the first layer and the second side having no opposing layer or contact surface;
wherein the thickness at least partially defines the fluid transport path where the second side is exposed to air for evaporation of the perspiration;
wherein the fibers include bi-component fibers that are mechanically carded, lapped, and fused in space as a network so that the wearable article has structure and body;

wherein the wearable article is washable and reusable.

2. The article of claim 1 , wherein the fibers processed for alignment form a carded web.

3. The article of claim 1 , wherein one or more of the first layer and the second layer exhibits a permeability of about 600 L/m 2 /s or greater at 100 Pa.

4. The article of claim 3 , wherein the first layer and the second layer each exhibit a permeability of about 600 L/m 2 /s or greater at 100 Pa.

5. The article of claim 1 , wherein the article has a thickness of 35 mm or less.

6. The article of claim 1 , wherein the fibers of the second layer have an average linear mass density of about 15 denier or less.

7. The article of claim 1 , wherein the fibers of the second layer have an average staple length of about 30 mm to about 65 mm.

8. The article of claim 1 , wherein the fibers of the second layer have a non-circular cross-section.

9. The article of claim 1 , wherein the fibers of the second layer include synthetic fibers.

10. The article of claim 9 , wherein the synthetic fibers comprise polyester, polypropylene, polyethylene, Nylon, aramid, imide, acrylate fibers, or combination thereof.

11. The article of claim 10 , wherein the synthetic fibers are polyester fibers, and the polyester fibers are polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), co-polyester/polyester (CoPET/PET) adhesive bi-component fibers, or a combination thereof.

12. The article of claim 1 , wherein the second layer comprises an elastomeric binder.

13. The article of claim 1 , wherein the second layer includes fibers regenerated from postconsumer waste.

14. The article of claim 1 , wherein the fibers of the second layer are a different material than material of the first layer.

15. The article of claim 1 , wherein the first layer is made from Lycra, polyester, polyethylene terephthalate, or a combination thereof.

16. The article of claim 1 , wherein the fibers include particles, binder, or both, embedded therein.

17. The article of claim 16 , wherein the embedded particles increase a surface area of a fiber by 50% or more.

18. The article of claim 1 , wherein the first layer is joined with the second layer.

19. A wearable article for transferring perspiration away from an outer surface of a user comprising:
a. a first layer that is permeable and is configured to contact the perspiration on the outer surface of the user while the wearable article is being worn;
b. a second layer that is a fibrous layer including fibers that have been carded for alignment in a substantially parallel orientation relative to each other, the second layer configured to include a plurality of undulations having a crest and a trough defined from being vertically lapped and thereby resulting in a plurality of fibers oriented generally perpendicularly to the first layer and a plurality of interstitial spaces between and among the fibers for defining a fluid transport path for transporting the perspiration away from the first layer and through the second layer;
wherein the interstitial spaces are defined by a frequency of the undulations;
wherein the material of the second layer contains a mixture of synthetic fibers and a binder in an amount about 40 percent by weight or less of the fibrous layer;
wherein the fibers of the second layer have an average linear mass density of about 15 denier or less;
wherein the fibers and/or binder include bi-component fibers that are mechanically carded, lapped, and fused in space as a network so that the wearable article has structure and body; and

c. a third layer that is permeable and receives the perspiration from the second layer and is configured for wicking of the perspiration transported from the second layer and distributing the perspiration to promote evaporation, wherein the third layer is the outermost layer of the wearable article;
wherein a total thickness of the second layer is greater than a total thickness of the first layer and the third layer;
wherein the first layer, the second layer, and the third layer each exhibit a permeability of about 600 L/m 2 /s or greater at 100 Pa;
wherein the first layer, the third layer, or both comprises Lycra, polyester, polyethylene terephthalate, or a combination thereof; and
wherein the article exhibits antimicrobial characteristics, antifungal characteristics, or both.

20. The article of claim 18 , wherein the first layer and the second layer are laminated together.

21. The article of claim 1 , wherein one or both of the first layer and the second layer exhibits a permeability of about 600 L/m 2 /s or greater at 100 Pa; wherein the article has a thickness of 35 mm or less; wherein the fibers of the second layer include polyester fibers comprising polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), co-polyester/polyester (CoPET/PET) adhesive bi-component fibers, or a combination thereof; wherein the second layer comprises an elastomeric binder; and wherein the first layer is made from Lycra, polyester, PET, or a combination thereof.

22. The article of claim 1 , wherein the article comprises silver, copper, or both, for providing antimicrobial characteristics, antifungal characteristics, or both.

23. The article of claim 19 , wherein the article includes one or more adhesive layers adapted to join the first layer to the second layer.

24. The wearable article of claim 19 , wherein the binder is a bi-component binder and/or an elastomeric binder.

25. The wearable article of claim 19 , wherein the binder includes fibers and/or spherical particles.

26. The wearable article of claim 19 , wherein the binder is present in an amount about 30 percent by weight or less.

27. The wearable article of claim 19 , wherein the synthetic fibers of the second layer include polyester fibers.

28. The wearable article of claim 19 , wherein the article comprises silver, co

Assignees

• Zephyros Inc

Inventors

• Thompson Greg
• Engel Marc
• Chaut Christophe

Classifications

• A41D31/125 Primary

  Moisture handling or wicking function through layered materials · CPC title

• A41D31/285

  using layered materials · CPC title

• D10B2401/13

  anti-allergenic or anti-bacterial · CPC title

• A41D31/305

  using layered materials · CPC title

• A41B2400/62

  through several layers · CPC title