Breathable, wicking nonwoven material

Patent metadata

Field	Value
Publication number	US-11606994-B2
Application number	US-201816955932-A
Country	US
Kind code	B2
Filing date	Dec 20, 2018
Priority date	Dec 20, 2017
Publication date	Mar 21, 2023
Grant date	Mar 21, 2023

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, washable, and reusable multi-layer article having a user contacting surface and an exterior surface, the article comprising:
a. one or more moisture wicking layers; and
b. a nonwoven fibrous layer having a plurality of fibers including generally vertically oriented fibers, wherein the plurality of fibers of the fibrous layer are carded and lapped into a three-dimensional structure;
wherein at least a portion of the generally vertically oriented fibers of the fibrous layer are positioned within the article to be oriented generally perpendicularly to a surface having or producing moisture;
wherein the fibrous layer includes bi-component fibers that are fused in space as a network so that the article has sufficient structure and body and the fibrous layer has a permeability of about 600 L/m 2 /s or greater at 100 Pa;
wherein the article is adapted to remove the moisture from the surface having or producing moisture via one or more of the moisture wicking layers transferring moisture to the fibrous layer;
wherein the article is a three-dimensional shaped thermoformable and/or moldable article having a desired shape;
wherein the article is adapted to pull the moisture through the article, and onto the exterior surface of the article, wherein the exterior surface is an outermost surface of the article;
wherein each layer of the article is permeable and/or breathable to encourage evaporation of the moisture and, to allow air flow through the article all of the layers of the article.

2. The article of claim 1 , wherein the surface having or producing moisture is skin of a body.

3. The article of claim 2 , wherein the fibrous layer is sandwiched between two moisture wicking layers, wherein one of the moisture wicking layers is adapted to contact the skin, and an opposing moisture wicking layer faces away from the skin.

4. The article of claim 1 , wherein the fibrous layer is sandwiched between two moisture wicking layers.

5. The article of claim 4 , wherein the article includes an outer moisture wicking layer that faces away from the surface having or producing moisture.

6. The article of claim 1 , wherein one of the moisture wicking layers is adapted to contact the surface having or producing moisture.

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

8. The article of claim 7 , wherein fibers of the fibrous layer have a cross-section having a plurality of lobes and/or deep grooves.

9. The article of claim 1 , wherein the type and/or orientation of the fibers of the fibrous layer creates a capillary effect to pull the moisture away from the surface.

10. The article of claim 1 , wherein one or more of the moisture wicking layers transfers moisture to the fibrous layer and spreads the moisture over a larger surface area of the one or more fibrous layers and/or fibers thereof.

11. The article of claim 1 , wherein the article exhibits structural resiliency to provide cushioning.

12. The article of claim 1 , wherein the fibrous layer is formed by a vertical lapping process.

13. The article of claim 1 , wherein the article exhibits antimicrobial characteristics, antifungal characteristics, odor resistance, mold or mildew resistance, or a combination thereof.

14. The article of claim 1 , wherein at least a portion of the fibers of the article are treated with or include silver or copper.

15. The article of claim 1 , wherein one or more layers include fibers having embedded particles comprising active carbon, sand, fruit or nut shells, or a combination thereof.

16. The article of claim 1 , wherein the fibrous layer includes fibers selected from polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), co-polyester/polyester (CoPET/PET) adhesive bi-component fibers, or a combination thereof.

17. The article of claim 16 , wherein the fibrous layer includes fibers including PET and bi-component fibers including a copolymer including PET.

18. The article of claim 16 , wherein the fibrous layer includes elastic bicomponent PET, PBT, PTT or a combination thereof.

19. The article of claim 1 , wherein the article has a permeability of about 600 L/m 2 /s or greater at 100 Pa.

Assignees

• Zephyros Inc

Inventors

• Thompson Greg
• Engel Marc
• Chaut Christophe

Classifications

• B32B2307/728

  Hydrophilic · CPC title

• B32B5/266

  next to one or more non-woven fabric layers · CPC title

• B32B2437/00

  Clothing · CPC title

• B32B2255/205

  Metallic coating · CPC title

• B32B2255/02

  on fibrous or filamentary layer · CPC title