Synthetic insulation with microporous membrane

Abstract

An insulation package and method of formation including a functional fabric layer, a breathable water repellant insulating layer, and a highly breathable microporous membrane layer having a network of pores. The functional fabric, the highly breathable insulating layer and the microporous membrane layer are laminated to one another to form a waterproof breathable insultion package.

1 . An insulation package comprising: 
 at least one functional fabric layer;    a highly breathable microporous membrane layer having a network of pores,    a breathable water repellant insulating layer; and    wherein the functional fabric, microporous membrane layer and the insulating layer, are laminated to one another to form a waterproof breathable insulated fabric.    
   
   
       2 . The insulation package of  claim 1 , wherein at least one of the at least one functional fabric layers is a water resistant fabric.  
   
   
       3 . The insulation package of  claim 2 , wherein the functional fabric layer is coated with a cire coating.  
   
   
       4 . The insulating package of  claim 1 , further comprising a second functional fabric layer.  
   
   
       5 . The insulating package of  claim 4 , wherein the second functional fabric is laminated to the insulating layer on the non-membrane side.  
   
   
       6 . The insulation package of  claim 1 , wherein the size of a pore in the network of pores is defined by stretching the microporous membrane.  
   
   
       7 . The insulation package of  claim 1 , wherein the said insulation package permits vapor transfer and inhibits water transfer.  
   
   
       8 . The insulation package of  claim 1 , wherein the highly breathable water repellant insulation is nonwoven and comprises fibers selected from the group consisting of microfibers, macrofiber, natural fibers, and blends thereof.  
   
   
       9 . The insulation package of  claim 1 , wherein the highly breathable water repellant insulation is woven and comprises fibers selected from the group consisting of microfibers, macrofiber, natural fibers, and blends thereof.  
   
   
       10 . The insulation package of  claim 1 , wherein the highly breathable water repellant insulating layer has a cohesive fiber structure comprising an assemblage of: 
 (a) from 70 to 95 weight percent of spun and drawn, synthetic polymeric microfibers having a diameter of from 3 to 12 microns; and    (b) from 5 to 30 weight percent of synthetic polymeric macrofibers having a diameter of 12 to 50 microns.    
   
   
       11 . The insulation package of  claim 1 , wherein the breathable water resistant insulating layer formed as a batt having a smooth surface compatible for lamination techniques.  
   
   
       12 . The insulation package of  claim 11 , wherein the smooth surface is formed by at least one process selected from the group consisting of IR calendaring, hot plate calendaring, using heated rollers, resin coatings, and hot air oven processing.  
   
   
       13 . The insulation package of  claim 1 , wherein the functional fabric is selected from the group consisting of fleece, woven, and nonwoven fabrics.  
   
   
       14 . A method of forming a waterproof insulation package comprising the steps of: 
 providing a first layer of functional fabric;    providing a second layer of microporous membrane;    providing a third layer of breathable water repellant insulation;    bonding the first layer to said second layer; and    bonding the second layer to the third layer.    
   
   
       15 . The method of  claim 14 , further comprising the step of forming the third layer as a batt.  
   
   
       16 . The method of  claim 15 , further comprising the step of forming a smooth surface on said batt.  
   
   
       17 . The method of  claim 14 , wherein the bonding of the first and second layers is a lamination process.  
   
   
       18 . The method of  claim 14 , wherein the bonding of the second and third layers is a lamination process.  
   
   
       19 . The method of  claim 14 , further comprising the step of providing a second functional fabric layer.  
   
   
       20 . The method of  claim 17 , wherein the second functional fabric layer is laminated to the insulating layer.