Multi-layer composite fabric garment

Abstract

A composite fabric garment includes a first garment portion disposed in one or more upper regions of the fabric garment, i.e. those regions relatively more likely in use to be exposed to wind and rain, and a second garment portion disposed in one or more lower regions of the fabric garment, i.e. those regions relatively less likely in use to be exposed to wind and rain. The first garment portion is formed of a first composite fabric having first inner and outer fabric layers and a first intermediate barrier layer disposed between and bonded to at least one of the first inner and outer fabric layers, the first intermediate barrier layer being breathable and substantially impermeable to wind and liquid water. The second garment portion is formed of a second composite fabric formed of second inner and outer fabric layers and having predetermined air permeability. In one embodiment, the second garment portion further includes a second intermediate, breathable, air-permeable barrier layer disposed between and bonded to at least one of the second inner and outer fabric layers. In another embodiment, the second garment portion is formed of a composite fabric having controlled air permeability in a non-laminate absent a barrier.

1 . A composite fabric garment having an upper region that is relatively more likely in use to be exposed to wind and rain, and one or more lower regions that are relatively less likely in use to be exposed to wind and rain, the garment comprising:
 a first garment portion, forming the upper region, wherein said first garment portion is formed of a first composite fabric comprising:
 a first inner fabric layer; 
 a first outer fabric layer; and 
 a first intermediate barrier layer disposed between and bonded to at least one of said first inner fabric layer and said first outer fabric layer, said first intermediate barrier layer being breathable and substantially impermeable to wind and liquid water; and 
   a second garment portion forming the one or more lower regions, wherein said second garment portion is formed of a second composite fabric having predetermined air permeability and comprising:
 a second inner fabric layer; 
 a second outer fabric layer; and 
 a second intermediate barrier layer disposed therebetween, wherein said second intermediate barrier layer is selected from the group consisting of foamed adhesive in a discontinuous film, adhesive in a continuous film mechanically altered, and breathable adhesive in a discontinuous film, and wherein the second intermediate, breathable, air-permeable barrier layer has a variable level of water vapor diffusion resistance that substantially decreases with increase in air speed of moving air impinging on the second composite fabric, 
   
     and further wherein the second garment portion has a relatively higher level of breathability and air permeability than said first garment portion. 
   
   
       2 . The composite fabric garment of  claim 1 , wherein said one or more lower regions of said fabric garment include a wearer's lower chest region and below. 
   
   
       3 . The composite fabric garment of  claim 1 , wherein at least one of the first inner fabric layer and the second inner fabric layer comprises yarn with a plurality of synthetic fibers rendered hydrophilic. 
   
   
       4 . The composite fabric garment of  claim 3 , wherein the synthetic fibers of at least one of the first inner fabric layer and the second inner fabric layer are selected from the group consisting of polyester and nylon. 
   
   
       5 . The composite fabric garment of  claim 1 , wherein the second intermediate barrier comprises foamed adhesive in a discontinuous film. 
   
   
       6 . The composite fabric garment of  claim 1 , wherein the first inner fabric layer is hydrophilic. 
   
   
       7 . The composite fabric garment of  claim 1 , wherein the first outer fabric layer is hydrophobic. 
   
   
       8 . The composite fabric garment of  claim 1 , wherein at least one of the first inner fabric layer and the second inner fabric layer defines a surface comprising discrete pillar regions of relatively deeper pile, said discrete pillar regions of relatively deeper pile being spaced apart and isolated from each other by regions of relatively shorter pile or no pile that form a plurality of channels passing among said discrete pillar regions, said plurality of channels defining insulation regions to contain a cushion of air for promoting warmth under static conditions during periods of wearer inactivity and defining circulation regions creating avenues for flow of air and enhanced evaporation of moisture from the skin of the wearer for creating a heat dissipation or cooling effect during periods of physical activity by the wearer. 
   
   
       9 . The composite fabric garment of  claim 8 , wherein the plurality of channels formed along at least one of the first inner fabric layer and the second inner fabric layer comprises a plurality of intersecting vertical and horizontal channels. 
   
   
       10 . The composite fabric garment of  claim 9 , wherein the vertical channels formed along at least one of the first inner fabric layer and the second inner fabric layer are constructed by tipped and tipless sinkers, high and low sinkers, or a combination thereof. 
   
   
       11 . The composite fabric garment of  claim 1 , wherein at least one of the first outer fabric layer and the second outer fabric layer comprises a knit construction of multi-filament, interlaced yarns with one or more outer surface regions having a non-continuous coating comprising discrete coating segments of coating material applied to bind individual yarn fibers together for enhanced resistance of the outer surface region to abrasion, pilling or fraying. 
   
   
       12 . The composite fabric garment of  claim 1 , wherein at least one of the first inner fabric layer and the second inner fabric layer has a raised surface in a form selected from the group consisting of: velour, shearling, and loop terry. 
   
   
       13 . The composite fabric garment of  claim 1 , wherein at least one of the first outer fabric layer and the second outer fabric layer has a construction selected from the group consisting of: woven construction, circular knit construction, single face knit construction, double face knit construction, and warp knit construction. 
   
   
       14 . The composite fabric garment of  claim 13 , wherein at least one of the first outer fabric layer and the second outer fabric layer has at least one-way stretch. 
   
   
       15 . The composite fabric garment of  claim 14 , wherein at least one of the first outer fabric layer and the second outer fabric layer has two-way stretch. 
   
   
       16 . The composite fabric garment of  claim 13 , wherein at least one of the first outer fabric layer and the second outer fabric layer has a raised surface in one or more regions. 
   
   
       17 . The composite fabric garment of  claim 13 , wherein at least one of the first outer fabric layer and the second outer fabric layer has an unraised surface in one or more regions. 
   
   
       18 . The composite fabric garment of  claim 1 , wherein, in the upper portion of the composite fabric garment, at least the outer layer has a construction with minimal seams for improved resistance to penetration of water. 
   
   
       19 . The composite fabric garment of  claim 1 , wherein at least one of the first outer fabric layer and the second outer fabric layer comprises a fabric of knitted or woven construction of multi-filament, interlaced yarns with one or more outer surface regions having a non-continuous coating of binder material adhered to yarns and to yarn fibers at least at interlacing intersections for enhanced durability of the outer surface region to pilling or fraying. 
   
   
       20 . The composite fabric garment of  claim 19 , wherein adhering of the binder material to yarn fibers is limited in a manner to substantially avoid restriction of air permeability through the second composite fabric article. 
   
   
       21 . The composite fabric garment of  claim 1 , wherein the first inner fabric layer comprises a raised inner surface and a plain outer surface, the first inner fabric layer being formed of essentially hydrophobic material rendered hydrophilic to permit wicking of moisture from the raised inner surface to the plain outer surface, and wherein the first intermediate barrier layer comprises a first hydrophilic layer bonded to at least one of the first inner fabric layer and the first outer fabric layer, the first intermediate barrier layer permitting moisture vapor transmission. 
   
   
       22 . The composite fabric garment of  claim 1 , wherein the first inner fabric layer comprises a raised inner surface and a plain outer surface, the first inner fabric layer being formed of essentially hydrophilic material to permit wicking of moisture from the raised inner surface to the plain outer surface, and wherein the first intermediate barrier layer comprises a non-porous hydrophilic layer, the first intermediate barrier layer permitting water vapor transport, and wherein a first hydrophilic adhesive layer affixes the first intermediate barrier layer to at least one of an outer surface of the first inner fabric layer and an inner surface of the first outer fabric layer. 
   
   
       23 . The composite fabric garment of  claim 1 , wherein said second garment portion has a construction selected from the group consisting of woven construction, circular knit construction, and warp knit construction. 
   
   
       24 . The composite fabric garment of  claim 1 , wherein said second garment portion has relatively higher water vapor permeability in moving air and relatively lower water vapor permeability in static air. 
   
   
       25 . The composite fabric garment of  claim 1 , wherein the first garment portion has an air permeability of about 0 CFM to about 60 CFM. 
   
   
       26 . The composite fabric garment of  claim 1 , wherein the second garment portion has an air permeability of about 10 CFM to about 100 CFM. 
   
   
       27 . The composite fabric garment of  claim 1 , wherein the second garment portion comprises a fabric selected from the group consisting of: single face knit construction and double face knit construction. 
   
   
       28 . The composite fabric garment of  claim 1 , wherein the adhesive in a continuous film is mechanically altered by one or both of crushing or stretching.