Multi-Functional Fabric

Abstract

A fabric that includes porous fibers is provided. The porous fibers are formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer. A microinclusion additive and nanoinclusion additive may also be dispersed within the continuous phase in the form of discrete domains, wherein a porous network is defined in the composition that includes a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less.

1 - 37 . (canceled) 
     
     
         38 . A fabric comprising a plurality of porous fibers, wherein the fibers are formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer, and further wherein a microinclusion additive and nanoinclusion additive are dispersed within the continuous phase in the form of discrete domains, wherein a porous network is defined in the composition that includes a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less. 
     
     
         39 . The fabric of  claim 38 , wherein the fabric exhibits a water vapor transmission rate of about 300 g/m2-24 hours or more, thermal conductivity of from about 0.02 to about 0.10 watts per meter-kelvin, and/or hydrohead value of about 50 centimeters or more. 
     
     
         40 . The fabric of  claim 38 , wherein the microinclusion additive includes a propylene homopolymer, propylene/α-olefin copolymer, ethylene/α-olefin copolymer, or a combination thereof. 
     
     
         41 . The fabric of  claim 38 , wherein the nanoinclusion additive includes a polyepoxide. 
     
     
         42 . The fabric of  claim 38 , wherein the microinclusion additive constitutes from about 1 wt. % to about 30 wt. % of the composition, based on the weight of the continuous phase. 
     
     
         43 . The fabric of  claim 38 , wherein the nanoinclusion additive constitutes from about 0.05 wt. % to about 20 wt. % of the composition, based on the weight of the continuous phase. 
     
     
         44 . The fabric of  claim 38 , wherein the thermoplastic composition further comprises an interphase modifier. 
     
     
         45 . The fabric of  claim 44 , wherein the interphase modifier is a silicone, silicone-polyether copolymer, aliphatic polyester, aromatic polyester, alkylene glycol, alkane diol, amine oxide, fatty acid ester, or a combination thereof. 
     
     
         46 . The fabric of  claim 38 , wherein the porous network further includes micropores having an average cross-sectional dimension of from about 0.5 to about 30 micrometers. 
     
     
         47 . The fabric of  claim 46 , wherein the aspect ratio of the micropores is from about 1 to about 30. 
     
     
         48 . The fabric of  claim 38 , wherein the microinclusion additive is in the form of micro-scale domains and the nanoinclusion additive is in the form of nano-scale domains, wherein the micro-scale domains have an average cross-sectional dimension of from about 0.5 micrometers to about 250 micrometers and the nano-scale domains have an average cross-sectional dimension of from about 1 nanometer to about 500 nanometers. 
     
     
         49 . The fabric of  claim 38 , wherein the total pore volume of the fibers is from about 15% to about 80% per cubic centimeter. 
     
     
         50 . The fabric of  claim 38 , wherein nanopores constitute about 20 vol. % or more of the total pore volume of the fibers 
     
     
         51 . The fabric of  claim 38 , wherein the continuous phase constitutes from about 60 wt. % to about 99 wt. % of the thermoplastic composition. 
     
     
         52 . The fabric of  claim 38 , wherein the matrix polymer includes a polyester or polyolefin. 
     
     
         53 . The fabric of  claim 38 , wherein the fabric is a nonwoven fabric. 
     
     
         54 . The fabric of  claim 38 , wherein the fabric is a woven or knit fabric that contains a plurality of yarns, wherein at least a portion of the yarns includes the porous fibers. 
     
     
         55 . The fabric of  claim 38 , wherein the fabric is a composite that further contains textile fibers. 
     
     
         56 . The fabric of  claim 55 , wherein the composite includes yarns formed from a combination of the porous fibers and the textile fibers. 
     
     
         57 . The fabric of  claim 55 , wherein the composite includes yarns formed from the porous fibers and yarns formed from the textile fibers.