Textile constructs formed with fusible filaments

Abstract

A textile construct with a performance film formative built into a textile structure. The textile construct needs only to be subject to a fusing agent to cause the performance film formative to convert from its lattice structure (e.g., knit or woven structure) into a film that is built into a retained lattice structure of the textile. More particularly, the formation of the textile construct is based on fusion of selected filaments, e.g., thermoplastic fibers or yarns, to selectively create a film on one side or layer in the construct while substantially preserving the lattice structure of an opposing side or adjacent layer of non-fusible filaments in a lattice structure. This creates a hybrid film/lattice textile construct. Both open-faced and sandwiched constructions of the film in a unitary structure with the retained lattice structure of another side or layer(s) are possible.

1 . An article of manufacture comprising a textile construct, comprising:
 a unitary, hybrid structure of a textile lattice formed from filaments and a thermoplastic film;   the thermoplastic film forming a first side or layer of the textile construct comprising a film of fused material having a substantially solid surface area of at least 90%;   a second side or layer of the textile construct comprising a discrete knit or woven lattice structure of filaments, the second side or layer being adjacent to and coextensive with the first side or layer and fused to it; and   wherein the article is selected from the group of an article of apparel, footwear, tent, and backpack.   
     
     
         2 . The article of  claim 1  wherein the article is an item of footwear. 
     
     
         3 . The article of  claim 1  wherein the article is an item of apparel. 
     
     
         4 . The article of  claim 1  wherein the layer comprises a plurality of planar sections and one section has material properties that are different from an adjacent section. 
     
     
         5 . The article of  claim 4  wherein a first section has different breathability from a second section. 
     
     
         6 . The article of  claim 5  wherein the first section comprises a waterproof, breathable membrane and the second section does not. 
     
     
         7 . The article of  claim 4  wherein the first section and section sections differ in elasticity. 
     
     
         8 . The article of  claim 1  wherein the layer comprises a pocket. 
     
     
         9 . The article of  claim 1  wherein the layer is formed to have a non-planar, 3D shape that is conformed to a selected area of an intended user's anatomy, the film being fused to impart the 3D shape. 
     
     
         10 . The article of  claim 1  wherein the layer is configured to form a shaping dart. 
     
     
         11 . The article of  claim 1  wherein the layer is configured to form one or more buttonholes. 
     
     
         12 . The article of  claim 1  wherein the layer is configured to form a trim effect. 
     
     
         13 . The article of  claim 1  wherein the textile lattice comprises a knit structure. 
     
     
         14 . An article of manufacture comprising a textile construct, comprising:
 a unitary, hybrid structure of a textile lattice formed from filaments and a thermoplastic film;   the thermoplastic film forming a first side or layer of the textile construct comprising a film of fused material having a substantially solid surface area of at least 90%;   a second side or layer of the textile construct comprising a discrete knit or woven lattice structure of filaments, the second side or layer being adjacent to and coextensive with the first side or layer and fused to it;   wherein the article is selected from the group of an article of apparel, footwear, tent, and backpack; and   the article further comprising an outer layer, the hybrid structure being assembled so that the film is an intermediate layer between the outer layer and the lattice structure wherein the film comprises a porous membrane of fused material has a porosity or diffusibility sufficient to allow for selective blocking of liquid phase water on one surface adjacent the outer layer and passage of vapor phase water through the fused lattice surface, the porosity being sufficient for air permeability of 1.0 to 80 CFM.   
     
     
         15 . The article of  claim 14  wherein the porous membrane of fused material has a pore density of at least 9 billion pores per square inch and/or average pore size of 0.2 microns or less. 
     
     
         16 . The article of  claim 15  wherein the membrane provides waterproofness or water resistance and/or breathability to the construct according to any one of the following standards:
 Low range hydrostatic—AATCC127 (Option 2) or JIS L1092; 
 High range hydrostatic—ASTM D751 (Fed Std 191-A55); 
 MVTR (upright)—ASTM E96B; 
 MVTR (inverted)—JIS L 1099 (Method B); and 
 Air Permeability—ASTM D737. 
 
     
     
         17 . The article of  claim 1  wherein the construct has an elasticity of 1% to about 30%. 
     
     
         18 . The article of claim of  17  wherein the film has a thickness of from about 0.5 mm to about 3 mm. 
     
     
         19 . A method of forming a textile construct, comprising:
 providing a composite textile lattice structure comprising an arrangement of (i) a first group of fusible filaments in a first lattice structure and (ii) a second group of non-fusible filaments in a second lattice structure, the non-fusible filaments comprising shrinkable filaments that are non-fusible relative to the fusible filaments, the first and second lattice structures being coextensively intermeshed to form the composite lattice structure, with the fusible filaments being selectively disposed primarily on one side of the composite lattice structure;   subjecting the composite lattice structure to a fusing agent sufficient to selectively cause the fusible filaments in the first lattice structure to fuse into a film substantially on one side or layer of the construct while maintaining the second lattice structure substantially in a discrete lattice structure, the fused film and the discrete lattice structure being coextensively fused together, the film of fused material having a substantially solid surface area of at least 90%; and   assembling the composite lattice structure into an article selected from the group of an article of apparel, footwear, tent, and backpack.   
     
     
         20 . The method of  claim 19  further comprising the step of imparting a non-planar, 3D shape to the composite structure.