MXPA99003707A - Outdoor fabric - Google Patents

Abstract

An outdoor protective fabric (10) is disclosed having (i) a UV stable outer nonwoven web (127) of multicomponent sheath/core fibers having a polyethylene polymer sheath component and a polypropylene polymer core component;(ii) a breathable barrier layer (167), such as a meltblown web or microporous film;and (iii) an interior nonwoven web (147) of multicomponent fibers comprising a polyethylene polymer component and a nylon component.

Description

FABRIC FOR EXTERIORS Field of the Invention The present invention relates generally to recreational and outdoor fabrics. More particularly, the present invention relates to non-woven laminates for recreational and outdoor fabrics.

Background of the Invention Significant exposure to the sun and bad weather can seriously degrade the appearance of many products such as, for example, by causing colors to fade, paint or other coatings to peel and make sores, by oxidation ( for example rust) and the like. In addition, the appearance of many products, of automobiles in particular, can be mistreated from exposure to other hazards such as the breaking of branches, leaves, bird droppings, and so on. In addition, in addition to degrading appearance, extended exposure to the weather can significantly shorten the life expectancy of many products. Therefore, products which are subject to prolonged exposure to the weather are commonly provided with protective covers designed to limit the adverse effects of such exposure. Similarly, the Human exposure to bad weather and / or extended sun can be unpleasant and, if it is for significant durations, can be potentially dangerous to one's health. Therefore, outer fabrics which provide some means of protecting the environment are frequently used in products such as tarpaulins, tents and in clothing that is waterproof or weatherproofed and the like.

Weathering fabrics typically require sufficient strength to resist tearing, tearing and punctures. These fabrics commonly act as a barrier to water thus providing protection from rain and other forms of precipitation. In this regard, some fabrics have the ability to act as a barrier to water in the liquid state while at the same time remaining n-breathable "in the sense that water vapor can pass through the fabric. for breathing are often preferred in many products such as, for example, in a car cover since a breathable cover helps to prevent moisture buildup under the cover and on one side of the surface of the automobile. The ability to breathe is similarly preferred in outdoor clothing because breathable fabrics are more comfortable to wear than similar apparels without the ability to breathe, however, as the level of ability to breathe frequently increases. barrier properties of the fabric decrease. Thus, many breathable fabrics fail to provide sufficient barrier properties and are prone to draining when subjected to heavy rain or other harsh conditions. In addition, the outer fabrics also provide protection from the effects of sunlight, particularly from ultraviolet (UV) radiation and the heat that accompanies it. Even when weathering fabrics are expected to gradually lose the desired strength and barrier properties over time, they are very susceptible to premature degradation as a result of extended exposure to intense sunlight.

Nonwoven fabrics provide multiple forms of protection from exposure to the weather and are expected to do so for extended periods of time. However, the effects of weathering are such that even protective fabrics specifically intended for exterior use may lose their desired properties and appearance prematurely. Therefore, there is a continuing need for outdoor fabrics which are capable of providing protection from the adverse effects associated with extended exposure to the sun and bad weather. There is also a need for a fabric for the exterior which provides excellent water barrier properties and which still also provides good capacity for breathe. In addition, there is still a need for such fabrics which are durable and capable of retaining the desired properties, such as strength or barrier properties when subjected to the rigors of prolonged exposure to the weather.

Synthesis of the Invention The aforementioned needs are satisfied and the problems experienced by those skilled in the art are overcome by the non-woven fabric for the exterior of the present invention which in one aspect comprises a first outer layer of bicomponent fibers having a configuration of sheath / core wherein the sheath component comprises a stable polymer, ultraviolet radiation and a waterproof barrier layer. The invention may further include a second outer layer wherein the barrier layer is placed between the first and second outer layers. In addition, the first outer layer may comprise bicomponent fibers having a sheath / core configuration wherein the sheath component comprises a stabilized saturated polyolefin of damaged thermoplastic amine. In addition, the sheath / core configuration of the first outer layer can, in one aspect, comprise a UV stabilized polyolefin sheath, and a UV stabilized polypropylene core. In still another aspect of the invention the second outer layer may comprise a layer of durable support such as a sheath / core bicomponent fiber layer having a UV stabilized polyethylene sheath and a nylon core. In a further aspect of the invention, the barrier layer may comprise a breathable film. In a further aspect of the invention the polymer comprising the sheath component of the first and second layers and of the barrier layer can be of similar or identical polymers.

In a still further aspect of the present invention, the fabric for the exterior may comprise a first outer layer of stable UV fibers and a barrier layer comprising a microporous film capable of breathing and impervious to water. The barrier film may, for example, comprise a filled-stretched polyolefin film stabilized against ultraviolet radiation. The invention may further include a second outer layer wherein the barrier layer is placed between the first and second outer layers. In addition, the first outer layer may comprise bicomponent fibers having a sheath / core configuration wherein the sheath components comprise a thermoplastic polymer wa stability against ultraviolet radiation superior to agüella of the core component. Furthermore, the sheath / core configuration of the first outer layer can, in one aspect, comprise a polyethylene sheath stabilized against ultraviolet radiation and a polypropylene core stabilized against the s ultraviolet radiation. In yet a further aspect of the invention the second outer layer may comprise a durable backing layer such as a layer of bicomponent sheath / core fibers having a polyethylene sheath stabilized against ultraviolet radiation and a nylon core. The sheath component of the first and second outer layers and the barrier layer can each also comprise similar or identical polymers.

Brief Description of the Drawings Figure 1 is a partially sectioned perspective view of a multi-layer laminate of the present invention.

Figure 2 is a cross-sectional view of a concentric sheath / bicomponent fiber of the present invention; Figure 3 is a partially sectional perspective view of an alternate embodiment of a multi-layer laminate of the present invention; Figure 4 is a perspective view of the laminate of Figure 1 illustrating a representative joint pattern; Figure 5 is a cross-sectional view of the laminate of Figure 4 taken along lines 5-5; Figure 6 is a schematic view of a representative joint pattern; Y Figure 7 is a schematic view of a process line for making the fabric of the present invention.

Definitions As used herein, the term "water impermeable" refers to a material which does not allow water in the liquid state to easily pass through it having a minimum hydro head value of at least about 30 mbar . The hydro head as used herein refers to a measure of the liquid barrier properties of a fabric. A fabric with a higher hydro head reading indicates that it has a greater barrier to penetration of the liquid than a fabric with a lower hydro head.

As aguí was used, the term "ultraviolet radiation stable" refers to a polymeric composition which retains at least 40% (corrected) of its tensile strength after twelve months of exposure. The stability to ultraviolet radiation can be assessed through a South Florida test which can be conducted by exposing non-woven fabrics to the sun without any support in Miami Florida. The samples are facing south at a 45 ° angle. Each cycle concludes with a modified stress test to measure the degradation or change in fabric strength. This provides a measure of the durability of the fabric. The stability of the relative ultraviolet radiation can be assessed by comparing the length of time the fabric retains at least 40% (corrected) of its tensile strength. The tensile strength of a fabric can be measured according to the ASTM D-1682-64 test. In addition, the calculation of the corrected 40% tensile strength can be obtained by adding the sum of the months to 50, 40 and 30% retention of tensile strength and dividing by three.

As used herein, the term "breathability" refers to a material which is permeable to water vapor and has a minimum MVTR of at least about 100 g / m2 / 24 hours. The MVTR of a fabric is also frequently mentioned as the water vapor transmission rate (WVTR).

As used here, the term "non-woven fabric" or "nonwoven fabric" refers to a fabric having a structure of individual fibers or threads which are interleaved but not in an identifiable manner as in a knitted fabric. Weaves or non-woven fabrics have been formed from many processes such as, for example, blow-through processes, spunbond processes, bonded and hydroentangled webbed processes.

As used herein, the term "spunbonded fibers" refers to fibers of small diameter which are formed by extruding molten thermoplastic material as filaments from a plurality of usually circular and thin capillary vessels of a spinner with the diameter of the melted and extruded filaments then being easily reduced as described in, for example, U.S. Patent No. 4,340,563 issued to Appel et al., and in U.S. Patent No. 3,692,618 issued to Dorschner et al., In U.S. Patent No. 3,802,817 issued to Matsuki et al .; in U.S. Patent Nos. 3,338,992 and 3,341,394 issued to Kinney, U.S. Patent No. 3,502,763 issued to Hartman; U.S. Patent No. 3,542,615 issued to Dobo et al .; U.S. Patent No. 5,382,400 issued to Pike et al. and U.S. Patent No. 5,534,339 issued to Stokes; whose complete contents are incorporated here by reference. Spunbond fibers are generally non-sticky when they are deposited on a collecting surface. Spunbonded fibers are generally continuous and typically have Average diameters (from a sample of at least 10) larger than about 7 microns, often between about 10 and 30 microns.

As used herein, the term "meltblown fibers" refers to fibers formed by extruding a melted thermoplastic material through a plurality of capillary matrix vessels, usually circular and thin as melted threads or filaments into gas streams. (for example, air) usually hot, high speed and convergent which attenuate the filaments of the melted thermoplastic material to reduce its diameter, which can be a microfiber diameter. Then, the melt blown fibers are cooled and carried by the high velocity gas stream and deposited on a collecting surface to form a meltblown fabric of randomly disbd melt. Such a process is described, for example, in United States of America Patent No. 3,849,241 issued to Butin et al. Melt-blown fibers are microfibers which can be continuous or discontinuous, are generally smaller than 10 microns in average diameter and are generally sticky when deposited on a collecting surface.

As used herein, the term "fibers", except as otherwise indicated, includes discontinuous yarns having a defined length, such as fibers of short length, and which also include filaments which are continuous threads of material.

As used herein, the term "polymer" generally includes but is not limited to homopolymers, copolymers, such as, for example, block, graft, random, and alternating copolymers, terpolymers, et cetera, and mixtures and modifications thereof. In addition, unless specifically limited otherwise, the term "polymer" will include all geometric or spatial configurations of the molecule. These configurations include, but are not limited to, isotactic, syndiotactic and random symmetries.

As used herein, the term "multicomponent fibers" refers to fibers which have been formed from at least two polymers. Such fibers are typically extruded from separate extruders but are spun together to form a fiber. Multicomponent fibers include conjugated and / or bicomponent fibers. The polymers are usually different from one another through the conjugated fibers and can have components comprising either identical or similar polymers. The polymers are arranged in areas placed essentially differently, across the cross section of the multicomponent fibers and extend continuously along the length of the multicomponent fibers. Multicomponent fibers are shown in U.S. Patent No. 5,108,820 issued to Kaneko et al., in U.S. Patent No. 4,795,668 issued to Krueger et al., in U.S. Patent No. 5,336,552 issued. a? track and others and in U.S. Patent No. 5,382,400 issued to Pike et al., the complete contents of which are incorporated herein by reference. For bicomponent fibers, the polymers may be present in proportions (by volume) of 75/25, 50/50, 25/75 or other desired proportions. The multicomponent fibers may also have various forms such as for example those described in U.S. Patent No. 5,277,976 issued to Hogle et al., In U.S. Patent No. 5,466,410 issued to Hills and in US Pat. US Pat. Nos. 5,069,970 and 5,057,368 issued to Largman et al.

As used herein, the term "hot air knife" or "HAK" refers to a process of joining a layer of fibers, particularly spun-bonded, in order to give it sufficient integrity, for example to increase the stiffness of the fabric , for additional processing but does not mean relatively stronger bonding processes such as , thermal bonding and ultrasonic bonding. A hot air blade is a device which focuses a stream of heated air at a very high flow rate generally from about 1,000 to about 10,000 feet per minute (fpm) (305 to 3050 meters per minute), or more particularly from about 3,000 to 5,000 feet per minute (915 to 1525 meters per minute) directed to the non-woven fabric immediately after its formation. The air temperature is usually in the range of the melting point of at least one of the polymers used in the fabric, generally between about 200 and 550 ° F (93 and 290 ° C) for the thermoplastic polymers commonly used in the fabric. the union with spinning. Control of air temperature, speed, pressure, volume and other factors helps to avoid damage to the woven while its integrity is increased. The focused airflow of the hot air blade is arranged and directed by at least one slot about 1/8 to 1 inch (3 to 25 mm) wide, particularly about 3/8 inch (9.44). millimeters) serving as the outlet for heated air to the fabric, with the groove running in a direction essentially transverse to the machine over essentially the full width of the fabric. In other embodiments, there may be a plurality of grooves arranged one next to another or separated by a slight gap. The groove is usually, even if not essentially continuous and may be composed of closely spaced holes for example. The hot air blade may have a plenum to distribute and contain the heated air before it leaves the slot. The plenum pressure of the hot air blade is usually from around of 1.0 and 12.0 inches of water (2 to 22 mmHg), and the hot air blade is positioned between about 0.25 and 10 inches and more preferably 0.75 to 3.0 inches (19 to 76 mm) above the forming wire. In a particular embodiment the cross-sectional area of the plenum of the hot air knife for the flow in the transverse direction (for example the cross-sectional area of plenum in the machine direction) is at least twice the area of total slot output. Since the foraminous wire upon which the spin-bonded polymer is formed generally moves at a high velocity rate, the time of exposure of any particular part of the fabric to the air discharged from the hot air knife is often less than one tenth of Tin second and thus "of about one - hundredth of a second in contrast to the process of bonding through air which has a much longer residence time." The process of hot air blade has a higher range of variability and control of many factors such as air temperature, velocity, pressure, volume, groove or arrangement and size of the orifice, and the distance from the plenum of the hot air knife to the fabric. hot air blade is further described in United States of America patent application No. 08 / 362,328 issued to Arnold et al., filed on December 22, 1994 and Commonly assigned, whose full contents are incorporated here by reference.

As used herein, "air binding" or " " refers to a joining process of a nonwoven conjugate fiber fabric in which the heated air, which is hot enough to melt one of the polymers of Multicomponent fibers forced through the tissue. The melting and resolidification of the polymer provides the bond between the fibers to integrate the fabric. The air speed is typically between 100 and 500 feet per minute and the dwell time can be as long as 6 seconds. Bonding through air has a relatively restricted variability and since the TAB air bonding requires the melting of at least one component to achieve the bond, this is particularly useful in relation to conjugate fiber fabrics or those for which include an adhesive. In the unison through air, air that has a temperature above the melting temperature of at least one of the exposed components is directed through the fabric and into a perforated roller that holds the fabric. Alternatively, the air-binding device can be a flat arrangement in which the air is directed vertically downwards onto the fabric. The operating conditions of the two configurations are similar, the primary difference being the geometry of the fabric during joining.

As used herein, the "ultrasonic unit" means a process carried out for example by passing the cloth between a sonic horn and an anvil roller as illustrated in U.S. Patent No. 4,374,888 issued to Bornslaeger, the complete contents of which are incorporated herein by reference.

As used herein, "knit stitch" means the joining of one or more layers of cloth at a plurality of discrete stitches. For example, thermal bonding generally involves passing a fabric or fabric of fibers to be joined from a heated roller assembly such as, for example, a heated calender roll and an anvil roller. A calender roll is usually patterned in some manner so that the entire fabric is not bonded across its entire surface, and the anvil roller is usually flat. As a result of this, various patterns for the calendering rolls have been developed for functional and / or aesthetic reasons. An example of a pattern has points and is that of Hansen Pennings or "pattern H_tP" with about a 30% bond area with about 200 joints / square inch as taught in the United States of America patent No. 3,855,046 issued to Hansen & Pennings. The HStP pattern has bolt or square stitch areas where each bolt has a side dimension of 0.038 inches (0.965 millimeters), a gap of 0.070 inches (1.778 millimeters) between the bolts, and a 0.023 inch unit depth. (0.584 millimeters). The resulting pattern when it was new had a united area of about 29.5%. Another typical point knit pattern is the expanded Hansen Pennings pattern or "EHP" which produces a 15% joined area when new with a square bolt having a side dimension of 0.037 inches (0.94 millimeters), a spacing of 0.097 inch (2.464 mm) bolt and 0.039 inch (0.991 mm) depth. Another typical point pattern pattern designated "714" has square bolt joint areas where each bolt has a side dimension of 0.023 inches, a "0.062 inch (1,575 mm) spacing between the bolts and a joint depth of 0.033. inches (0.838 millimeters) The resulting pattern has a bonded area of around 15% when new, and other patterns include a diamond pattern with slightly off-center and repetitive diamonds with about a 16-inch area when new. In addition, a wire weave pattern, which gives the non-woven fabric a woven appearance having a bolt density of about 302 bolts per square inch and resulting in a bonded area of about 17% when new Typically, the percent bond area will vary from about 5% to about 30% of the area of the cloth laminate fabric.The knit join holds the laminate layers together so As it imparts integrity to each individual layer by joining the filaments and / or fibers within each layer without destroying the cloth's ability to breathe.

As used herein, the term "outer fabric" means a fabric which is used primarily, but not exclusively, in the open. Outdoor fabrics include fabric used for protective covers, tow or camper fabric, tents, awnings, agricultural fabrics and outdoor clothing such as head coverings, industrial worr and full suits, pants , shirts, coats, gloves, socks, shoe covers and the like.

As used herein, the term "protective cover" refers to a cover for vehicles such as cars, trucks, boats, airplanes, motorcycles, bicycles, golf carts, etc., covers for equipment frequently left outside such as grills, equipment garden and patio (mowers, rototrilladoras, etc.), and meadow furniture as well as floor covers, table covers and covers for outdoor lunch area.

Description of Preferred Additions With reference to Figure 1, the weather cloths of the present invention will be described in greater detail. As illustrated, the laminate 10 may comprise the first outer layer 12, the second outer layer 14, and a barrier layer 16 placed between the first outer layer 12 and the outer layer 12. second outer layer 14. The first outer layer 12 is adapted to provide the resistance to the desired ultraviolet radiation, the barrier layer 16 is adapted to provide a water impermeable barrier and a second outer layer 14 adapted to provide the additional strength and the support for the barrier layer 16 and the laminate 10. Thus, the laminate 10 can be used, for example, as a protective cover for a motor vehicle by placing a laminate 10 on the car so that the second outer layer 14 is facing the automobile (not shown) and the first outer layer 12 faces the environment.

The first outer layer 12 comprises an integrated layer of fibers stable to ultraviolet radiation, desirably an integrated nonwoven fabric of continuous fibers. In a preferred embodiment, referring to Figure 2, the fibers comprise multi-component fibers of core / shell type having a first component A which covers the second component B and forms a peripheral surface along substantially the entire length of the fibers. Multicomponent fibers may be eccentric or concentric and it is desirable for the fibers to comprise continuous filaments in which the wrapper component A forms the entire peripheral surface along the length of the fiber 20 thereby minimizing the impact of the ultraviolet radiation on the fiber. component B. In a similar way, even when multicomponent fibers can Being eccentric or concentric in configuration, concentric bicomponent fibers are preferred. Since the orientation of the core component within the fiber can vary in many production methods, in order to ensure sufficient protection of the core component it is desirable that the pod component comprises at least about 50% of the area of the core component. surface in cross section of the fiber. Component A of the multicomponent fibers comprises a polymer stable to ultraviolet radiation and the stability to the desired ultraviolet radiation can be achieved by selecting an inherently good polymer composition having good stability to ultraviolet radiation and / or by adding one or more stabilizers for ultraviolet radiation for the polymeric composition.

Numerous stabilizers to ultraviolet radiation are known in the art which can be added to the polymer composition of component A in order to achieve the desired ultraviolet radiation stability. Examples of such stabilizers include, but are not limited to the following 2-hydroxybenzophenones; 2-hydroxybenzotriazoles; hydroxybenzoates, metal chelate stabilizers; and light stabilizers of damaged amine. An example of the hydrobenzoate stabilizers is 2,4-di-t-butylphenyl ester and those described in U.S. Patent No. 3,206,431. The chelated metal stabilizers they are also known in the art and primarily include niguel complexes. Desirably, the stabilizers used in the present invention are light stabilizers of damaged amine which refer to a class of stabilizers which include a cyclic amine moiety that does not have hydrogen atoms adjacent to the nitrogen atom. Impaired amines are described in U.S. Patent No. 5,200,443 issued to Hudson and numerous examples of such amines are commercially available, examples including under the HOSTAVIN N30 brand of Hoechst Celanese Corporation; CYASORB UV-3346 from Cytec Industries of West Patterson, NJ; UVASIL-299 from Great Lakes Chemical Company of West Lafayette, Indiana, and UVINOL 4049 from BASF. Harmless amines particularly well suited for use in the present invention are commercially available under the trade name CHIMA ™ SORB 944 and CHIMASSORB 119 from Ciba-Geigy Corporation of Hawthorne, New York. Typically, ultraviolet radiation stabilizers are added to the polymeric composition prior to melt spinning, such as, for example, by incorporating the stabilizer into the polymer pellets used to produce the extrudate so that each of the components of The resulting conjugate fiber has the desired amounts of stabilizer against ultraviolet radiation. It should be noted that the damaged amine stabilizers having molecular weights above 1,000, desirably between about 1,000 and 5,000, typically provide improved stabilization compared to similar lower molecular weight stabilizers. Desirably, the amount of amine impaired within the polymer composition is between about 0.5% and about 3% by weight. However, the manner and amount of ultraviolet stabilizer added to the polymer compositions will naturally vary with the particular polymer formulation and the selected ultraviolet stabilizer.

Suitable materials for component A include, but are not limited to polyolefins, polyamides and polyesters. Desirably component A comprises the saturated polyolefins and mixtures thereof stabilized with hindered amine light stabilizers. Preferably polymers such as polyethylene, linear low density polyethylene, high density polyethylene, polypropylene and mixtures and / or copolymers thereof are used and incorporate light hindered amine stabilizers. A preferred embodiment of component A comprises polyethylene having about 1.25% by weight of CHIMASSORB ultraviolet stabilizer 119 of Ciba Geigy and about 1% by weight of gray pigment. CHIMASSORB 119 is a monomeric hindered amine stabilizer which has the following structural formula: (I) R-NH- (CH-) 3-N- (CH.) 2-N- (CH_) 3-NH-R where R is (CAS Registry No. 106990-43-6.) In addition, the pigments can also be added to the polymer composition of component A in order to improve the ultraviolet stability and / or improve the aesthetics of the resulting product. The choice of pigments can be selected for aesthetic and / or functional considerations. However, it will be appreciated that even simple organic pigments can have an adverse effect on ultraviolet stability. In this aspect it can be advantageous to use pigments which they also improve the ultraviolet stability such as for example the use of metal oxide pigments in conjunction with hindered amine stabilizers; see U.S. Patent No. 5,200,443 issued to Hudson and U.S. Patent Application No. 08 / 257,248 filed June 9, 1994, the entire contents of which are incorporated by reference. . In addition, other stabilization packages and / or methods for improving ultraviolet stability can be used in connection with the present invention; as additional examples, see United States of America patent application No. 08 / 673,606 filed on June 25, 1996 and application No. 08 / 562,722 filed on November 27, 1995, the complete contents of which are incorporated here for reference. In addition, the ultraviolet radiation stability of the first outer layer 12 can be further improved by applying a protective coating against the ultraviolet radiation on its exposed surface, see for example the United States of America Patent No. 4,818,600 and the world publication No. 96/25548 issued to DeLucia and others, whose full contents of the aforementioned references are incorporated herein by reference.

The component B of the multicomponent fibers can comprise a structural component and desirably has good tensile strength. In addition, it is important to notice Since the first outer layer 12 will often experience extended exposure to direct sunlight, the ultraviolet radiation will penetrate into the multicomponent fiber 20 and will impact the component B. Therefore, it can often be desirable for component B to comprise a stable polymer composition. in ultraviolet light. However, since component B is enveloped by component A the degree of ultraviolet radiation impacting component B is significantly reduced and it will typically be desirable for component A to comprise a material having superior ultraviolet radiation stability relative to that of component B. Due to the impact of diminished ultraviolet radiation on component B of conjugated fiber 20 it is believed that it is possible to use a wider range of polymeric materials and / or ultraviolet stabilizers in the weathertop fabric of the present invention while that good stability to ultraviolet radiation is achieved. further, due to the decreased functional coatings on component B a less expensive polymeric composition can be used such as for example, one using less ultraviolet stabilizer and / or a polymer with less inherent ultraviolet stability. Suitable materials for component B include polyolefins, polyamides, and polyesters which desirably include some amount of ultraviolet stabilizers. Optionally, the polymer composition of component B may also include pigments and / or other additives as desired. A preferred embodiment of Component B comprises polypropylene having about 1.25% by weight of CHIMASSORB 944 ultraviolet stabilizer from Ciba-Geigy.

Together the components A and B comprise multicomponent fiber 20. Although not shown, the multicomponent fiber 20 does not need to be limited to two components. In addition, the multicomponent fiber can comprise identical or similar polymers with varying amounts or types of ultraviolet stabilizer. The multicomponent fibers 20 preferably form the first outer layer 12 of the laminate 10. The first outer layer 12 may comprise a woven fabric or a non-woven fabric. Desirably the multicomponent fibers 20 comprise an integrated nonwoven fabric of fibers joined with continuous spinning. As indicated above, the yarn-bound fibers are not generally tacky when placed on a surface to form a fabric. It is usually necessary to impart additional integrity to the fabric by one or more means known in the art such as, for example, by knitting, air binding, HAK, hydroentangling, needle piercing or joining. of adhesive. Desirably, the integrity is imparted to the spunbonded fiber fabric by thermal point bonding as described in U.S. Patent No. 3,855,046 issued to Hansen et al., The entire contents of which are incorporated herein by reference. reference. In the reference to Figure 1, the point joints 18 create interfiber joints between the spunbonded fibers and impart integrity to the first outer layer 12. Desirably the first outer layer comprises a material having a basis weight of between about 1 and about 4 ounces per square yard (ounces per square yard), and, more desirably, between about 1.5 ounces per square yard to about 3.5 ounces per square yard. In a preferred embodiment of the present invention, the first outer layer 12 comprises a woven knitted fabric of 2.5 ounces per square yard of fibers joined by sheath spinning / core 50/50 d two layers of woven knitted fabric of 1.25 ounces per square yard of fibers joined with 50/50 sheath / core yarn. However, the first outer layer 12 may alternatively comprise a woven fabric, a knitted fabric, a spun and tied material, carded and bonded fabrics, needle punched material and / or a similar fabric.

Between the first outer layer 12 and the second outer layer 14 is placed the barrier layer 16 which comprises a water impermeable layer. Preferably the barrier layer 16 has a hydro head value in excess of about 30 mbar and more preferably at least about 80 mbar. Desirably the barrier layer 16 also has the ability to breathe, that is the barrier layer 16 allows the water vapor to pass or migrate through the same In this aspect the barrier layer 16 preferably has an MVTR of at least about 100 g / mV day and even more preferably of at least about 300 g / m Day or 800 g / m Day. Even though the extent of ultraviolet radiation is significantly reduced by overlaying the first outer layer 12 it is important to note that ultraviolet radiation will frequently penetrate the first outer layer 12 and impact the barrier layer 16. It will often therefore be desirable to adding stabilizers to ultraviolet light for and / or to select a material inherently stable to ultraviolet radiation for the barrier layer 16. In addition, heat stabilizers, pigments and other additives can similarly be added to the barrier layer 16 as desired. Numerous materials are available which may comprise the barrier layer 16 such as, for example, the films, the foams, the non-porous films, the microporous films and the microporous nonwoven materials. Most non-porous films act as a complete barrier to the passage of water and, therefore, they will create a non-breathable laminate. However, certain non-porous films, such as certain polyurethane films, act as a barrier to water in the liquid state and still allow the water vapor to migrate through it. In addition, many melt blowing fabrics having a basis weight of at least 0.3 ounces per square yard exhibit the desired barrier properties and still have the capacity to breathe due to the porous structure of fabrics blown with fusion. Desirably, such meltblown fabrics used in the present invention have a basis weight of between about 0.3 and about 1.5 ounces per square yard. Referring to Figure 3, the barrier layer 16 may comprise multiple layers 16a and 16b, such as two layers of meltblown fabrics.

The films which have been respirable, but which remain impermeable to the liquid by the formation of gaps or microporous openings dimensioned to allow the transmission of water vapor through them are similarly known in the art. Laminates 10 incorporating this latter type of breathable films are generally preferred. These films can be made vapor permeable by adding filler particles to the film composition and either roll up or stretch the film causing fractures to form where the filler particles are located. The amount of filler within the film and the degree of stretching and / or rolling is controlled to impart the desired degree of vapor permeability. The use of such films in connection with the present invention allows an outdoor fabric having an MVTR of about 10 g / m3 / 24 hours and still with a hydrostatic head of at least about 100 mbar. are typically formed from a movie of polyolefin such as polyethylene or polypropylene. Microporous liquid impervious films are discussed to a large extent as discussed in U.S. Pat. 4, 777, 073 granted to Shet and in the patent application of the States United of America No. 08/755, 664 filed on November 25, 1996 by McCormack; the patent application of the United States of America No. 08/882, 712 filed on June 25, 1997 by McCormack et al .; and the patent application of the United States of America filed on September 15, 1997, express mail No. RB879662575US, whose complete contents are incorporated to it by reference. Films and laminates with additional breathing capacity with the required barrier properties can also be used in connection with the present invention; see, for example, the patents of United States of America Nos. 3, 953, 566 and 4, 194, 041. A particularly desirable material for use in the present invention is a biaxially oriented linear low density polyethylene (LLDPE) film material which is from about 50% to about 70. % by weight of calcium carbonate and which is commercially available from Exxon Chemical Patents, Inc. , of Linden, New Jersey under the brand EXXAIRE. In a preferred embodiment, the barrier layer 16 comprises a microporous polyolefin film of a thickness of about 0.5 to about 2 mils and which also includes the ultraviolet stabilizers. For example, the layer barrier 16 may comprise a one-thousandth microporous microporous linear low density polyethylene (LLDPE) film having about 1.5% by weight of a CHIMASSORB 944 ultraviolet stabilizer from Ciba-Geigy which was presented with about 50% by CaCo weight, and stretched in both machine directions and transverse to the machine.

The outer fabric 10 may, optionally, include an additional layer whereby the liquid impermeable barrier 16 is positioned between the first outer layer 12 and the second outer layer 14. The second outer layer 14 preferably comprises a material which has good strength to abrasion and good resistance and which is able to be attached to the other layers. The second outer layer 14 may comprise a woven fabric, a knitted fabric, a material tied with yarn, carded and united tends, a needle punched material or a nonwoven fabric bonded with yarn with the desired strength and abrasion characteristics. With many applications of the fabric, such as a protective car cover, it is also desirable that the second outer layer be hydrophobic so as to prevent water from being held there. In this aspect it will be appreciated that most polyolefins are inherently hydrophobic. In addition, the ultraviolet radiation will also penetrate into the second outer layer, although considerably less than that experienced by the sheath component of the first outer layer 12. Therefore, depending on the material selected to comprise the second outer layer 14 it will often be desirable to add ultraviolet stabilizers thereto. In a preferred embodiment the second outer layer 14 may comprise a layer similar to the first outer layer 12. In one aspect, the second outer layer 14 may comprise a layer of sheath / core spunbonded fibers such as, for example, fibers sheath / core 50/50 continuous where the sheath component comprises polyethylene with 1.25% ultraviolet stabilizer CHIMASSORB 119 and 1% gray pigment and the core component nylon-6. Although nylon has a relatively poor degree of ultraviolet stability, due to the decreased levels of ultraviolet radiation impacting the second outer layer 14, it will often be necessary to include the ultraviolet stabilizer in the core component even when such materials are used. However, in a preferred embodiment about 1.25% by weight of the CHIMASSORB 944 ultraviolet stabilizer can be included in the nylon component. The second outer layer 14 desirably has a basis weight of about 0.75 to about 2.5, and more preferably from about 1.0 to about 2.0 ounces per square yard. In addition, heat stabilizers, pigments and other additives may also be included within the polymer formulas as desired.

The first outer layer 12, the barrier layer 16 and the second outer layer 14 collectively comprise the laminate 10. Although the present disclosure primarily discusses the use of three layers it will be appreciated by those skilled in the art that additional outer layers may be used. and / or additional interlayers in relation to the laminates discussed aguí. The additional layers can be used to increase the tensile strength, the peel strength, the barrier properties or other characteristics as desired. The multiple layers are laminated together to form a unique cohesive fabric. The adhesion between the multiple layers can be achieved by various means known in the art such as, for example, ultrasonic bonding, thermal bonding or adhesive bonding. However, thermal bonding or ultrasonic bonding are preferred since adhesives will often degrade or react with the components with exposure to extended ultraviolet radiation. In addition, where the collective basis weight of the individual layers exceeds 3.0 ounces per square yard, it will be more desirable to laminate the materials using the ultrasonic unit since at these higher base weights the thermal base joined laminates of higher base weights may experience delamination. due to the poor resistance to peeling. With reference to Figure 4, the bonding points 24 are created such as by the application of thermal or ultrasonic energy, by melting the polymer compositions having a melted point lower. Desirably the bonding is achieved by heating the regions of the laminate above the melting point of the materials comprising the sheath component of the fibers comprising the first outer layer 12 and the second outer layer 14. Depending on the composition of the barrier layer With the application of sufficient energy and pressure, the softening and / or melting of the composition of the polymer in the barrier material can also be achieved. In the particular embodiment of Figure 4, the stitches 24 comprise an ultrasonic knit pattern. Typically, the junction points themselves form non-breathing areas within the film. Therefore, when barrier layers with breathability are employed, it is preferred that the bonded area be less than about 50% of the surface area of the laminate and, more desirably, from about 5 to about 30% of the area. Of surface. An exemplary ultrasonic pattern is shown in Figure 6 which creates a bonded area of about 10-20%, preferably about 18%. However, numerous other patterns of marriage, such as those discussed above. The section of definitions in relation to the thermal point union can similarly be used with the present invention.

The laminate of the present invention allows the use of a wider array of materials while providing a laminate stable to ultraviolet radiation.

In addition, the present invention provides a cohesive material with excellent attributes, such as a desired combination of superior water barrier properties, good breathability and good resistance to high stress. By selecting the polymers in the respective sheath components and the film having similar or identical melting points, the thermal and / or ultrasonic bonding of the multiple layers will produce highly defined and improved bonded areas between both the sheath component of the layers exteriors and the barrier layer. For example, the sheath and barrier layer components can each comprise similar polymers such as, for example, various polyethylene compositions and / or blends having similar melting points. Furthermore, it is believed that the present invention provides improved lamination having a superior combination of ultraviolet radiation stability and resistance retention.

With reference to Figure 7, a process line 30 for making a laminate of the present invention is described. The hoppers 32a and 32b can be filled with the respective polymer components 33a and 33b. The polymeric components are then melted and extruded by the respective extruders 34a and 34b through the polymer conduits 36a and 36b and through the spinner 38. The spinning organs are well known to those skilled in the art and generally include a box containing a package of spinning which includes a plurality of plates stacked one on top of the other with a pattern of apertures arranged to create flow paths to direct the polymeric components as desired. As the extruded filaments extend below the spinner member 38, a stream of air from the cooling blower 40 cools the bicomponent filaments 42. The filaments 42 are pulled into a suction device or fiber pulling unit 44 and to the foraminous surface which is caused by 46 moves with the aid of vacuum 48, to form an unbonded layer of fibers joined with bicomponent yarn 50. The fiber layer of unbonded component 50 can be lightly compressed by compression rollers 52 and then joined thermal point by means of the roller-joiner assembly with pattern 54 thus creating the first layer 56 of the fibers joined with bicomponent yarn joined together. Those skilled in the art will appreciate that the spunbonded web can be pre-rolled and rolled onto a supply roll and fed into the process. The barrier fabric 58 and the second layer 60 of the bicomponent bonded spunbonded material can each be unwound from the respective supply rolls 59 and 61 and overlapped with the first layer 56 so that the barrier fabric 58 is placed between the two layers. two layers joined with yarn 56 and 60. The three layers 56, 58 and 60 can be fed through the pressure point 64 of the guide roller assembly 62. The multiple overlapped materials are then passed between a sonic horn 66 and the anvil with pattern 68 to join ultrasonically the material forming the cohesive laminate 60. Preferably the thicker layer, typically the first outer layer 12 faces the ultrasonic horn in order to provide more protection to the barrier layer 16. The laminate 70 can then be wound onto a roll reel (not shown) or, alternatively, it can be cut to the desired dimensions and / or directly incorporated into a product as desired.

The laminate of the present invention can be shaped and sized according to its intended application. For example, it is known in the art to provide protective covers which are specifically manufactured to fit comfortably around the article to be protected. In this aspect many protective covers for automobiles are designed specifically for certain cars, trucks or vans. In addition, it is also known in the art to provide a weatherare, such as protective fabrics, comprising more than one type of fabric to provide areas with different functional properties. In particular, it is known to provide a protective fabric with a breathable part and a non-breathing part. The non-respirable areas typically provide greater liquid barrier properties and are therefore designed to be placed on the top of the article when in place and the breathable sections designed to be placed in place. those areas less susceptible to runoff during heavy precipitation, such as the sides. Although such configurations can be used in connection with the present invention these are not required due to the excellent combination of breathability and liquid barrier properties provided by the present invention. t-pr-fii-ip? i test entog Hidroca-beza: This test measures the liquid barrier properties of a fabric. The hydro head test determines the height of water or amount of water pressure (in millibars) that the fabric will hold before the liquid passes through it. A cloth with a higher hydrohead reading indicates that it has a greater barrier to liquid penetration than a cloth with a lower hydro head. The hydro head can operate according to federal test standard 191A, method 551. The hydrohead data cited here was obtained using a test similar to the aforementioned federal test standard except as modified and indicated below. The hydro head was determined using a hydrostatic head tester available from Mario Enterprises, Inc., of Concord, North Carolina. The specimen was subjected to standardized water pressure, increased at a constant rate until the first sign of runoff appeared on the surface of the fabric in three separate areas (the runoff at the edge, the adjacent clamps are ignored). Non-sustained fabrics, such as a thin film, can be supported to prevent premature rupture of the specimen.

The water vapor transmission rate (WVTR) or the moisture vapor transmission rate (MVTR) for the sample materials was calculated according to the ASTM E96-80 standard. Circular samples measuring three inches in diameter were cut from each of the test materials and checked with a piece of CELGARD ™ 2500 film from Hoechst Celanese Corporation of Sommerville, New Jersey. The film CELGARD'U 2500 is a microporous polypropylene film. Three samples were prepared for each material. The test dish was a tray of Vapometer number 60-1 distributed by the Thwing-Albert Instrument Company of Philadelphia, Pennsylvania.

One hundred milliliters of water were poured into each Vapometer tray and individual samples of the test materials and control material were placed through the open top portions of the individual trays. The bolted flanges were tightened to form a seal along the edges of the tray, leaving the associated test material or control material exposed to the ambient atmosphere over a circle of 6.5 centimeters in diameter having an exposed area of approximately 33.17 square centimeters. The trays were placed in an oven of forced air at 100 degrees F (32 degrees Celsius) or for 1 hour to balance. The oven was a constant temperature oven with the external air circulating through it to prevent the accumulation of water vapor inside. A suitable forced air furnace is for example, a Blue M Power-0-Matic 60 furnace distributed by Blue M. Electric Company of Blue Island, Illinois. When the balance was complete, the trays were removed from the oven, weighed and immediately returned to the oven. After 24 hours, the trays were removed from the oven and weighed again. The preliminary water vapor transmission rate values were calculated with the equation (I) given below: (I) The water vapor transmission rate = (weight loss grams over 24 hours) x 315.5 g / m2 / 24 hours.

The relative humidity inside the oven was specifically controlled.

Under the predetermined set conditions of 100 degrees F (32 degrees Celsius) and ambient relative humidity, the water vapor transmission rate for the CELGARD ™ 2500 control has been defined as being 5000 grams per square meter per 24 hours. Therefore, the control sample was run for each test and the preliminary test values were corrected to establish the conditions using equation (II) given below: (II) Water vapor transmission rate = (WVTR test / WVTR control) x (5000 g / m2 / 24 hours).

Mullen break: This test measures the resistance of textile fabrics to breaking when subjected to hydraulic pressure. Break resistance was defined as the hydrostatic pressure required to break a fabric by deflecting it with a force, applied through a rubber diaphragm, at right angles to the plane of the fabric. This method measures the resistance to breakage of products up to 0.6 millimeters thick, having a breaking strength of between 200 pounds per square inch. The pressure is generated by forcing a liquid (glycerin) into a chamber at a rate of 95 ± 5 ml / min. The specimen, maintained between the annular clauses, is subjected to increasing pressure at a controlled rate until the specimen is broken. Break resistance is expressed in pounds. This procedure conforms to the official TAPPI standard T-403 os-76, except that the specimen size is 5 inches (12.6 centimeters) square and ten specimens were tested. The test equipment used is a Mullen breakthrough resistance tester driven by B. G. Perkins & Son Inc., by G.P.O. 366, Chicopee, MA 01021 or Testing Machines Inc., 400 Bayview Ave., Amityville, New York 11701. The sample must be conditioned to ASTM conditions of 65 ± 2 percent relative humidity and 72 ± 2 degrees F (22 ± 1 degree Celsius), or TAPPI conditions of 50 ± 2 percent relative union and 72 ± 1.8 degrees F before the test.

Stress Test to Grips Stress test to gripping is a measurement of a resistance to the breaking and lengthening or tension of a fabric when it is subjected to a unidirectional tension. This test is known in the art and conforms to the specifications of the 5100 method of the federal test method standard 191A. The results are expressed in pounds or grams at break and percent stretch before breaking. The upper numbers indicate a more stretchable and stronger fabric. The term "load" means the load or maximum force expressed in units of weight, required for the breaking or breaking of the specimen in a stress test. The term "total energy" means the total energy under a load against the elongation curve as expressed in units of weight-length. The term (elongation) means the increase in length of a specimen during a stress test. The grip tension test uses two clamps, each having jaws with each jaw having a face in contact with the sample. The clamps hold the material in the same plane, usually vertically, separately by 3 inches (76 millimeters) and move and separate at a specified rate of extension. The grip strength and grip elongation resistance values are obtained by using a sample size of 4 inches (102 millimeters) by 6 inches (152 millimeters) with a slab face size of 1 inch (25 millimeters) per 1 inch, and a constant rate of extension of 300 m / minute. The sample is wider than the handle jaws to give representative results of effective resistance of the fibers in the grasped width combined with the additional strength contributed by the adjacent fibers in the fabric. The specimen is grasped in, for example, a Sintech 2 tester, available from Sintech Corporation, 1001 Sheldon Drive, Cary, North Carolina 27513, an Instron ™ model, available from Instron Corporation of 2500 Washington Street, Canton, MA 02021 , a Thwing-Albert INTELLECT II model available from the Thwing-Albert Instrument Company, 10960 Dutton Road, Philadelphia, Pennsylvania 19154. This closely simulates fabric tension conditions in actual use. The results are reported on an average of multiple specimens and can be carried out with the specimen in the transverse direction (CD) or the machine direction (MD).

Tension, Strip The tensile strip test is similar to the grip tension and measures the peak and breaking loads and the elongation of peak percentage and breaking of a fabric. This test measures the load (resistance) in grams and elongation in percent. In the strip tensile test, two handles, each having two jaws with each jaw having a face in contact with the sample, hold the material in the same plane, usually vertically, separated by 3 inches and move and they separate at a specified rate of extension. The values for strip tension strength and strip elongation were obtained using a sample size of 3 inches by 6 inches, with a jaw face size of 1 inch in height by 3 inches in width, and a constant rate extension of 300 mm / min. The Sintech 2 tester, available from Sintech Corporation, 1001 Sheldon Drive, Cary, North Carolina 27513, the Instron TM model, available from Instron Corporation of 2500 Washington Street, Canton, MA 02021, or a Thwing-Albert INTELLECT II model available from the Thwing-Albert Instrument Company, 10960 Dutton Road, Philadelphia, Pennsylvania 19154 may be used for this test. The results are reported on an average of multiple specimens and can be carried out with the specimen in the transverse direction (CD) or the machine direction (MD).

Pr-test of Torn Traps Torn test "trap" or trapezoid is a tension test applicable to both woven and non-woven fabrics. The full width of the specimen is grasped between the handles, so the test measures primarily the joint or interlock and the strength of the specimens. individual fibers directly in the stress load, rather than the strength of the composite structure of the fabric as a whole. The procedure is useful for estimating the relative ease of tearing a fabric. This is particularly useful in determining any appreciable difference in strength between the machine and the transverse direction of the fabric. When performing the trap tear test, an outer line of a trapezoid is drawn on a 3-by-6-inch (75 by 152-millimeter) specimen with the longest dimension in the direction being tested, and the specimen is cuts in the shape of the trapezoid. The trapezoid has a side of 4 inches (102 millimeters) and a side of 1 inch (25 millimeters) which are parallel and which are separated by 3 inches (76 millimeters). A small preliminary cut of 5/8 inches (15 millimeters) is made in the middle of the shorter of the parallel sides. The specimen is grasped in, for example, an INSTRON model TM available from Instron Corporation of 2500 Washington Street, Canton, MA 02021, or a Thwing-Albert model INTELLECT II available, from the Thwing-Albert Instrument Company, 10960 Dutton Road, Philadelphia , Pennsylvania 19154, which has parallel clamps 3 inches long (76 millimeters). The specimen is grasped along the non-parallel sides of the trapezoid so that the fabric on the longer side is loose and the fabric along the short side is tight and cut in half between the handles. A continuous load was applied on the specimen so that the tearing was propagates through the specimen width. It should be noted that the longest direction is the direction that is being tested even when the tear is perpendicular to the length of the specimen. The force required to completely tear the specimen was recorded in pounds with the higher numbers indicating greater resistance to tearing. The test method used conforms to the standard test ASTM D1117-14 except that the tear load is calculated as the average of the highest and highest peaks recorded rather than the lowest and highest peaks. Multiple specimens for each sample must be tested.

Test of South Florida: This test was conducted by exposing the fabric to the sun without backing in Miami Florida, the samples are facing south at a 45 degree angle. Each cycle concludes with a modified stress test in pounds to measure the degradation or change in fabric strength. This provides a measure of the durability of the fabric.

Example 1 A first non-woven fabric of fibers bonded with continuous 50/50 sheath / core yarn was made having a linear low density polyethylene sheath component (Dow 6811 an LLDPE) containing 1.25 percent hindered amine light light stabilizer (CHIMASSORB 119 of Ciba-Geigy) and 1 percent of gray pigment. The pigment comprised titanium dioxide (DuPont R960), Quinacridone Magenta (Sun Chemical 448-0010) blue / red phthalo (Sun Chemical 448-0748), and carbon black (Cabot Regal 660). The core component of the fiber comprised polypropylene (Exxon 3445) containing about 1.25 light hindered amine stabilizer (CHIMASSORB 944 from Ciba-Geigy). The spunbonded fiber fabric was then patterned with a wire weave pattern to form an integrated nonwoven fabric of bicomponent fibers having a basis weight of about 2.5 ounces per square yard. A second woven fabric of bonded fibers with continuous 50/50 sheath / core yarn was made having a linear low density polyethylene sheath component (Dow 6811 a LLDPE) containing 1.25 percent light hindered amine stabilizer (CHIMASSORB 119 from Ciba-Geigy) and 1 percent gray pigment. The core component of the fiber comprised nildn 6 (Nyltech 2169) containing about 1.25 percent of light amine stabilizer impaired (CHIMASSORB 944 from Ciba-Geigy). The spunbond fabric was then patterned with a wire weave pattern to form an integrated nonwoven fabric of bicomponent fibers having a basis weight of about 1.2 ounces per square yard. A barrier layer was superimposed between the first and second nonwoven sheets and ultrasonically bonded with the pattern shown in Figure 6. The barrier layer comprised a microporous linear low density polyethylene film.

(LLDPE) having about 1.5 percent by weight of CHIMASSORB 944 UV stabilizer from Ciba-Geigy and which was filled with about 50 percent by weight CaC03 and stretched in both the directions of the machine and transverse to the machine. The resulting laminate comprised a 4.6-ounce fabric per square yard with the following properties: 0.04-inch volume; Hydrohead > 200 mbar; Water vapor transmission rate 3465; breaking Mullen 93 pounds per square inch; Machine direction tension (MD) 114 pounds; cross machine direction (CD) 81 pounds; trap in the machine direction 46 pounds; trap in the transverse direction 26 pounds.

Although the invention has been described in detail with respect to the various embodiments thereof, it will be apparent to those skilled in the art that various alterations, modifications and other changes may be made without departing from the spirit and scope of the present invention. Therefore, it is attempted that all such modifications, alterations and other changes are encompassed by the claims.

Claims (24)

R E I V I N D I C A C I O N S

1. A laminate of fabric for the weather that includes: a first layer of multicomponent fibers having a sheath / core configuration, said sheath component comprising a polyethylene polymer composition and said core component comprising a polypropylene polymer composition; a barrier layer impermeable to water; Y a second layer of multicomponent fibers comprising a first polyethylene component and a second polyamide component and wherein said water impermeable barrier layer is positioned between said first and second multicomponent fiber layers.

2. The fabric for weathering, as claimed in clause 1, characterized in that said first multi-component fiber layer has a sheath / core configuration wherein the proportion of the sheath component to the core component is between 75/25 and 25/75, by volume.

3. The fabric for weathering, as claimed in clause 1, characterized in that said multicomponent fibers have a sheath / core configuration in which the proportion of the pod component to the core component is about 50/50 by volume .

4. The fabric for weathering, as claimed in clause 2, characterized in that the sheath component of said first multi-component fiber layer comprises a polyethylene polymer and a hindered amine stabilizer.

5. The fabric for weathering, as claimed in clause 4, characterized by said second layer of multicomponent fibers having a sheath / core configuration.

6. The fabric for weathering, as claimed in clause 5, characterized by said sheath component of said second layer of multicomponent fibers comprises nylon.

7. The fabric for weathering, as claimed in clause 1, characterized in that said laminate has a pattern of knit joints and a hydro head of at least 80 mbar.

8. The fabric for weathering, as claimed in clause 6, characterized in that said polyethylene polymer composition of said second multicomponent fibers comprises a polyethylene polymer and a hindered amine.

9. The fabric for weathering, as claimed in clause 1, characterized in that it comprises a third layer of multicomponent fibers wherein said first and third layers are placed side by side.

10. The fabric for weathering, as claimed in clause 9, characterized in that said third layer of multicomponent fibers comprises sheath / core fibers wherein said sheath component comprises a polyethylene polymer composition.

11. The fabric for weathering, as claimed in clause 1, characterized in that said barrier layer comprises a polyolefin meltblown fabric having a basis weight of at least 0.3 ounces per square yard.

12. The fabric for weathering, as claimed in clause 1, characterized in that said barrier layer comprises a film capable of breathing.

13. The fabric for weathering, as claimed in clause 12, characterized in that said breathable film comprises a microporous polyolefin film.

14. The fabric for weathering, as claimed in clause 13, characterized in that said breathable film comprises a micropores polyethylene film.

15. The fabric for weathering, as claimed in clause 12, characterized in that said microporous polyolefin film comprises a multilayer film having an outer polyethylene layer.

16. The fabric for weathering, as claimed in clause 14, characterized in that said microporous film comprises a film filled with multiple layers.

17. The fabric for weathering, as claimed in clause 12, characterized in that said breathable film comprises a microporous film comprising at least about 35% by weight of filler particles and a polyethylene polymer composition. and also where said laminate is knitted.

18. The fabric for weathering, as claimed in clause 17, characterized in that the polyethylene polymer composition of said breathable film comprises a polyethylene polymer and between about 0.5 and about 3.0% by weight of a hindered amine stabilizer.

19. The fabric for weathering, as claimed in clause 13, characterized in that said first layer of multicomponent fibers has a heavier basis weight than said second layer of multicomponent fibers.

20. The fabric for weathering, as claimed in clause 9, characterized in that said layers of first and third multi-component fibers have a combined basis weight heavier than the basis weight of said second layer of multicomponent fibers.

21. The fabric for weathering, as claimed in clause 4, characterized in that said hindered amine stabilizer comprises 0.5 to about 3.0% by weight of said composition of polyethylene polymer and has a formula: R R I I (I) R- H- (CH _), - N- (CH _) _- N- (CH 2), - N? -R where R is

22. The fabric for weathering, as claimed in clause 1, characterized in that said laminate is ultrasonically joined.

23. The fabric for weathering, as claimed in clause 9, characterized in that said laminate is ultrasonically joined.

24. The fabric for weathering, as claimed in clause 17, characterized by said laminate is ultrasonically bonded. SUMMARY A weatherproofing fabric having (i) an outer nonwoven fabric stable to ultraviolet radiation of multi-component sheath / core fibers having a sheath component of polyethylene polymer and a core component of polypropylene polymer is disclosed. (ii) a breathable barrier layer, such as a microporous film or meltblown fabric; and (iii) an inner non-woven fabric of multicomponent fibers comprising a polyethylene polymer component and a nylon component.