US20140137307A1

US20140137307A1 - Method for Manufacturing a Waterproof and Breathable Article of Clothing

Info

Publication number: US20140137307A1
Application number: US14/085,896
Authority: US
Inventors: Sylvain Borreau; Mimoun Aamer; Serge Piranda
Original assignee: Decathlon SE
Current assignee: Decathlon SE
Priority date: 2012-11-21
Filing date: 2013-11-21
Publication date: 2014-05-22
Also published as: FR2998142A1; FR2998142B1; CN103829412A; HK1198111A1; RU2013151153A; EP2735240A1

Abstract

The invention relates to a method for manufacturing a waterproof and breathable article of clothing 1 comprising an envelope 2 that has inner 3 and outer 4 surfaces, the method involving: at least one step of coating (100), during which the inner surface 3 is outward-facing, comprising coating the outward-facing inner surface with a solution 6 with a base of at least one polymer, with air A under pressure being injected into the envelope during the coating, then drying the envelope in order to form a first layer 10 of waterproof and breathable polymer on the inner surface; and at least one step of impregnation (200), during which the inner surface 3 is inward-facing, comprising pouring into the envelope a solution 11 with a base of at least one polymer, removing the excess solution 11, injecting air A under pressure into the envelope, and drying the envelope in order to form a second layer 15 of waterproof and breathable polymer on the first layer 10.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims priority under 35 USC 119 and/or 365 of French Patent Application No. FR-12 61097 filed on Nov. 21, 2012 with the French Institut National de la Propriété Industrielle (INPI). The contents of the above-identified Application are relied upon and incorporated herein in their entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The invention relates to a method for manufacturing a waterproof and breathable article of clothing, as well as such an article obtained by implementing such a method.
It applies especially to sports articles intended for use in difficult climatic conditions due to the cold and/or inclement weather, such as for example gloves, shoes, insulated slippers, bonnets or hoods.
2. Description of the Related Art
During the practice of sports, the body gives off perspiration, in particular in the form of water vapour. However, wearing unsuitable articles of clothing, for example conventional waterproof articles intended to protect against the cold and/or inclement weather, can be uncomfortable, in that these articles do not allow the water vapour to be removed towards the exterior.
In order to overcome these disadvantages, waterproof and breathable articles of clothing are known which are arranged to prevent the humidity coming from the exterior from penetrating inside said articles while allowing the water vapour generated by the body of the wearer to be removed to the outside.
To do so, waterproof and breathable articles are known comprising an outer envelope generally at least water-repellent, an inner lining having thermal insulation properties, as well as a waterproof and breathable insert arranged between said envelope and said lining. The insert comprises in particular an impermeable membrane but which allows the water vapour to pass in order to confer the expected breathability, for example by being microporous or hydrophilic.
However, these articles do not provide entire satisfaction, in that their manufacture is long and expensive. Moreover, when used during high humidity conditions, the water coming from the exterior can pass through the envelope via its seam holes, the impermeability of which is generally lacking, then be stopped by the insert, in such a way that said water is retained between said envelope and said insert while waiting to be removed by evaporation. However, this water, by being retained as such in the article of clothing, can over time generate a sensation of cold and/or humidity for the wearer, thus rendering the wearing of said article unpleasant for said wearer.
Furthermore, the presence of water in the vicinity of the insert compromises the removal of the water vapour generated by the body of the wearer, in such a way that said water vapour remains inside the article of clothing and is condensed, which also constitutes discomfort for the wearer.
In addition, when the wearer is exposed to wind, the water retained between the envelope and the insert evaporates slowly, which also generates a sensation of cold for the wearer. Moreover, the drying time of the article of clothing is very greatly increased, which renders its use less pleasant after a first use in high humidity conditions.

BRIEF SUMMARY OF THE INVENTION

The invention aims to improve prior art by proposing a method for manufacturing an article of clothing wherein a waterproof and breathable barrier is formed directly on the inner surface of the envelope of said article, which makes it possible to prevent water weight gain of said article when it is used in a wet environment while improving its quality and its lifespan.
For this purpose, according to a first aspect, the invention relates to a method for manufacturing a waterproof and breathable article of clothing, said article comprising an envelope that has an inner surface intended to be worn in the vicinity of a portion of the body of a wearer and an outer surface opposite said inner surface, said method providing for:

- at least one step of coating (100), during which said envelope is turned over in such a way that its inner surface is outward-facing, said step providing for coating said inner surface with a solution with a base of at least one waterproof and breathable polymer, with air under pressure being injected into said envelope during said coating, then for drying said envelope in order to form a first layer of waterproof and breathable polymer on said inner surface; and
- at least one step of impregnation (200), during which said envelope is turned over in such a way that its inner surface covered with the first layer of polymer is inward-facing, said step providing for pouring into said envelope a solution with a base of at least one waterproof and breathable polymer, for removing the excess solution from said envelope, for injecting air under pressure into said envelope, then for drying said envelope in order to form a second layer of waterproof and breathable polymer on the first layer.

According to a second aspect, the invention relates to a waterproof and breathable article of clothing obtained by implementing such a method.
Other particularities and advantages of the invention shall appear in the following description, made in reference to the annexed figures diagrammatically showing the steps of a method according to an embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart depicting a method in accordance with the invention.

FIG. 2 is a more detailed flowchart in accordance with the invention shown in FIG. 1.

FIG. 3 is a more detailed flowchart in accordance with the invention shown in FIG. 1.

FIG. 4A and FIG. 4B depict a side view and cutaway view respectively of an exemplary article of clothing prepared for the coating process of the method shown in FIG. 1.

FIG. 5A and FIG. 5B depict an exemplary article of clothing being coated by the method shown in FIG. 1.

FIG. 6A and FIG. 6B depict a side view and cutaway view respectively of an exemplary article of clothing after the coating process of the method shown in FIG. 1.

FIG. 7A and FIG. 7B depict a side view and cutaway view respectively of an exemplary article of clothing turned for the impregnating process of the method shown in FIG. 1.

FIG. 8A depicts the addition and removal of the solution for the impregnating process of the method shown in FIG. 1.

FIG. 8B depicts the injection of air during the impregnating process of the method shown in FIG. 1.

FIG. 9A and FIG. 9B depict a side view and cutaway view respectively of an exemplary article of clothing prepared by the method shown in FIG. 1.

FIG. 10A and FIG. 10B depict a side view and cutaway view respectively of an exemplary lined article of clothing prepared by the method shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

In relation with the figures, a method for manufacturing a waterproof and breathable article of clothing 1 is described, said article of clothing comprising an envelope 2 which has an inner surface 3 intended to be worn in the vicinity of a portion of the body of a wearer and an outer surface 4 opposite said inner surface. As shown in FIG. 1, the method comprises providing an article of clothing (50), turning the envelope over in such a way that the inner surface is facing outwards (60), coating the outward-facing inner surface with polymer (100), turning the envelope over in such a way that the inner surface is facing inwards (150), and impregnating the inner surface with polymer (200).
In the embodiment shown, the article of clothing 1 is a glove of the mitten type, with a compartment for the thumb and a shared compartment for the other fingers. In other embodiments, the article of clothing 1 is for example a glove of another type, a shoe, a slipper, a bonnet or a hood.
The method provides for forming a waterproof and breathable barrier 5 directly on the inner surface 3 of the envelope 2, which makes it possible to simply, inexpensively and in a manner that is easy to automate manufacture articles of clothing 1 with complex and varied shapes such as those described hereinabove. As such, the method offers a wide range of choices as for the aesthetics of the articles of clothing 1 to be manufactured.
To do so, the method provides at least one step of coating (100), during which the envelope 2 is turned over in such a way that its inner surface 3 is outward-facing (60), said step providing for coating said inner surface with a first solution 6 with a base of at least one waterproof and breathable polymer.
In some embodiments, the step of coating (100) provides for using a first solution 6 comprising a hydrophilic polymer, in particular with a polyurethane base, as much as polyurethane is recognised for its satisfactory properties as a barrier to liquid water and for transferring the water vapour in order to confer the expected breathability. In some embodiments, the polymer is used in aqueous phase, which makes it possible to use a first solution 6 devoid of non-aqueous solvent.
Moreover, as shown in FIG. 2, FIG. 5A and FIG. 5B, the outward-facing inner surface is coated with first solution 6 while injecting air into the envelope (110). Air A under pressure is injected into the envelope 2 during the coating in order to shape it via inflating, which makes it possible to coat its inner surface 3 homogeneously and, in the case where said envelope is assembled by stitching, to prevent the polymer from penetrating inside the envelope 2 through the seams. Furthermore, the pressure of the air A is sufficient to provide for the shaping of the envelope 2 so that the coating perfectly hugs the three-dimensional shape of the envelope 2.
To do so, the envelope 2 is placed, after having been turned over, on a base 7 with a shape that is adapted to that of the opening of said envelope, said base being connected to a device 8 for injecting air. The device 8 is arranged to inject air A under pressure into said envelope by the intermediary of said base.
As shown in FIG. 3, in one embodiment, the step of coating (100) provides for coating the inner surface 3 by immersing the envelope 2 in a bath 9 containing the first solution 6 while injecting air into the envelope (112). In some embodiments, according to the type of the article of clothing 1 and the desired performances for said article in terms of impermeability and breathability, the temperature of the bath 9, the immersion time of the envelope 2 in said bath and/or the concentration of polymer in the solution 6 are varied.
In another embodiment, shown in FIG. 3, the step of coating (100) provides for coating the inner surface 3 by spraying the polymer solution 6 onto said inner surface 3 while injecting air into the envelope (114), with the spraying time then being chosen according to the type of the article of clothing 1 and the desired performances.
The step of coating (100) then provides for drying the envelope 2 in order to form a first layer 10 of waterproof and breathable polymer on its outward-facing inner surface 3 (120). In one embodiment, the envelope 2 is placed in an oven, in order to form the layer 10 by cross-linking of the polymer.
In one embodiment, the step of coating (100) provides for injecting air under pressure into the envelope 2 while it is being dried, with the pressure of the air being sufficient to guarantee the shaping of said envelope, which makes it possible to dry said envelope homogeneously. As such, as the layer 10 is dried on the shaped envelope 2, a perfect geometrical concordance is guaranteed between said layer and said envelope in order to render the entire inner surface 3 waterproof and breathable.
In some embodiments, in order to further improve the homogeneity of the layer 10, the envelope 2 is subjected, after coating and before drying, to a preliminary light drying, for example by using a fan, in order to remove the bubbles that may have formed on the inner surface 3.
As such, after drying of the envelope 2, the inner surface 3 is fully covered with a thin waterproof and breathable layer 10, as shown in FIG. 6B. Furthermore, the layer 10 is formed by cross-linking of the polymer, which allows said layer to be joined with the envelope 2.
As shown in FIG. 2, according to the desired performances for the article of clothing, in some embodiments the method provides for repeating the steps of coating and drying (130) at least two times, which makes it possible to vary the thickness of the first layer 10 by superimposition of several sublayers. In some embodiments, the step of coating (100) provides in particular for using first solutions 6 of different compositions at each iteration. In some embodiments, the step of drying is omitted or shortened between repetitions to provide an incompletely dry or cured sublayer, permitting better cohesion of the next application of the first solution.
If the envelope 2 is formed by stitching, and in particular by assembling several parts by stitching, the repetition of the step of coating (130) makes it possible to guarantee a good coverage of the holes formed by said seams, and therefore a good impermeability of the final article of clothing.
The method then provides at least one step of impregnation (200), during which the envelope 2 is turned over in such a way that the inner surface 3 covered with the first layer 10 of polymer is inward-facing (150), as shown in FIG. 7B. This step of impregnation (200) provides for pouring into the envelope 2 a solution 11 with a base of at least one waterproof and breathable polymer (210).
To do so, as shown in FIG. 8A, in some embodiments the turned envelope 2, inner surface 3 arranged facing inwards, is arranged on a base 7 with a shape adapted to that of the opening of said envelope, said base being connected to a device 12 for injecting liquid supplied by a tank 13 containing the second polymer solution 11.
Like the step of coating (100), in some embodiments, the step of impregnation (200) uses, for the same reasons as said step of coating, a second solution 11 comprising a hydrophilic polymer, in particular with a polyurethane base. In some embodiments, the polymer is used in aqueous phase, which makes it possible to use a second solution 11 devoid of non-aqueous solvent. In some embodiments, the composition of the first solution 6 is the same as the composition of the second solution 11, which reduces manufacturing costs and complexity. In other embodiments, the composition of the second solution 11 is different from that of the first solution 6, allowing the selection of advantageously higher or lower viscosity solutions to ensure impregnation without penetrating through the envelope, or for the selection of desired surface properties on the finished product.
Once the first layer 10 of polymer has been covered by the second solution 11, the step of impregnation (200) provides for removing the excess solution 11 from the envelope 2 (220) and for injecting air A under pressure into said envelope (230), in order to force said solution to penetrate into the seams and into any pores or voids in the first layer 10 in order to guarantee a perfect sealing of the seams and the inner surface.
To apply the second solution 11, in some embodiments the base 7 is connected to a device 14 for pumping arranged to pump the second solution 11 into the envelope 2 and to return the excess solution 11 into a tank, for example the same tank 13 as that used previously, as shown in FIG. 8A. Then, the base 7 is connected to a device 8 for injecting air arranged to inject air A under pressure into the envelope 2 by the intermediary of said base as shown FIG. 8B.
According to the type of the article of clothing 1 and the desired performances for said article in terms of impermeability and breathability, the temperature of the solution 11, the impregnation time, and/or the concentration in polymer of the solution 11 can in particular be varied.
In some embodiments, in order to improve the aesthetics of the article of clothing 1, the envelope 2 is subjected, after the injection of air A under pressure, to a suitable rinsing in order to remove the excess solution 11 of polymer that may have bled onto the outer surface 4 of said envelope during said injection of air.
The step of impregnation (200) then provides for drying the envelope 2 in order to form a second layer 15 of waterproof and breathable polymer on the first layer 10 (240). In some embodiments, the envelope 2 is placed in an oven, in order to form the second layer 15 by cross-linking of the polymer.
In some embodiments, the step of impregnation (200) also provides for injecting air under pressure into the envelope 2 while it is being dried, with the pressure of the air being sufficient to guarantee the shaping of said envelope, which makes it possible to dry said envelope homogeneously, including in the seams.
As such, after the drying of the envelope 2, the first layer 10 is covered with a second layer 15 of polymer that is thin, waterproof and breathable, as shown in FIG. 9B. Advantageously, the polymer of the second layer 15 is chosen for its chemical affinity with the polymer of the first layer 10 or, if said first layer comprises a superimposition of sublayers made of different polymers, with the polymer of the last of said sublayers, which allows said second layer to be joined with said first layer, in order to form a waterproof and breathable barrier 5. For example, in some embodiments, the first solution 6 and second solution 11 used by the steps of coating (100) and of impregnation (200) are identical, which makes it possible to benefit from a maximum chemical affinity.
In particular, if the envelope 2 is formed by stitching, and in particular by assembling several parts by stitching, the step of impregnation (200) makes it possible to seal the last seam holes or any pores or voids that were not covered after the step of coating (100), and as such to provide for optimum and reliable impermeability.
According to the desired performances for the article of clothing 1, in some embodiments, the method provides for repeating the step of impregnation (200) at least two times (250), which makes it possible to vary the thickness of the second layer 15 by superimposition of several sublayers. In some embodiments, the step of impregnation (200) also provides for using solutions 11 of different compositions at each iteration, for example to select desired surface properties for the outermost sublayer while maintaining adequate cohesion of the inner sublayers to each other and to first layer 10.
The combination of the two steps of coating (100) and of impregnation (200) makes it possible to confer to the article of clothing 1 a perfect global impermeability, in particular on the seams, while making it possible to retain good grasping, good sensations in terms of touch, and good breathability.
In some embodiments, a lining 16 is arranged in the envelope 2 in order to cover the inner surface 3 (225) as shown in FIG. 10B. In particular, in some embodiments the step of impregnation (200) provides for arranging the lining in the envelope 2 before it is dried, in order to fix said lining 16 to said envelope during said drying by the intermediary of the second layer 15 of polymer. In particular, if the step of impregnation (200) is repeated several times, the lining is arranged in the envelope 2 during the last iteration.
In some embodiments, in particular for sports articles intended to be used during difficult climatic conditions, the lining 16 includes at least one layer of material that has thermal insulation properties, for example with a base of cotton, foam or polar fleece.
In some embodiments, air under pressure is injected into the lining 16 before the second layer of polymer is fully dried or cured, in order to allow said lining 16 to be in close contact with the inner surface 3 of the envelope 2. To do so, the lining is arranged in the envelope 2 after it is impregnated (225), then the lining—envelope 2 unit is arranged on the base 7 connected to the device 8 for injecting air and air pressure is injected (227), with the whole then being placed in an oven for drying (245).
As such, during the drying, the second layer 15 is formed by cross-linking of the polymer and makes it possible, thanks to said cross-linking, to reliably fix the lining to the envelope 2.

Claims

We claim:

1. A method for manufacturing a waterproof and breathable article of clothing comprising the steps of:

providing an article of clothing (1), said article comprising an envelope (2) that has an inner surface (3) intended to be worn in the vicinity of a portion of the body of a wearer and an outer surface (4) opposite said inner surface;

turning the envelope over in such a way that its inner surface (3) is outward-facing;

coating (100) the article, wherein the step of coating the article comprises the steps of:

coating said inner surface with a first solution (6) comprising at least one waterproof and breathable polymer, with air (A) under pressure being injected into said envelope during said coating; and

drying said envelope in order to form a first layer (10) of waterproof and breathable polymer on said inner surface;

turning the envelope over in such a way that its inner surface (3) covered with the first layer (10) of polymer is inward-facing; and

impregnating (200) the article, wherein the step of impregnating the article comprises the steps of:

pouring into said envelope a second solution (11) comprising at least one waterproof and breathable polymer;

removing the excess second solution (11) from said envelope;

injecting air (A) under pressure into said envelope; and

drying said envelope in order to form a second layer (15) of waterproof and breathable polymer on the first layer (10).

2. The method according to claim 1, wherein the first solution (6) and/or the second solution (11) comprises a hydrophilic polymer with a polyurethane base.

3. A method according to claim 1, wherein the step of coating the article (100) and/or the step of impregnating the article (200) is repeated at least two times.

4. A method according to claim 3, wherein the step of coating said inner surface with a first solution (6) utilizes first solutions (6) of different compositions at each repetition, and/or the step of pouring into said envelope (11) utilizes second solutions (11) of different compositions at each repetition.

5. A method according to claim 1, wherein the step of coating the inner surface (3) further comprises the step of immersing the envelope (2) in a bath (9) containing the solution (6) of polymer.

6. A method according to claim 1, wherein the step of coating the inner surface (3) further comprises the step of spraying the solution (6) of polymer on said inner surface.

7. A method according to claim 1, wherein the step of drying the envelope to form a first layer (10) and/or the step of drying the envelope to form a second layer (15) further comprises injecting air under pressure into the envelope (2) while it is being dried.

8. A method according to any of claims 1, further comprising the step of arranging a lining in the envelope (2) after the excess second solution (11) is removed and before drying said envelope, in order to fix said lining to said envelope during said drying by the intermediary of the second layer (15) of polymer.

9. A method according to claim 8, further comprising the step of injecting air under pressure into the lining.

10. A method according to claim 8 wherein the lining comprises at least one layer of material that has thermal insulation properties.

11. A waterproof and breathable article of clothing obtained by implementing the method of claim 1.

12. A method for manufacturing a waterproof and breathable article of clothing comprising the steps of:

providing an article of clothing comprising an envelope having an inner surface and an outer surface;

coating said inner surface with a first solution while pressure is applied to said outer surface; and

impregnating said inner surface with a second solution while pressure is applied to said inner surface.

13. The method of claim 12, wherein the step of coating said inner surface with a first solution further comprises the steps of:

turning the article of clothing such that said inner surface is outward-facing; and

applying said first solution to said inner surface while applying air pressure to said outer surface.

14. The method of claim 12, wherein the step of impregnating said inner surface with a second solution further comprises the steps of;

turning the article of clothing such that said inner surface is inward-facing;

applying said second solution to said inner surface; and

applying air pressure to said inner surface after said second solution is applied.

15. The method of claim 13 wherein the step of applying said first solution further comprises the step of immersing said article of clothing at least partially into said first solution.

16. The method of claim 13 wherein the step of applying said first solution further comprises the step of spraying said first solution onto at least a portion of said article of clothing.

17. The method of claim 14 further comprising the steps of arranging a liner to the inner surface after said second solution is applied and pressing said liner against said inner surface.

18. A method for manufacturing a waterproof and breathable article of clothing comprising the steps of:

turning the article of clothing such that said inner surface is outward-facing;

coating said inner surface with a first solution comprising at least one waterproof and breathable polymer while applying air under pressure to the outer surface to form a layer on said inner surface;

turning the article of clothing such that said inner surface is inward-facing; and

impregnating said inner surface with a second solution.

19. The method of claim 18, wherein the step of impregnating said inner surface with a second solution further comprises the steps of:

applying said second solution to said layer on said inner surface, wherein said second solution comprises at least one waterproof and breathable polymer; and

applying air pressure to said inner surface to force said second solution into any pores and voids in said layer; and

20. The method of claim 18, further comprising the steps of:

arranging a liner to the inner surface after impregnating said inner surface with said second solution; and

pressing said liner against the second solution before the second solution is fully dried or cured to fix the liner to the inner surface.