WO2014087161A1 - Perfectionnements apportés et se rapportant à des tissus - Google Patents

Perfectionnements apportés et se rapportant à des tissus Download PDF

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Publication number
WO2014087161A1
WO2014087161A1 PCT/GB2013/053207 GB2013053207W WO2014087161A1 WO 2014087161 A1 WO2014087161 A1 WO 2014087161A1 GB 2013053207 W GB2013053207 W GB 2013053207W WO 2014087161 A1 WO2014087161 A1 WO 2014087161A1
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WIPO (PCT)
Prior art keywords
layer
fabric
fibres
porosity
fabric according
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Application number
PCT/GB2013/053207
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English (en)
Inventor
Thomas Jordan William HARTLAND
Stephen J. Russell
Original Assignee
Herbert Parkinson Limited
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Publication date
Application filed by Herbert Parkinson Limited filed Critical Herbert Parkinson Limited
Priority to GB1505770.6A priority Critical patent/GB2527400A/en
Publication of WO2014087161A1 publication Critical patent/WO2014087161A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary

Definitions

  • the present invention relates to multi-layered fabrics for example, though not exclusively, for use in articles containing natural and/or synthetic fillings, such as down and/or feathers or the like, for thermal insulation or acoustic insulation.
  • High quality filled products e.g. duvets, pillows and similar textile articles such as quilts, mattress toppers, sleeping bags, outdoor jackets/clothing, gloves
  • an inner insulation (filling) material consisting of feathers and/or down that is retained by an outer covering fabric.
  • the outer fabric must be of a tightly woven fabric construction with a minimum inter-yarn pore size (i.e. the size of the spaces between yarns) that prevents components of the filling (e.g. parts of the feather or down) from being able to penetrate the outer fabric during repeated mechanical agitation or washing of the entire assembly.
  • This is particularly challenging in respect of the shaft, distal barbules or proximal barbules of feathers and down fillings because of their small diameter relative to the inter-yarn pore sizes of the covering fabric.
  • any article in prolonged contact with human skin, or creating a microclimate around a person, must allow the passage of excess heat and moisture vapour to the external environment to meet comfort requirements. This is particularly so when the ambient conditions are warm (ca. 14-30°C).
  • the materials of the covering fabric, and filling materials, each introduce airflow resistance between a user and their immediate environment. Thermal and osmotic gradients can be adversely affected as a result.
  • a suitable air permeability and rate of moisture vapour transfer from the user to the immediate environment are particularly important requirements of the covering fabric and are largely affected by its thickness and porosity.
  • the current invention seeks to address these matters.
  • the invention is to employ a fabric or web of nonwoven construction (e.g. thermoplastic polymer fibres) as a barrier to feather or down penetration through an adjacent woven fabric layer, which may serve as an outer cover layer for e.g. an article of clothing or bedding. Since the woven fabric layer is no longer required to provide feather penetration resistance alone, and may work in synergy with the adjacent nonwoven fabric.
  • the packing of the constituent yarns and construction of its weave need not be as dense/close and can possess a larger pore size, greater porosity, air permeability and breathability which would not otherwise be possible were it serving as the sole barrier to penetration by elements of the filling material (e.g. feather quills, or similar filling fibres).
  • Down and Feather mixes are particularly, but not exclusively, referenced due to their widespread use in industry as thermal insulators and renowned difficulty to contain, sometimes even in closely woven, low permeability materials. It is suggested, but not asserted, that this is due to the fractal morphology of down, which includes fibrils (e.g. between 2-6 ⁇ diameter, 100-500 ⁇ length) extending from sub branches (e.g. between 8-20 ⁇ diameter, 0.5-3.5cm length) that in turn project from a central core.
  • Figure 1 B shows an example Scanning Electron Microscope (SEM) Image showing the sub branches and fibrils extending from the short central stem.
  • SEM Scanning Electron Microscope
  • Fibrils typically show triangle nodes and crotches located at regular intervals of approximately 20 to 30 microns, as seen in Figure 1 C. These nodes and crotches may have a maximum transverse dimension of 3 to 5 times that of the fibrils themselves.
  • the crotches and triangle nodes maybe so large that they hold in place the crossing fibrils that happen to make contact with each other under compression force providing a valuable feature of recoverable loftiness.
  • the inventors have been very surprised to find that a synergy exists between the woven and nonwoven fabric layers when in contact, which results in a multi-layered fabric having a degree of resistance to feather/down penetration which is not displayed by any one of the component fabric layers individually, due to the relatively large pore sizes.
  • the multi-layered fabric has been found to be effectual in containing down/feather according to the standard method in BS EN ISO 12131 -1 :1999 and/or EN 12131 -2:1999.
  • this synergy may be the result of relatively randomly arranged fibres (or filaments) of the nonwoven fabric layer obstructing, and partially occluding, open pores of the woven fabric layer and engaging, entangling or forming a frictional contact with the relatively regular structure/scaffold of the adjacent (e.g. woven) fabric such that either one helps support the other to better resist the displacement of fibres/yarns by an element of a filling material (e.g. feather shaft, barbules) attempting to pass through.
  • a filling material e.g. feather shaft, barbules
  • this principle of the invention is applicable to other types of fine natural or synthetic filling materials other than feathers/down, such as fibrous filling materials (synthetic or natural), and blends thereof. This is aided by the interaction of the nonwoven fabric layer with fibres (hairs) protruding from the yarns of the woven fabric layer. Experimental evidence is presented which supports for this suggestion.
  • the present invention is relevant to, but not limited to, highly porous covering material for filled articles such as (but not limited to) bedding, garments and related articles that simultaneously retains fibrous elements of filling material (e.g. down and/or feather or synthetic materials) and is characterised by air and moisture vapour permeability.
  • the fabric assembly of the invention has been found to be washable in an aqueous medium using conventional domestic processes known in the art, most preferably at temperatures ⁇ 100°C.
  • a more breathable cover fabric allows a greater rate of throughput of such air and , therefore, a quicker recovery of the original volume.
  • the invention may provide a multi-layered fabric including a first layer comprising a woven or knitted fabric having an optical porosity of between 0.06% and 35% , or a porosity of between 50% and 95% ; and , a second layer comprising a nonwoven fabric or web having an optical porosity of between 0.1 % and 15% , or a porosity of between 75% and 98% .
  • the porosity of the first layer may be between 80% and 95% , or more preferably between 83% and 90% .
  • the porosity of the second layer may be between 80% and 97% , or more preferably between 82% and 96% , or more preferably between 85% and 90%.
  • a breathable multi-layered fabric in which the first, woven or knitted layer has a high porosity permitting a light-weight construction, lower cost, and higher air permeability.
  • a second layer of nonwoven fabric provides a barrier to penetration of the first layer by parts of feathers or down .
  • the multi-layered fabric may serve as an outer layer of e.g . an article of clothing or bedding containing feathers and/or down or even man-made filamentary insulating materials.
  • the application of the multi-layered fabric is not only in garments or the like, but in any application (domestic or industrial) where it is necessary to contain a filamentary filling (natural or synthetic) without incurring (or at least reducing the occurrence of) condensation or overheating .
  • An industrial example would be for retaining filamentary filtering materials in the presence of significant temperature and/or humidity gradients such as in industrial cooling processes/apparatus or the like.
  • references to "woven” and “knitted” fabric may include a reference to a fabric comprising a structure including interlaced or intermeshed yarns, threads or fibres.
  • the industry reference book: “Textile Terms and Definitions” (10 th Edition, 1995), by J E Mclntyre & P N Daniels [ISBN 1 870812 77 8] defines knitting as the process of forming a fabric by intermeshing of loops of yarn, and defines weaving as the action of producing a fabric by the interlacing of warp and weft threads.
  • the porosity of a fabric may be calculated by measuring the total volume of a fabric and the total volume of fibres in the fabric.
  • the total volume of a fabric sample may be determined by multiplying the area (A) of the fabric sample by the measured thickness (7) of the fabric sample.
  • the total volume of the constituent fibres of a fabric sample may be determined by dividing the density (D) of the constituent fibres of the fabric by the measured mass (1/1/) of the fabric sample.
  • Porosity may be calculated based on the following formula:
  • Optical porosity characterises the extent to which pores in the fabric are visually obstructed by yarns, filaments or fibres when viewed in light reflected or transmitted from one side of the fabric. This may be determined using a digital imaging system using e.g. a CCD camera or other digital camera.
  • the resulting image data comprises "void pixels” that correspond to the open pores (the void fraction) and "solid pixels” that correspond to the yarns, fibres or filaments (the solid fraction) in the same two-dimensional image.
  • Optical porosity P (%) can then be defined as:
  • void pixels and solid pixels
  • void pixels preferably refer, respectively, to those pixels within an image of a fabric that are deemed to wholly or predominantly contain a part of a pore/void ("void pixel") or wholly or predominantly contain a part of a yarn, fibre, filament or solid fraction ("solid pixel").
  • a pixel value "X" (typically between the two extremes of 0 and 255) of a given image pixel within an image of a fabric is referred to a threshold pixel value " i h res h oi d " to differentiate between "void pixels” and "solid pixels” such that:
  • reflected light e.g. front illumination of the sample, or "dark-field” illumination
  • the threshold value X T hreshoid may be a pixel value of 75, for example, in a digital imaging device arranged to provide pixel values between the two extreme values of 0 (zero) and 255, inclusive. More generally, the threshold pixel value may be about 1/3 of the upper extreme pixel value at which the imaging device operates (e.g. 255). This has been found to be effective and reliable.
  • Settings on a digital imaging device are preferably selected such that the sensor chip (e.g. CCD, CMOS) of the digital imaging device is able to operate within its "linear" region in which pixels values of pixels within the sensor chip are proportional to the amount of image- bearing light they receive, thereby avoiding underexposure or overexposure in the image.
  • This may be achieved by the appropriate settings for digital imaging device (e.g. using camera control software) such as "gain”, “gamma” and “exposure time” for a given illumination situation, as would be readily apparent to the skilled person.
  • substantially no saturation of pixel values occurs within the pixel values of the image recorded by the digital image device.
  • the image being recorded is substantially in- focus upon the sensor chip such that the image recorded by the digital imaging device is a substantially focussed image.
  • the image may be an image generated by an electron microscope (e.g. Scanning Electron Microscope) or may be an image generated by an optical microscope using forward illumination ("dark field").
  • the result is that the solid fraction of the illuminated fabric, whether illuminated by electrons or by photons, is generally brighter than the void fraction/pores of the illuminated fabric, within the captured image of the illuminated fabric. Illuminating the sample in this way with light/electrons that will not be directly collected by the imaging system, and thus will not form part of the image, produces the appearance of a dark, almost black, background with bright objects on it.
  • a magnification setting of x500 has been found to be suitable for image capture e.g. when using an electron microscope, particularly when imaging the fabric of the second layer.
  • a magnification setting of between x5 and x200 (e.g. x8) has been found to be suitable for image capture particularly when imaging the fabric of the first layer.
  • Optical porosity differs from volume or mass based porosity measurements in that it only characterises inter-fibre pores that extend from one side of the fabric to the other.
  • the reduction of these through-pores, particularly those with pore diameters greater than 5 ⁇ is a key requirement in the retention of down and feather filling materials.
  • the invention may provide a multi-layered fabric including a first layer comprising a woven or knitted fabric having an optical porosity exceeding 0.06% and less than 35%, preferably between 0.5% and 30% and a second layer comprising a nonwoven fabric or web preferably with an optical porosity that exceeds 0.1 % and is less than 15%, preferably from 0.2% to 1 1 %, or even more preferably from 0.2% to 8%, or yet more preferably from 0.2% to 6%.
  • nonwoven fabric or “nonwoven web” may be defined as in ISO standard 9092 and CEN EN 29092 and/or may be taken to include a reference to a web having a structure of individual fibres, filaments or threads which are interlaid in for example, a randomly distributed, irregular or otherwise non-periodic manner.
  • Nonwoven fabrics or webs may be formed from any one of a number of different processes such as will be readily apparent to the skilled person. For example, a meltblowing processes, a spunbonding processes, or a bonded carded web process are all examples known in the art.
  • the second layer preferably includes fibres of plastics and/or polymer material, which comprise one or more of: spunbond, meltblown, electrospun or centrifugally spun fibres.
  • the latter may also be referred to as forcespun fibres.
  • the plastics and/or polymer material is preferably a thermoplastic material, such as a thermoplastic polymer material.
  • meltblown fibres includes a reference to fibres or filaments formed by extruding molten plastic (e.g. thermoplastic) materials through a number of fine, usually circular, die capillaries as molten filaments into a high velocity, usually heated, gas (e.g. air) stream which attenuates the filaments of molten plastic material to reduce their diameter. Thereafter, the meltblown fibres may be transported by the high velocity gas stream and deposited on a collecting surface to form a web of randomly distributed meltblown fibres. Such a process is disclosed, for example, in patent no. US3849241 .
  • spunbond fibres includes a reference to fibres formed by extruding molten plastics (e.g.
  • thermoplastic material as filaments from a number of fine, usually circular capillaries of a spinnerette with a diameter similar to the extruded filaments then being rapidly reduced in a manner such as is described, for example, in patent no. US4340563 or patent no. US3692618.
  • electropun fibres includes a reference to fibres formed by a process of electrspinning. Examples are described in: "A review on polymer nanofibres by electrospinning and their applications in nanocomposites”; by Z.-M. Huang et a/. , Composites Science and Technology 63 (2003) 2223-2253.
  • the term "polymer” may include, but is not limited to, homopolymers, copolymers, terpolymers, etc. and blends and modifications thereof, and includes a reference to all possible geometrical configurations and symmetries of the material.
  • the second layer may itself be a multi-layer of nonwoven fabric sub-layers.
  • the second layer may comprise a first sub-layer and a second sub-layer arranged adjacent to the first sub-layer.
  • the second sub-layer may comprise fibres/filaments, which have an average diameter that is less than the average diameter of the fibres/filaments of the first sub-layer.
  • the second layer may include a layer (e.g. a first sub-layer) comprising spunbond fibres and a layer (e.g.
  • meltblown fibres or electrospun fibres of forcespun fibres comprising one of: meltblown fibres or electrospun fibres of forcespun fibres.
  • the second layer may itself comprise a multi-layer, or laminate, of different nonwoven fabrics.
  • the first sub-layer of the second layer e.g. of spunbond fibres
  • the first sub-layer of the second layer may be arranged immediately adjacent to the first layer (woven/knitted fabric) such that the two make frictional contact, or are free to do so. It has been found that meltblown or electrospun fibres or forcespun fibres may generally be finer in diameter than are spunbond fibres and produce a greater number of fibres per unit volume (or solid surface volume) for a given porosity.
  • the spunbond fibres may tend to be thicker in diameter than the meltblown or electrospun fibres and have been found to provide a robust barrier against penetration by larger objects such as the quills of feathers and down.
  • the second layer may be provided as a multi-layer of different nonwoven fabrics, which respectively serve as a barrier to different components of heterogeneous filling material (e.g. feathers and down).
  • the second layer may comprise a third sub-layer, as well as the second sub-layer and the first sub-layer, in which the second sub-layer is arranged intermediate the first sub-layer and the third sub-layer (e.g. arranged in a laminate structure).
  • the intermediate second sub-layer may be arranged between the first and third sub-layers (e.g. sandwiched) and is preferably in contact with each.
  • the intermediate sub-layer may comprise fibres/filaments, which have an average diameter which is less than the average diameter of the fibres/filaments of each of the first sub-layer or the third sub-layer.
  • the second layer may include a sub-layer comprising meltblown fibres or electrospun fibres between two sub-layers which each comprise spunbond fibres.
  • the second, nonwoven layer may comprise three sub-layers of which the intermediate sub-layer is meltblown or electrospun.
  • This three-layer laminate has been found to be particularly effective in providing a barrier to feather/down penetration preferably when the weight of the intermediate second sub-layer as a proportion of the entire second layer is above a desired value of about 10%. It is suggested, but not asserted, that, in use, the first and third outer sub-layers serve to anchor or restrain a feather quill and thereby restrict its ability to move (e.g.
  • the second layer preferably includes meltblown fibres or electrospun or forcespun fibres which comprise between 10% and 50% of the second layer by weight, or more preferably between 13% and 50%, or yet more preferably between 15% and 50% of the second layer by weight. These values provide for sufficient meltblown or electrospun or forcespun fibres/filaments per unit volume for providing a barrier to elements of feather or down.
  • the second layer preferably has an air permeability of between 25cm 3 /cm 2 /s and 120cm 3 /cm 2 /s. Air permeability may be determined according to the test method of BS EN ISO 9237:1995; 5cm 2 test area (deviations from this standard are noted in appendix A).
  • the fibres of the second layer preferably such as a said first or third sub-layer thereof, have an average fibre diameter, which is from ⁇ ⁇ to 25 ⁇ , and more preferably from 18 ⁇ to 19 ⁇ , preferably with a standard deviation from ⁇ . ⁇ to 2.5 ⁇ , most preferably about 1. ⁇ to 1 .8 ⁇ .
  • the fibres of the second layer preferably such as a said second sub-layer thereof, have an average fibre diameter which is less than 9 ⁇ , and more preferably less than 5 ⁇ , and yet more preferably no greater than about 3.6 ⁇ , preferably with standard deviation from 0.3 ⁇ to ⁇ . ⁇ , most preferably about ⁇ . ⁇ .
  • the average inter-fibre pore diameter of the second layer is preferably between 9 ⁇ and 12 ⁇ .
  • the minimum pore size may be in the range 3.5 ⁇ to 4.5 ⁇ , and the maximum pore size may be in the range 30 ⁇ to 55 ⁇ .
  • the second layer preferably has a fabric area density of between 10gm “2 and 10Ogm “2 , or more preferably, between 15gm "2 and 55gm “2 .
  • the sub-layers are preferably thermally bonded to connect them together as one laminate layer.
  • the layers are preferably point-bonded, i.e. the thermal bonds may be spatially separated and distributed.
  • the sub-layers may be attached together by means of mechanical bonding, preferably hydroentangling using methods known in the art.
  • the first and second layers may either be connected together continuously as in the form of laminated structure or discontinuously, such that the distance between each layer is variable and the two layers are connected only at certain locations arranged randomly or periodically.
  • the polymer composition is preferably composed of a hydrophobic, thermoplastic polymer such as polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), coPET, polyamide (PA), CoPA, polylactic acid (PLA), polybutylene terephthalate (PBT), polytrimefhyiene terephthalate (PTT) or combinations thereof.
  • the first layer preferably comprises staple fibre yarns, which are woven (e.g. interlaced) or knitted (e.g. intermeshed) together.
  • one, some or substantially all the yarns of the first layer are hairy. Yarn hairiness characterises the frequency of hairs (fibres) protruding above the surface of a textile yarn.
  • Hairs consist of protruding fibres, looped fibres and loosely wrapped fibres. Especially, in case of staple spun yarns, since multiple fibres are bound in a single yarn, fibres tend to protrude beyond the main body of the yarn even though the yarn is twisted or otherwise frictionally bound.
  • a well known measure of yarn hairiness is the so-called USTER Hairiness Index (H) formulated by Uster Technologies (www.uster.com) and widely accepted within the art. This defines hairiness as the total (cumulative) length, measured in centimetres, of protruding fibres/hairs originating from one centimetre of the observed yarn, divided by 1 cm.
  • the hairiness index (H) is therefore dimensionless (i.e. cm/cm).
  • the measured hair length are the lengths of the hairs projected onto a 2-dimensional (2D) plane within which the 1 cm yarn length resides (i.e. parallel to the plane),
  • the 2D plane may be the plane of a 2D image of the hairy yarn in question if hair lengths are measured via image inspection/processing, or may be the 2D plane of an array of photoelectric sensors arranged to detect the quantity of light scattered to them by hairs of the yarn.
  • H Hairiness Index
  • an effective methodology for evaluating the Hairiness Index (H) of a yarn is to make the evaluation over a 0.5cm evaluation length by visual inspection and manual image processing of a 0.5cm evaluation length within an image of a sample yarn taken at a magnification of about x40 (optically or via an SEM).
  • the total (cumulative) length, measured in centimetres, of protruding fibres/hairs originating from the 0.5cm evaluation length of the observed yarn is then simply doubled to represent the estimated total (cumulative) length over a 1 cm evaluation length of the same yarn, in accordance with the USTER Hairiness Index (H) definition.
  • the hairiness index represents double the cumulative length of hairs (in cm) measured over an initial evaluation length of the fabric or yarn of 0.5 cm herein, divided by 1 cm.
  • images of the yarns may be taken and calibrated with image analysis software using the procedure stated in the Image Calibration section of Appendix B.
  • the length of a hair protruding from the central yarn body can be measured from the point (referred to herein as the "stem") at which it is seen within the image to detach (e.g. protrude, loop out from or otherwise become visibly salient or stand proud) from the central yarn body.
  • the length of the hair may be measured from its "stem” to its terminal end.
  • the terminal end may be the physical end of the hair visible within the image, or the point at which it re-enters the central yarn body (i.e. another "stem").
  • magnification may preferably be set at the largest possible while still capturing an evaluation length (e.g. 5mm length) of yarn to give the best resolution of visible hairs.
  • dark field microscopy may be used, with light sources (e.g. twin single spot LEDs at 10cm) illuminating the yarn specimen, to reduce the translucency of fibres and the chance of missing them.
  • the hairiness index (H) of the fabric of the first layer is preferably between 2 (e.g. 10 mm cumulative hair length over a 0.5cm evaluation length, doubled) and 20 (e.g. 100 mm cumulative hair length over a 0.5cm evaluation length, doubled), when measured over a 1 cm evaluation length, or over a 0.5cm evaluation length doubled as described above. More preferably, the hairiness index (H) is between 4 and 12 (e.g. 20 mm and 60 mm cumulative hair length over a 0.5cm evaluation length, doubled), when measured over a 1 cm evaluation length, or over a 0.5cm evaluation length doubled as described above.
  • the hairiness index (H) may be an average value of a plurality of hairiness indices for the first layer, e.g. measurements are taken at a plurality (e.g. many) different locations and evaluation lengths, across the fabric.
  • the cover factor of the first layer is preferably less than 40, preferably between 15 and 40, and more preferably between 25 and 35.
  • the cover factor of the factor was calculated as follows separately for both the warp and the weft directions in the fabric:
  • the overall cover factor of the fabric is the sum of the warp and weft cover factors.
  • the cover factor is a measure of the tightness of the woven fabric structure. A lower cover factor indicates a more open fabric. It is also possible for the hairiness of the woven fabric of the first layer to increase as its cover factor value falls due to reduced yarn twist, reduced axial fibre alignment or mechanical surface finishing treatments, such as raising, that produce a pile on the fabric surface. An increase in yarn hairiness enables a stronger synergistic interaction as described above, whereby protruding fibres of the first layer engage with the filaments or fibres of the second layer to enhance the frictional interference between the two layers.
  • the average inter-yarn pore diameter of the first layer is preferably between 5 ⁇ and ⁇ . These values may be determined according to any suitable method known in the art. An example is given below.
  • the first layer preferably has a fabric area density of between 20gm "2 and 120gm "2 .
  • the first layer preferably has an air permeability of between 3cm 3 /cm 2 /s and 250cm 3 /cm 2 /s. Air permeability may be determined according to the well-known test method of or BS EN ISO 9237:1995; 5cm 2 test area).
  • the structure of the first (outer) layer alone is preferably a woven fabric or a warp knitted fabric characterised with a relatively high mean inter-yarn pore diameter (e.g. such as determined by the image analysis procedure given below) such that, alone, it is insufficient to prevent penetration of tendrils or barbules of feather, down or admixtures of both.
  • the first layer may comprise interlaced or intermeshed yarns composed of naturally occurring fibre materials such as cotton, flax (linen), ramie, hemp, bamboo, wool and silk (or blends thereof as well as blends with staple man-made fibres). It may be constructed from regenerated cellulose man-made fibre or filaments such as Tencel (lyocell), viscose, cellulose acetate and triacetate, polynosic rayon and cuprammonium rayon.
  • the invention may provide an article comprising down and/or feathers contained within a container formed from a multi-layered fabric as described above.
  • the article may be an article of clothing or bedding. Examples include duvets, quilts, comforters, bed sheets, pillows, sleeping bags, hats, gloves, jackets, coats, trousers (e.g. skiing trousers) and tops.
  • the invention may also be applied to articles that are not bedding or clothing, but are used for insulation purposes where breathability, light-weight and/or rapidity of drying are important. Examples include light-weight lagging for pipes, aircraft/vehicular insulation and light-weight temporary shelters (e.g. bivouacs ("bivvy”) or ients).
  • the invention may provide an article comprising multi-layered fabric as described above, and including a first portion of a said fabric ultrasonically welded to a second portion of a said fabric wherein the second layer of the first portion is in direct contact with the second layer of the second portion where welded. This has been found to provide a strong bond.
  • the invention may provide a method of manufacturing a multi-layered fabric comprising, providing a first layer comprising a woven or knitted fabric having an optical porosity of between 0.06% and 35%, or a porosity of between 50% and 95%; and, a second layer comprising a nonwoven fabric or web having an optical porosity of between 0.1 % and 15%, or a porosity of between 75% and 98%; and, arranging the second layer and the first layer together to provide a multi-layer fabric.
  • the porosity of the first layer may be between 80% and 95%, or more preferably between 83% and 90%.
  • the porosity of the second layer may be between 80% and 97%, or more preferably between 82% and 96%, or more preferably between 85% and 90%.
  • the second layer preferably includes fibres of plastics and/or polymer material, which comprise one or more of: spunbond, meltblown or electrospun or forcespun fibres.
  • the plastics and/or polymer material is preferably a thermoplastic material, such as a thermoplastic polymer material.
  • the method may include arranging the first layer directly in contact with the second layer.
  • the method may include attaching the second layer to the first layer.
  • the method may include forming the second layer to include a sub-layer comprising spunbond fibres and a sub-layer comprising one of: meltblown fibres or electrospun fibres.
  • the method may include forming the second layer to include a sub-layer comprising meltblown fibres or electrospun fibres arranged between two further sub-layers which each comprise spunbond fibres.
  • the sub-layers method may include thermally bonding fibres of the sub-layers to connect them together as one laminate layer.
  • the method may include connecting the sublayers together by means of hydro-entangling using methods known in the art.
  • Embodiments of the invention may comprise multiple separate, but adjacent inner layers of non-woven material. Embodiments of the invention may also comprise multiple adjacent inner layers of nonwoven material that have been assembled to form one unified layer.
  • a meltblown fibre layer may be made up of one or more individual layers of meltblown (M) fibres sandwiched between two or more spunbond layers (S). Examples include, but are not limited to, the following configuration/layering structure: SMS, SMMS, SMMMS, SSMMSS, SSMMS.
  • Versions of our invention comprising a second layer with a fabric area density between 40 and 50g/m 2 demonstrated substantially complete resistance to fine fibre percolation when tested with five 40°C wash and 65°C dry cycles (in accordance with British Standard BS EN ISO 6330). It is suggested, but not asserted, that densities upwards of 40g/m 2 are desirable to withstand the mechanical irritation of repeated washing procedures.
  • weights also support the use of lower quality fillings, specifically down and feather which has higher ratios of feather to down.
  • a 90:10 down and feather mix from Hungarian geese was selected for the above fine fibre percolation tests (unless otherwise stated).
  • At lower ratios of down to feather - such as commercially available 80:20 there is an increased challenge in retaining the filling without using one densely woven cambric material due to the increased amount of quills in the mix that have the ability to damage lightweight (e.g. ⁇ 35gsm) aforesaid second layers.
  • a combination comprising a lightweight cotton said first layer (e.g. 133x72, 40ne) with a e.g. a 35g/m 2 said second layer also demonstrated substantially 100% allergen barrier efficacy when tested in accordance with the SP304 "Allergen barrier with Airflow test at Airmid Healthgroup laboratories.
  • the embodiment of the invention substantially prevented the through-movement of allergen particles such as "fel d 1 " particles which are less than ⁇ ⁇ in diameter and dust mite faecal pellets, "derp 1 " which ranges between ⁇ ⁇ and 40 ⁇ .
  • allergen particles such as "fel d 1 " particles which are less than ⁇ ⁇ in diameter and dust mite faecal pellets, "derp 1 " which ranges between ⁇ ⁇ and 40 ⁇ .
  • the term “Fel d 1 " refers to the primary allergenic protein from cats, and "Derp 1 " is the primary allergenic protein from European dust mites.
  • the dust mite itself has a size of 250 ⁇ to 300 ⁇ .
  • current cambric fabrics used in down and feather bedding demonstrated 99% allergen barrier efficacy in the same test, failing to prevent 1 % of small respirable particles that can cause asthma and allergies.
  • the invention may provide a method of manufacturing an article comprising providing multi- layered fabric as described above, and ultrasonically welding a first portion of a said fabric to a second portion of a said fabric wherein the second layer of the first portion is in direct contact with the second layer of the second portion where welded. This is a simple and quicker way to form a strong bond, as compared to sewing.
  • the second layer of the fabric may have a mean pore size (e.g. around 10 ⁇ ), which much too small for the mites and their lavae to get through. Also, asthma/allergy triggering "Der p1 ", “Der p2", “Fel d1 " particles (see above) can range anywhere between 0.2- 40 ⁇ in diameter. Despite a mean pore size within the second layer of fabric which may typically be greater than 0.2 ⁇ , an allergy barrier with airflow test demonstrated that the second layer materials (e.g.
  • Normal cambric weave cover fabric is usually dust mite proof as a result of having a weave structure sufficiently dense to make it down proof.
  • construction of an item of bedding such as a pillow or duvet, or other article, includes seams which are not effective barriers to mites and larvae. This is because the needles used to produce/sew a seam punch large holes through the cover fabric, sufficient to admit mites into the filler material held within the cover. Also any increases in humidity/temperature after a night's sleep are lost only slowly to the environment (cambric's low air permeability) making it more favourable for dust mites to live in the filling once they get in.
  • a filling material e.g.
  • the invention may provide an article of bedding or clothing comprising a fabric according to the invention in its first aspect, which defines a container part for containing a filling material and having one or more seams sewn along the fabric which join together two opposing parts of the fabric, and wherein the seam is isolated from the container part by a substantially continuous weld between the respective second layers of the opposing parts of the fabric.
  • the second layer of the fabric may preferably be a synthetic polymer material susceptible to ultrasonic welding, and the aforesaid welds may be ultrasonic welds. Ultrasonic welding uses high frequency vibrations to generate frictional heat between molecules, which are then pressed together and bonded with a pressurised welding foot.
  • one, some or all of the boundaries/edges of the container part are defined by one or a plurality of said welds thereby to define the shape of the container part.
  • One, some or each of the sewn seams may each be contained collectively or individually/separately between two respective said welds extending along substantially the whole length of the sewn seam.
  • the two said welds may be parallel to each other and may also be parallel to the sewn seam they isolate.
  • one some or each sewn seam is wholly surrounded by a said weld or welds.
  • the weld or welds may be substantially linear.
  • a plurality of welds may cross over each other in such a way as to collectively enclose a region of the fabric which is isolated from the container part and which contains a sewn seam.
  • Figure 1A, 1 B and 1 C show an electron microscope images of a main shaft and tendrils of a feather (Fig.l A), and down (Fig.l B) possessing triangle nodes and crotches (Fig.l C) upon a fibril, used as insulation filling in an item or bedding or clothing;
  • Figure 2 shows a scanning electron microscope image of a quill tip of the feather of Figure 1 ;
  • Figure 3 shows a scanning electron microscope image of down micro-structure including barbules
  • Figure 4 shows a scanning electron microscope image of a woven cotton fabric with a tightly- woven, low-porosity, satin weave pattern that is down-proof;
  • Figure 5 shows an electron microscope image of a porous cotton fabric with a loosely woven plain weave pattern, which is not down-proof
  • Figure 6 shows an electron microscope image of a nonwoven fabric comprising a layer of melt- blown thermoplastic polymer filaments (thinner) sandwiched between two layers of spunbond thermoplastic polymer filaments (thicker), with a porous structure, which is not down-proof
  • Figure 7 shows a scanning electron microscope image of a nonwoven fabric of Figure 6 at lower magnification comprising an array of separate thermal bonding (melted) points, which bond together the three layers of thermoplastic polymer filaments
  • Figure 8 schematically shows an article covered by a fabric according to an embodiment of the invention including a cut-away part showing component layers of as multi-layer fabric structure
  • Figure 9 schematically shows a duvet comprising a fabric according to Figure 8;
  • Figure 10 shows a cross-sectional view of the duvet of Figure 9;
  • Figure 1 1 schematically shows a perspective, cut-away view of the duvet of figures 9 and 10;
  • Figure 12 shows a pillow comprising a fabric according to Figure 8.
  • Figure 13 schematically shows a cross-sectional view of the pillow of Figure 12;
  • Figure 14 shows a sleeping bag comprising a fabric according to Figure 8.
  • Figure 15 shows a cross-sectional view of the sleeping bag of Figure 14;
  • Figure 16 shows a down jacket comprising a fabric according to Figure 8.
  • Figure 17 shows a cross-sectional view of the down jacket of Figure 16;
  • Figure 18 schematically shows an apparatus for manufacturing a nonwoven fabric such as shown in Figure 6;
  • Figure 19 schematically shows a cross-sectional view of a multi-layer fabric comprising the nonwoven fabric of Figure 18;
  • Figure 20 shows a perspective view of the nonwoven fabric of Figure 18
  • Figures 21 A and 21 B show graphs of peak penetration forces (Graph 1), and breaking strength (Graph 2) in tests conducted upon fabrics such as shown in Figure 19;
  • Figures 22 to 25 show an ultrasonic weld described in Appendix F;
  • Figures 26 to 38 schematically illustrate successive stages in the manufacture of an anti- allergen, hermetically sealed article according to an exemplary application of the fabric of an embodiment of the invention;
  • Figure 39 shows an optical image of the hollowfibre filling together with e reference scale bar (250 microns);
  • Figure 40 shows 35gsm SMS fabric SEM image taken at 500x magnification, and Figure 40 (right) shows the result of applying a mask to an area of interest (AOI) showing areas occluded by fibres (black) against optical pores (white);
  • AOI area of interest
  • Figure 41 shows a diagram of an apparatus for determining Coefficients of Friction.
  • FIGS. 1 , 2 and 3 there are shown scanning electron microscope images of elements of feathers used as insulation filling in items of clothing or bedding.
  • Figure 1 shows the main stem and filaments of a feather, while Figure 2 shows its quill/shaft tip.
  • Figure 3 shows the barbules present in filaments of feathers and down. These filaments and quills are prone to penetrate the covering fabric of the item (e.g. clothing, duvet or pillow) encasing them unless steps are taken to render the covering fabric resistant to such penetration ("down- proof).
  • Figure 4 shows a scanning electron microscope image of a woven cotton fabric with a tightly-woven, low-porosity, satin weave construction, which is designed to be down-proof (i.e. resistant to the penetration of quills or other parts of the feather or down). It has low air permeability and vapour breathability and is relatively heavy, stiff and expensive to use in bedding or clothing items as a result of the fabric density.
  • Figure 5 shows a scanning electron microscope image of a porous cotton fabric with a loosely woven plain weave construction that is not down-proof, but which is more air permeable and vapour breathable than is the fabric of Figure 4. It is lighter and cheaper to use in bedding or clothing items as a result. Note that the yarns of the fabric of Figure 5 are substantially hairier than those of the fabric of Figure 4.
  • Figure 6 shows a scanning electron microscope image of a nonwoven fabric comprising a layer of melt-blown (M) thermoplastic polymer filaments (thinner) sandwiched between two layers of spunbond (S) thermoplastic polymer filaments (thicker), with a porous structure, which is not down-proof.
  • M melt-blown
  • S spunbond
  • the SMS nonwoven fabric is light and has a high air permeability and moisture vapour breathability.
  • the filaments of the spunbond (S) components are located in the foreground and at the rear of the fabric, with the meltblown (M) component/s visible between them.
  • FIG 18 schematically shows a method and apparatus for manufacturing the SMS nonwoven fabric of Figure 6.
  • Spunbond fibres of a lower sub-layer of the nonwoven fabric are extruded as filaments of molten thermoplastic material from a number of fine, circular capillaries of a spinnerette (18).
  • the filaments are deposited on a collecting conveyor surface (24) to form a lower web (21) of approximately randomly distributed spunbond fibres.
  • meltblown fibres (M) of the intermediate sub-layer of the SMS fabric are extruded as molten filaments of thermoplastic materiall, through a number of fine, circular, die capillaries (19) into a high velocity, heated, gas stream (not shown) which attenuates the filaments reduce their diameter.
  • the meltblown filaments (22) are attenuated by the high velocity gas stream and deposited on the collecting conveyor surface (24) to form a web of approximately randomly disbursed meltblown fibres on top of the web of spunbond fibres (21 ).
  • a second and upper layer of spunbond fibres (23) is then deposited on top of the intermediate web of meltblown fibres by a second spinnerette (20).
  • a three-layer nonwoven fabric is thereby manufactured and is thermally bonded between a pair of heated calender rollers (25).
  • the upper roller is embossed (26) wherein projections on the surface of the roller and are brought into very close proximity to the opposing surface of the lower bonding roller (osculate) which acts in the manner of an anvil against which the three sub-layers (SMS) of the nonwoven fabric are pressed by the bonding nodes, which are heated to cause melting of the thermoplastic filaments of the pressed SMS layers to cause them to bond together there when the thermoplastic filaments re-solidify.
  • a pattern of separate and discrete bond points (27) are thereby formed in a regular configuration across the final nonwoven fabric (28) which fix together its three component sub-layers (SMS).
  • Figure 20 schematically shows such a final nonwoven fabric. It is noted that an electrospun (E) intermediate sub-layer (22) comprising thermoplastic polymer may be formed in place of the meltbown sub-layer.
  • Figure 7 shows a scanning electron microscope image of the nonwoven fabric of Figure 6 at lower magnification. This shows an array of separate heat-bonding (melting) points, which bond together the three layers of thermoplastic polymer filaments.
  • Figure 19 schematically shows a cross-sectional view of a multi-layer fabric (29) comprising the nonwoven fabric of Figure 6, 7 or 18 or 20, combined with a woven fabric such as is shown in Figure 5.
  • Figure 8 schematically shows a fabric of the type shown in Figure 19 including a cut-away part showing component outer woven layer (1) of a multi-layer fabric structure, overlying an inner feather-retaining layer (2) of nonwoven fabric for retaining the feathers of an insulating feather filling material (3).
  • a multi-layer fabric was constructed as follows.
  • the first layer was composed of 100% cotton of area density (basis weight) 80 gm 2 .
  • the fabric was woven and comprised twisted staple yarns. Pore diameters in the fabric ranged from 6.41 ⁇ to 167.06 ⁇ (as determined using a PMI tester: see Appendix C).
  • the air permeability of the fabric was 250cn 7cm 2 /sec.
  • the second layer consisted of a layered structure comprising an intermediate sub-layer of meltblown thermoplastic polypropylene fibres (M) sandwiched between two outer sub-layers of spunbond thermoplastic polypropylene fibres (S). The three sub-layers (SMS) of this structure were connected together at discrete locations by thermal point bonding of the SMS fabric.
  • M meltblown thermoplastic polypropylene fibres
  • S spunbond thermoplastic polypropylene fibres
  • the SMS fabric contained a melt-blown layer that represented 20% by weight of the entire weight of the SMS layer construction.
  • a duvet assembly (5) schematically shown in Figure 9 was made by bringing the first and second layers into contact, folded to make a 210mm by 140mm rectangle then sewn by sewing machine around three edges.
  • the final article was manufactured by injecting a 30g mixture of loose filling material (3) composed of 90% goose down and 10% feathers into the assembly and then sealing the article, again by sewing.
  • This construction resulted in the outer cover schematically illustrated in figure 10 and 1 1 , composed of the first layer (1) and the second (SMS) layer (2) 'free-floating' above the feather/down filling material (3) apart from at the sewn seams (4).
  • the down/feather penetration resistance of an article constructed according to BS EN ISO 12131 -1 : 1999 was then evaluated in line with the procedure provided. At 2700 revolutions and no penetration of the combined layers by the enclosed down/feather mixture was observed.
  • An additional benefit of using this construction is a reduction in outer material basis weight; 100 gm "2 (80% of which is the first layer of woven fabric) as opposed to 1 16 g m "2 of a typical current woven fabric (e.g. Cambric).
  • the reduction in weight also reduces overall material consumption costs.
  • First Layer 01 area density 80g/m 2 ; 600 ⁇ layer thickness; 27.96% optical porosity;
  • First Layer 02 area density 92g/m 2 ; 400 ⁇ layer thickness; 16.89% optical porosity;
  • First Layer 03 area density 1 16g/m 2 ; 400 ⁇ layer thickness; 0.06% optical porosity;
  • Second Layer R1 13.5% meltblown (MB) component, by weight; area density 15g/m 2 ;
  • Second Layer R2 20% MB component, by weight; area density 20g/m 2 ; 400 ⁇ layer thickness; 4.91 % optical porosity; 88% porosity.
  • Second Layer R3 22.5% MB component, by weight; area density 35 g/m 2 , 400 ⁇ layer thickness; 0.20% optical porosity; 83% porosity.
  • Table 1 B indicates the number of penetrations of down/feather (over 2mm in length, according to BS EN IS012132-1 : 1999) when the specified first layers ("Outer” layers: 01 ,02,03) were used in conjunction with one of three second layers (feather "Retainer” layers: R1 ,R2,R3). Note in Table 1 B, that only one combination R1/01 resulted in a rating other than acceptable or excellent.
  • the second layer had an area density of 15gm "2 (gsm), comprising thermal point-bonded SMS fabric with a 13.5% by weight melt-blown component, an optical porosity of 10.63%, a minimum pore diameter of 4.25 ⁇ and a maximum pore diameter of 51 .29 ⁇ .
  • This SMS fabric had an air permeability of 1 15.2cm 3 /cm 2 /sec.
  • the woven fabric first layer was composed of 100% cotton with an area density of 80gm "2 .
  • the fabric comprised staple yarns. Pore diameters in the fabric ranged from 6.41 ⁇ to 167.06 ⁇ (as determined using a PMI tester: see Appendix C). The air permeability of the fabric was 250cn 7cm 2 /sec.
  • the test sample was constructed according to BS EN ISO 12131 -1 :1999 and filled with 30g mixture of 90% goose down and 10% feathers before the assembly is sealed by means of machine sewing. There were 21 penetrations of the combined layers of primarily small feathers.
  • the next experiment combined layers R1 with 02, which was composed of 100% cotton of area density, 92gm "2 and comprised staple yarns. Pore diameters in the first fabric layer ranged from 2.17 ⁇ to 77.3 ⁇ (as determined using the PMI tester).
  • the air permeability of the outer layer was 33.4cm 3 /cm 2 /sec.
  • the test sample was again constructed according to BS EN IS012131 -1 :1999, and was filled with 30g mixture of 90% goose down and 10% feathers before the assembly is sealed by means of machine sewing.
  • first and second layers employed in this experiment were the same as specified in Example 2 given above (01 , 02, 03; R1 , R2, R3).
  • penetration testing of combinations of first layers (01 , 02) and second layers (R2, R3) were selected which comprised individual fabric layers that are not considered down-proof on their own (whereas first layer type 03 is down-proof on its own - a cambric weave with low porosity and permeability).
  • first layers (01 , 02) and second layers (R2, R3) were selected which comprised individual fabric layers that are not considered down-proof on their own (whereas first layer type 03 is down-proof on its own - a cambric weave with low porosity and permeability).
  • the large increase in penetration force in the multi-layer fabric as compared to each component fabric of the multi-layer supports the suggestion that there is frictional interaction between the component fabrics. If no synergy existed, one would expect to observe that the penetration resistance of the multi-layer fabric matches the penetration resistance of the most resistant component fabric. However, in each case shown in Graph 1 of Figure 21 A, the penetration resistance force of the multi-layer significantly exceeds the penetration resistance force of the most resistant component layer - namely, the first (outer) layer of woven fabric. In the case where the first layer 01 is combined with either of the second layers R2 and R3, the penetration resistance virtually doubles.
  • the highest coefficient of static friction was recorded in interactions with the densest first layer (03), which had values exceeding 1 .15.
  • the lowest recorded coefficient of static friction was 0.88. This is a preferable range of coefficient of static friction between the two layers suitable to assist in the prevention of down/feather permeation.
  • a high degree of inter-linkage suggests that the staple fibres of the cotton in the first layer can interlock with the filaments of the nonwoven fabric of the second layer, further preventing quills or tendrils from being able to deform the nonwoven second layer around them as would be required in order to project through the second layer.
  • Table 2 shows the cover factor, USTER yarn hairiness index (H) of yarns of the fabric (here given as an average of the hairiness index of 3 warp yarns and 3 weft yarns) and average coefficient of static friction ( ⁇ 5 ) for each of the three types of first layer ("Outers”: 01 , 02, 03) construction, the coefficients of friction being averages of two coefficients of static friction each associated with a respective one of the two second layers ("Retainers": R3, R3). Individual coefficients of static friction are shown in Table 3 for each one of six combinations of first and second fabric layer types: 01 with R2; 01 with R3; 02 with R2; 02 with R3; 03 with R2; 03 with R3. Average Ol/ l 01/R2 01/R3 02/ 1 02/R2 02/R3 i 03/R1 03./R2 03/R3 S O.SI 0.S9 0.9! 0.89 1 0.99 0.95
  • Example 1 described above, (no penetrations of down/feather filling), both the first (outer) and second (retainer) layers were not affixed to each other apart from at the seams of the article made from the multilayer fabric and containing the feather/down filling.
  • FIG. 10 and 1 1 1 exemplify how ultrasonic seams were only integrated at selected areas ('X'), where baffle walls (33) are required to prevent the migration of filling throughout the duvet.
  • Figure 1 1 demonstrates how the wall of each compartment (the baffle) (33) is welded into place, but can hang freely from the second (SMS) layer (2) and cotton first (outer) layer (1) in order to be bonded to the opposite side.
  • FIG. 1 1 A cross section of the ultrasonic weld (4) is shown in Figure 1 1 , which for this example, was made using an Ardmel Ultrasew H192 unit operating at 35kHz, 1200 watts, 3 mm bonding foot, speed up to 1 1 15 rpm and 12 'stitches' per 3 cm).
  • the fibres in the thermoplastic baffle wall tape and the second layer (SMS) were softened and pressured into the cotton outer, creating the bond.
  • Graph 2 of Figure 21 B shows the measured breaking strengths of the ultrasonic welds, measured according to our adaptation of BS EN IS013935-2:1999; Seam tensile properties of fabrics and made-up articles. Details are provided in Appendix F.
  • a second layer comprising SMS with an area density of 20g/m 2 was used (retainer layer) in combination with a cotton, woven first (outer) layer having an area density of 92g/m 2 . It was found that seams with little thermoplastic content had the lowest breaking strengths and simply using another additional second layer (retainer - the thermoplastic component) provided a 157% increase in bond strength.
  • thermoplastic polyurethane adhesives in the assemblies, to achieve breaking strengths up to 100N.
  • Figures 12 and 13 illustrate use of the multi-layer fabric is a pillow (10).
  • the outer seams (1 1) of the pillow are bonded either through traditional machine sewing or ultrasonic welding using a thermoplastic outer decorative piping, leaving the outer cotton (1) first layer and the SMS second layer (2) to remain free-floating, yet retaining feather-filling material (3).
  • Example 7 Referring to Figure 14, the invention may be used in a filled sleeping bag (15).
  • Figure 15 shows the sleeping bag in cross-section indicated in Figure 14.
  • the inner cavity (16), where the user sleeps, is protected from filling (6) ingress by first and second layers (2 and 3) that are of the same construction outlined above.
  • the outermost layer material (17) may be as specified in embodiments herein, or a may be a weather-proof or laminated fabric.
  • Figures 16 and 17 illustrate views of the use of the multi-layered fabric within down garments, such as a down jacket (30).
  • the outermost layer (31) may be a commonly used polymeric woven fabric with or without a laminate, or similar material.
  • the first layer (1) and the second (SMS) layer (2) prevent the feather/down filling (3) from penetrating into the user cavity (5).
  • Example 9
  • the embodiment comprised of a said first layer constructed from 133 warp yarns per inch and 72 weft yarns per inch, all yarns 40ne English cotton count, for an overall fabric thickness of 377 microns.
  • the cover factor of the fabric was calculated to be 32.41 % with an optical porosity of 12.48%.
  • Air Permeability measurements were taken in accordance with the standard procedure BS EN ISO 9237:1995 for apparel (100Pa pressure drop and a 20cm 2 test area), However, the testing apparatus used was a Textest Instruments FX3300 Labair 4.
  • the said first layer had an air permeability of 277mm/s.
  • the said second layer in the embodiment comprised of a three layer nonwoven polypropylene SMS structure with a fabric area density of 40gm "2 and a thickness of 401 microns.
  • Optical porosity was measured at 4.7% and air permeability at 203.1 mm/s.
  • the filling consisted of 100% polyester hollowfibre ranging between 28.06 ⁇ and 32.13 ⁇ in diameter (mean 30.404 ⁇ , Standard Deviation 1 .044 ⁇ , Coefficient of Variation 3.43). Fibre diameters were ascertained using the procedure outlined in Appendix B.
  • Figure 39 shows an optical image of the hollowfibre filling together with e reference scale bar (250 microns). Following the same methodology as used for down and feather penetration testing, the samples were subjected to 2700 rub cycles over approximately 20 minutes. Of the samples measured none presented any penetration of the filling material, demonstrating 100% barrier efficacy of our materials to this synthetic hollowfibre filling. It is suggested, but not asserted, that because hollowfibres are demonstrably above 2 ⁇ in diameter, the minimal diameter fibrils found attached to down clusters, embodiments of the invention may be successful at preventing this filling and other larger diameter synthetic fills or blend thereof, from migrating through the multi-layer case assembly.
  • FIG. 26 to 34 illustrate steps in a method for manufacturing a cover for article of bedding or clothing (in this example, a duvet) comprising a fabric described above in any embodiment of the invention.
  • the cover is arranged to be filled with a filling material such as described above (e.g. feathers, down or other fillers).
  • a filling material such as described above (e.g. feathers, down or other fillers).
  • Two opposing pieces/sheets of the fabric are joined to define a container part for containing a filling material and having one or more seams sewn along the fabric pieces which join together the two opposing pieces of the fabric.
  • the seam is isolated from the container part by a substantially continuous ultrasonically-formed weld between the respective second layers (e.g. SMS) of the opposing parts of the pieces of fabric.
  • the article of bedding or clothing may isolate any sewn holes from areas of filling material such as down and feather ultimately placed in the container part.
  • each of the container parts are formed in the cover in this way.
  • the boundaries/edges of each of the container parts are defined by a plurality of linear welds which define the shape of the container part in question.
  • Sewn seams dividing adjacent container parts of the cover are each contained between two linear such welds extending along substantially the whole length of the sewn seam. The two welds are parallel to each other and parallel to the sewn seam they isolate.
  • each container part may be closed-off by a further such ultrasonic seal.
  • Some of the sewn seams are wholly surrounded by a plurality of welds that cross over each other in such a way as to collectively enclose a region of each of the opposing fabric pieces which is isolated from any container part and which contains a sewn seam.
  • the exemplary article In order to manufacture the exemplary article, first provide two pieces of e.g. SMS nonwoven fabric, and an ultrasonic welder apparatus with ⁇ 1 cm welding foot.
  • a rotary ultrasonic welding apparatus may be used, or a "stamp" type welder may be used.
  • the first line i.e. from the left hand side
  • the next weld shall be positioned immediately next to the previous weld, such that two seal lines are placed adjacently in parallel and separated by a 2cm wide zone.
  • the next weld shall be positioned 31 .5cm from the previous weld, and the pattern shall be repeated until all ten lines across the width of the pair of opposed pieces have been welded;
  • each container part being bounded by ultrasonic weld lines 33 and 35 and each being in communication with a filling tube 32 through which filler material may be injected into the container part.
  • both component parts (as constructed in steps 7 and 8) are joined. Place the two components back to back so that on one side the piping is visible and on the other the inner bag is visible. Sew along the same line used to fasten the piping in place - again ensuring that no needle passes inside of the peripheral weld line 33 of the inner bag, and fasten the edge containing the projecting tubes in this way at the edge sections/spaces between projecting tubes);
  • the finished case ready for filling and sealing.
  • the sealed filling tubes may be tucked into the outer bag which maybe sewn closed at its edge there, without penetrating the inner bag.
  • the aperture was kept constant at 50% and no adjustment was made to brightness, contrast or gamma away from their default setting (i.e. 0, 0 and 1 .00 in Image Pro Plus respectively).
  • the Leica DFC295 camera was set at auto exposure, which ranged between 230 and 300ms - outside of these ranges there is a danger of underexposing or overexposing the image.
  • the average sample size for investigation was 1 .55mm by 1 .21 mm, with an image resolution of 1955 pixels by 1532 pixels.
  • the image is taken with the sample flat and the optical axis of the camera substantially perpendicular to the plane of the sample so as to be not oblique thereby avoiding foreshortening in the image.
  • image segmentation can be applied to the whole image without an area of interest being selected.
  • edges of fibres/yarns are ill defined either take a new, clear image or use a 'Sharpen' or enhance edges through either a 'Sober or 'Roberts' filter.
  • a cross section of the image was obtained and click 'Measure' ⁇ 'Measurements'.
  • line function draw from one side of the fibre selected to the other (side bars assist this function). The value is automatically recorded. Statistics were based on at least 20 replicates.
  • PMI Porometer (APP-1200AEX) to detect smallest, mean and maximum (bubble point) pore sizes.
  • the PMI porometer is able to detect fluid flow pathways (i.e. all through pores) which are not identifiable using Image Analysis because they are obscured by other features.
  • Input the characteristics of the material (I.e. thickness and diameter), properties of the wetting fluid (in this case 'Galwick' solution with a surface tension of 15.9 dynes/cm), pressure required (higher for denser samples) and save location.
  • absorbent/hygroscopic materials such as cotton
  • Galwick accessing the sample using the process outlined above. Leave the sample for 5 minutes for the Galwick to penetrate all pores. Reassemble the porometer and resume testing.
  • synthetic materials such as SMS/SES/SM etc. a wet up/dry up test is adequate and will take less time. The machine will not pause, but requires a saturated sample from the beginning.
  • a method for measuring penetration forces in fabric A strip of sample material/s (500mm x 80mm) was clamped in the sample clamping plate.
  • the plate used comprised two annular discs each with a 20cm outside diameter and a 5cm 2 internal cavity surrounded by a rubber sealing ring to more securely fasten the specimen between them (sandwiched) and held firm across the inner annular cavity.
  • the second (retainer) layer was placed facing upwardly in first contact with the needle, to simulate penetration from the inside of a garment or the like.
  • the clamping plate was mounted to an Instron 4301 tensile testing apparatus, similarly to BS EN ISO 9073-5:2008; Determination of resistance to mechanical penetration (ball burst procedure).
  • a 1 .5mm diameter darning needle with conical tip was used to undertake mechanical penetration of the samples.
  • the minimum shaft length gripped by the testing apparatus was 20mm.
  • a 100N load cell was used for measurements. This was connected to a computer running Picoscope software.
  • the needle After mounting the sample (within the claming plate) to the testing apparatus, the needle was lowered until the point of the needle only just makes contact with the specimen. This prevents lateral movement of the needle during its descent. For single samples the needle protruded 35mm from the bottom edge of the upper jaw clamp, for double layers this was 45mm (due to larger elongations).
  • the darning needle was perpendicular to the test specimen during each test. The speed of descent of the needle was controlled to 100mm/min, and the Instron's load balance was set to zero. Data recording software was commenced and the Instron activated to commence the test. The test was stopped manually after penetration of the layer(s) occurred.
  • the left hand tables relate to woven fabrics comprising different woven fabric constructions.
  • the right hand tables relate to nonwoven fabrics comprising SMS having either 20g/m 2 or 35g/m 2 area density. Peak penetration force (N) and elongation (%) for two layer assemblies
  • Test sample 3 is highlighted, and excluded from statistical analysis due to metal on metal contact between the upper jaw and clamping plate on the Instron testing equipment. These initial experiments informed to decision to increase needle projection to 45mm for testing two layer assemblies. Appendix E
  • Samples were prepared in accordance with BS EN ISO 13935-2:1999.
  • the second (SMS) layer was layered on the inside of the cotton sample before ultrasonic welding and as such (from the under-side upwards) the layering was as follows: First layer - Second layer - Second layer - First layer (e.g. Cotton - SMS - SMS - Cotton) and this constituted the area of the weld.
  • the Ardmel Ultrasew H192 was set to a power output of 60%, a speed of speed set at '9' and 20mm of pressure. With the gauge length set at 200mm the sample was placed with a second layer (e.g. of SMS) and first layer (e.g. cotton) in both top and bottom jaws, loading the sample according to the standard.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

Selon la présente invention, un tissu multicouche comprend une première couche (29) comprenant un tissu ou un tricot qui est doté d'une porosité optique comprise entre 0,06 % et 35 %, ou d'une porosité comprise entre 50 % et 95 % ; et, une seconde couche (28) comprenant un tissu non tissé ou un voile qui est doté d'une porosité optique comprise entre 0,1 % et 15 %, ou une porosité comprise entre 75 % et 98 %.
PCT/GB2013/053207 2012-12-04 2013-12-04 Perfectionnements apportés et se rapportant à des tissus WO2014087161A1 (fr)

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WO2016044609A1 (fr) * 2014-09-17 2016-03-24 Massachusetts Institute Of Technology Tissus opaques à la lumière visible et transparents aux infrarouges
TWI618829B (zh) * 2016-04-21 2018-03-21 遠東新世紀股份有限公司 擋絨織物
US10111480B2 (en) 2015-10-07 2018-10-30 Nike, Inc. Vented garment
EP3251534A4 (fr) * 2015-01-26 2019-01-02 Goldwin Inc. Article de retenue de chaleur
US10362820B2 (en) 2012-04-18 2019-07-30 Nike, Inc. Cold weather vented garment
US10743596B2 (en) 2016-10-06 2020-08-18 Nike, Inc. Insulated vented garment formed using non-woven polymer sheets
US11019865B2 (en) 2016-10-06 2021-06-01 Nike, Inc. Insulated garment
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US11406148B2 (en) 2015-10-07 2022-08-09 Nike, Inc. Vented garment
US11606992B2 (en) 2012-04-18 2023-03-21 Nike, Inc. Vented garment
US11690417B2 (en) 2018-10-03 2023-07-04 Nike, Inc. Woven breathable textile
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US10806199B2 (en) 2012-04-18 2020-10-20 Nike, Inc. Cold weather vented garment
US11606992B2 (en) 2012-04-18 2023-03-21 Nike, Inc. Vented garment
US11229250B2 (en) 2012-04-18 2022-01-25 Nike, Inc. Cold weather vented garment
US10362820B2 (en) 2012-04-18 2019-07-30 Nike, Inc. Cold weather vented garment
US10694797B2 (en) 2012-04-18 2020-06-30 Nike, Inc. Cold weather vented garment
US11992072B2 (en) 2012-04-18 2024-05-28 Nike, Inc. Vented garment
US9951446B2 (en) 2014-09-17 2018-04-24 Massachusetts Institute Of Technology Infrared transparent visible opaque fabrics
WO2016044609A1 (fr) * 2014-09-17 2016-03-24 Massachusetts Institute Of Technology Tissus opaques à la lumière visible et transparents aux infrarouges
US10842211B2 (en) 2015-01-26 2020-11-24 Goldwin Inc. Heat-retaining article
EP3251534A4 (fr) * 2015-01-26 2019-01-02 Goldwin Inc. Article de retenue de chaleur
US11406148B2 (en) 2015-10-07 2022-08-09 Nike, Inc. Vented garment
US10111480B2 (en) 2015-10-07 2018-10-30 Nike, Inc. Vented garment
TWI618829B (zh) * 2016-04-21 2018-03-21 遠東新世紀股份有限公司 擋絨織物
US11019865B2 (en) 2016-10-06 2021-06-01 Nike, Inc. Insulated garment
US11737503B2 (en) 2016-10-06 2023-08-29 Nike, Inc. Insulated garment
US11771156B2 (en) 2016-10-06 2023-10-03 Nike, Inc. Insulated vented garment formed using non-woven polymer sheets
US10743596B2 (en) 2016-10-06 2020-08-18 Nike, Inc. Insulated vented garment formed using non-woven polymer sheets
US11690417B2 (en) 2018-10-03 2023-07-04 Nike, Inc. Woven breathable textile
WO2022126008A1 (fr) * 2020-12-11 2022-06-16 Primaloft, Inc. Construction isolante multicouche perméable à l'air
US11998071B2 (en) 2022-06-17 2024-06-04 Nike, Inc. Vented garment

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