# US 9,040,436 B2 · Lightweight, durable apparel and laminates for making the same

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- Number: US 9,040,436 B2
- Document ID: US9040436B2
- Status: Granted
- Kind: B2
- Application number: 13/804,158
- Filed: 2013-03-14
- Published: 2013-08-01
- Granted: 2015-05-26
- Earliest claimed: 2009-05-13
- Assignees: W. L. Gore & Associates, Inc.
- Applicants: W. L. Gore & Associates, Inc.
- Inventors: Matthew A. Johnson; Edward C. Gunzel
- Web page: https://patentgrep.com/patent/US9040436B2

## CPC

- A41D 31/102: Waterproof and breathable
- A41D 13/00: Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches (helmets A42B3/00; clothing affording protection against chemical agents or for use at high altitudes A62B17/00; life-saving garments for use at sea, diving suits B63C; bulletproof or armoured clothing F41H; clothing affording protection against radiation G21F3/02)
- A41D 31/24: Resistant to mechanical stress, e.g. pierce-proof {(aprons resistant to mechanical aggressions A41D13/043)}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/22: characterised by the presence of two or more layers which {are next to each other and are fibrous, filamentary, formed of particles or foamed (layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04)}
- B32B 5/30: one layer {being formed of particles, e.g. chips,} granules, powder
- B32B 7/14: applied in spaced arrangements, e.g. in stripes
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/322: {comprising halogenated polyolefins, e.g. PTFE}
- B32B 27/40: comprising polyurethanes
- A41D 3/00: Overgarments (fur garments A41D5/00; for children A41D11/00; professional or sporting protective garments A41D13/00)
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/04: on a particulate layer
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/26: Polymeric coating
- B32B 2262/0246: Acrylic resin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/04: Cellulosic plastic fibres, e.g. rayon
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/101: Glass fibres
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2264/0257: Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers
- B32B 2305/026: Porous
- B32B 2307/4023: on the layer surface, e.g. ink
- B32B 2307/50: having particular mechanical properties
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/554: Wear resistance
- B32B 2307/558: Impact strength, toughness
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/724: Permeability to gases, adsorption
- B32B 2307/7265: Non-permeable
- B32B 2307/73: Hydrophobic
- B32B 2437/00: Clothing
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- Y10T 442/20: Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T 442/2139: Coating or impregnation specified as porous or permeable to a specific substance [e.g., water vapor, air, etc.]
- Y10T 442/2148: Coating or impregnation is specified as microporous but is not a foam
- Y10T 442/2164: Coating or impregnation specified as water repellent
- Y10T 442/2172: Also specified as oil repellent
- A41D: OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Laminates are described having a durable outer film surface for use in making lightweight liquidproof articles, including articles of apparel, such as outerwear garments. A method of making the laminate and a lightweight outerwear garment having an abrasion resistant exterior film surface is described.

## Claims

### Claim 1

An outerwear garment comprising:
a laminate comprising:
a first layer comprising a porous polytetrafluoroethylene (PTFE) membrane having an oleophobic outer film surface and an inner film surface opposing said outer film surface, said porous PTFE membrane having an average ball burst load greater than 17 lb force; and
a second layer comprising a knit textile bonded to said inner film surface of said porous PTFE membrane,
wherein said laminate is oriented in said outerwear garment such that said outer film surface of said porous PTFE membrane faces the environment and said knit textile faces a wearer of said outerwear garment,
wherein said laminate has a water pickup less than or equal to about 10 g/m2 when tested according to the Water Pickup Test,
wherein said laminate is liquidproof after more than 6000 abrasion movements on the outer film surface when tested according to the Liquidproof (Suter) After Hook Abrasion Test, and
wherein said laminate has a moisture vapor transmission rate greater than 10,000 g/m2/24 hours, wherein said porous PTFE membrane has an average maximum load in the transverse and longitudinal direction greater than 10 N,
wherein said porous PTFE membrane has an average modulus in the transverse and longitudinal direction greater than 40 MPa,
wherein said porous PTFE membrane has an average matrix tensile strength in the longitudinal and transverse direction greater than 90 MPa.

### Claim 2 (depends on 1)

The outerwear garment of claim 1, wherein said porous PTFE membrane has a mass per area between 19 g/m2 and 60 g/m2.

### Claim 3 (depends on 2)

The outerwear garment of claim 2, wherein said laminate has an average maximum load in the transverse and longitudinal direction greater than 10 N,
wherein said porous PTFE has an average modulus in the transverse and longitudinal direction greater than 40 MPa, and
wherein said porous PTFE has an average matrix tensile strength in the longitudinal and transverse direction greater than 90 MPa.

### Claim 4 (depends on 1)

The outerwear garment of claim 1, wherein said laminate has a water pickup less than or equal to about 6 g/m2 when tested according to the Water Pickup Test and a mass per area less than 200 g/m2.

### Claim 5 (depends on 1)

The outerwear garment of claim 1, wherein said laminate has a water pickup less than or equal to about 3 g/m2 when tested according to the Water Pickup Test and a mass per area less than 125/m2.

### Claim 6 (depends on 1)

The outerwear garment of claim 1, wherein said outer film surface is colorized and has a Delta-E less than 15.

### Claim 7 (depends on 1)

The outerwear garment of claim 1, wherein said laminate has a mass per area less than 200/m2,
wherein said outer film surface is colorized and has a Delta-E less than 15,
wherein said laminate has an average maximum load in the transverse and longitudinal direction greater than 20 N,
wherein said porous PTFE has an average modulus in the transverse and longitudinal direction greater than 60 MPa, and
wherein said porous PTFE has an average matrix tensile strength in the longitudinal and transverse direction greater than 150 MPa.

### Claim 8

An outerwear garment comprising:
a laminate comprising:
a first layer comprising a porous polytetrafluoroethylene (PTFE) membrane having an oleophobic outer film surface and an inner film surface opposing said outer film surface; and
a second layer comprising a knit textile bonded to said inner film surface of said porous PTFE membrane,
wherein said laminate is oriented in said outerwear garment such that said outer film surface of said porous PTFE membrane faces the environment and said knit textile faces a wearer of said garment,
wherein said porous PTFE membrane has an average ball burst load greater than 17 lb force,
wherein said porous PTFE membrane has an average maximum load in the transverse and longitudinal direction greater than 10 N,
wherein said porous PTFE membrane has an average modulus in the transverse and longitudinal direction greater than 40 MPa,
wherein said porous PTFE membrane has an average matrix tensile strength in the longitudinal and transverse direction greater than 90 MPa,
wherein said laminate has a mass per area less than 400 g/m2,
wherein said laminate has a water pickup less than or equal to about 10 g/m2 when tested according to the Water Pickup Test,
wherein said laminate is liquidproof after more than 6000 abrasion movements on the outer film surface when tested according to the Liquidproof (Suter) After Hook Abrasion Test, and
wherein said laminate has a moisture vapor transmission rate (MVTR) greater than 20,000 g/m2/24 hours.

### Claim 9 (depends on 8)

The outerwear garment of claim 8, wherein said porous PTFE membrane has an average ball burst load greater than 19 lb force,
wherein said porous PTFE membrane has an average maximum load in the transverse and longitudinal direction greater than 20 N,
wherein said porous PTFE membrane has an average modulus in the transverse and longitudinal direction greater than 60 MPa,
wherein said porous PTFE membrane has an average matrix tensile strength in the longitudinal and transverse direction greater than 100 MPa.

### Claim 10 (depends on 8)

The outerwear garment of claim 8, wherein said outer film surface is colorized and has a Delta-E less than 15.

### Claim 11 (depends on 8)

The outerwear garment of claim 8, wherein said porous PTFE membrane has an average toughness from 22 MPa to 42 MPa.

### Claim 12 (depends on 8)

The outerwear garment of claim 8, wherein said laminate has a water pickup less than or equal to about 10 g/m2 when tested according to the Water Pickup Test.

### Claim 13 (depends on 8)

The outerwear garment of claim 8, said laminate has a mass per area less than 200 g/m2.

### Claim 14 (depends on 8)

The outerwear garment of claim 8, wherein said laminate has a water pickup less than or equal to about 6 g/m2 when tested according to the Water Pickup Test.

### Claim 15 (depends on 1)

The outerwear garment of claim 1, wherein said laminate has a mass per area less than 400 g/m2.

### Claim 16 (depends on 1)

The outerwear garment of claim 1, wherein said textile is fire resistant.

### Claim 17 (depends on 8)

The outerwear garment of claim 8, wherein said textile is fire resistant.