Waterproof, breathable articles of apparel with fleece liners

Abstract

Articles of apparel and the method of making the same which include a uniquely constructed fleece liner and an elastomeric polyurethane film that will allow water vapor due to perspiration to transpire through the article, but will prevent water from external sources from reaching the wearer's extremities. The fleece liner component is constructed using a novel adhesive bonding process that produces a virtually seamless liner component that provides substantial warmth and comfort to the user.

I claim:  
     
         1 . A method of making an article of apparel used to cover a wearer's extremities comprising the steps of: 
 (a) depositing a heat activated adhesive on the first surface of a first fleece member to form a first precursor coated component, said heat activated adhesive comprising a powdered adhesive;    (b) placing a second fleece member component over said first precursor coated component to form an unbonded assemblage; and    (c) heating said unbonded assemblage along a line to an elevated temperature sufficient to melt said heat activated adhesive thereby bonding said first precursor coated component and second fleece member component together along said line.    
     
     
         2 . The method as defined in  claim 1  in which said line is in the shape of a foot.  
     
     
         3 . The method as defined in  claim 1  in which said unbonded assemblage is heated along said line to an elevated temperature of between about 350 and about 450 degrees Fahrenheit.  
     
     
         4 . A method of making an article of apparel used to cover a wearer's extremities using a die generally corresponding to the shape of the margin of the article of apparel, the method comprising the steps of: 
 (a) depositing a heat activated adhesive on the first surface of a first fleece member to form a first precursor coated component, said heat activated adhesive comprising a powdered adhesive;    (b) placing a second fleece member component over said first precursor coated component to form a precursor assemblage; and    (c) heating the die to an elevated temperature sufficient to melt said heat activated adhesive; and    (d) bringing said die into pressural engagement with said precursor assemblage to bond together said first precursor coated component and said second fleece member component to form an article of apparel.    
     
     
         5 . The method as defined in  claim 4  in which the die is heated to an elevated temperature of between about 350 and about 450 degrees Fahrenheit.  
     
     
         6 . The method as defined in  claim 4  in which the die is brought into pressural engagement with said precursor assemblage at a pressure of between about 40 and about 60 p.s.i.  
     
     
         7 . A method of making an article of apparel used to cover a wearer's extremities comprising the steps of: 
 (a) constructing a fleece liner component in accordance with the following steps: 
 (i) depositing a heat activated adhesive on the first surface of a first fleece member to form a first precursor;  
 (ii) overlaying a second fleece member over said first precursor to form an unbonded assemblage; and  
 (iii) heating said unbonded assemblage along a line defining the shape of the fleece liner to an elevated temperature sufficient to melt said heat activated adhesive to bond said first precursor and said second fleece member together along said line;  
   (b) depositing a heat activated adhesive on both surfaces of a stretchable, waterproof, breathable membrane to form a coated membrane;    (c) forming said coated membrane into a bladder having an extremity receiving portion in the general shape of the wearer's extremity to be covered, said bladder having a smooth outer surface and a smooth inner surface generally conformable to the contours of the extremity to be covered;    (d) placing said bladder over said fleece liner component to form a first assemblage;    (e) placing an outer fabric member over said first assemblage to form a second assemblage; and    (f) simultaneously heating said second assemblage to a temperature of between about 260 and about 390 degrees Fahrenheit and compressing said second assembly at a pressure sufficient to form a composite in which said fleece liner component and said outer fabric member are securely bonded to said bladder.    
     
     
         8 . A method as defined in  claim 7  in which said waterproof, breathable membrane comprises a thin, generally planar, smooth surfaced thin film having a wall thickness of between about 0.001 inch and about 0.0018 inch.  
     
     
         9 . A method as defined in  claim 7  in which the article of apparel comprises a sock.  
     
     
         10 . A method of making a sock used to cover a wearer's foot comprising the steps of: 
 (a) constructing a fleece liner component in accordance with the following steps: 
 (i) depositing a heat activated adhesive on the first surface of a first fleece member to form a first precursor,  
 (ii) overlaying a second fleece member over said first precursor to form an unbonded assemblage; and  
 (iii) heating said unbonded assemblage along a line having the shape of the sock to an elevated temperature sufficient to melt said heat activated adhesive to bond said first coated precursor and second fleece member together along said line;  
   (b) depositing heat activated adhesive on both surfaces of a stretchable, waterproof, breathable membrane to form a coated membrane;    (c) forming said coated membrane into a bladder, having an extremity receiving portion in the general shape of the wearer's foot, said bladder having a smooth outer surface and a smooth inner surface generally conformable to the contours of the extremity to be covered;    (d) placing said bladder over said fleece liner component to form a first assemblage;    (e) placing an outer fabric member over said first assemblage to form a second assemblage; and    (f) simultaneously heating said second assemblage to a temperature of between about 260 and about 390 degrees Fahrenheit and compressing said second assembly at a pressure sufficient to form a composite in which said fleece liner component and said outer fabric member are securely bonded to said bladder.    
     
     
         11 . A method as defined in  claim 10  in which said waterproof, breathable membrane comprises a thin, generally planar, smooth surfaced thin film having a wall thickness of between about 0.001 inch and about 0.0018 inch.  
     
     
         12 . The method as defined in  claim 11  in which said waterproof, breathable membrane comprises a material selected from a group consisting of urethane, polyurethane, and elastomers made from polyester, polyamides, cellulose derivatives and polyacrylic acid and a polytetraflouroethylene film.  
     
     
         13 . An article of apparel used to cover a wearer's extremities comprising: 
 (a) a pliant, generally extremity-shaped hollow bladder constructed from a waterproof, breathable material, said bladder including as a part thereof, a continuous extremity covering portion for enclosing there-within the wearer's extremity, including a continuous outer surface and a continuous inner surface generally conforming to the contours of the wearer's extremity; and    (b) a generally extremity shaped fleece liner having a continuous surface attached directly to said inner surface of said bladder along a substantial portion thereof.    
     
     
         14 . An article as defined in  claim 13  in which said fleece liner is bonded to said bladder by a heat activated adhesive.  
     
     
         15 . An article as defined in  claim 13  further including an outer fabric member bonded to the outer surface of said bladder.  
     
     
         16 . An article as defined in  claim 13  in which said article is adapted to cover a wearer's foot and in which said bladder and said fleece liner are in the general shape of a human foot.  
     
     
         17 . A waterproof footwear article for enclosing a wearer's foot, comprising: 
 (a) an elastomeric, breathable and waterproof stretchable elastic bladder having a continuous foot receiving portion the general shape of the wearer's foot and including continuous outer surface and a continuous inner surface generally conformable to the wearer's foot;    (b) an inner fleece liner bonded to said bladder along a substantial portion of said inner surface of said bladder; and    (c) an outer fabric covering bonded to said bladder along a substantial portion of said outer surface of said bladder.    
     
     
         18 . An article as defined in  claim 17  in which said elastomeric bladder permits the water vapor content of perspiration to pass therethrough in a direction toward said outer fabric covering, but prevents water in liquid form from passing therethrough toward said inner fleece liner.  
     
     
         19 . An article as defined in  claim 17  in which said bladder comprises a material selected from a group consisting of urethane, polyurethane, and elastomers made from polyester, polyamides, cellulose derivatives and polyacrylic acid and a polytetraflouroethylene film.  
     
     
         20 . An article as defined in  claim 19  in which said inner and outer socks are bonded to said bladder by a heat-activated adhesive.