Elastomer-enhanced fabrics, articles of manufacture including such fabrics, and methods of making same

Abstract

An elastomer-enhanced fabric includes one or more fiber strands, and an elastomeric material carried by the one or more fiber strands. The elastomeric material may comprise an elastomeric polymer and a plasticizer. The elastomeric material does not entirely fill all spaces between the one or more fiber strands, such that the fabric has a textured surface. Articles of manufacture include such elastomer-enhanced fabric. A method of forming an elastomer-enhanced fabric includes providing an elastomeric material on one or more fiber strands of a fabric, and causing the elastomeric material to not entirely fill all spaces between the one or more fiber strands, such that the fabric has a textured surface. The elastomeric material may comprise an elastomeric polymer and a plasticizer.

What is claimed is: 
     
         1 . An elastomer-enhanced fabric, comprising:
 one or more fiber strands, the one or more fiber strands including at least one fiber and an elastomeric material carried by the at least one fiber, the elastomeric material comprising an elastomeric polymer and a plasticizer;   wherein the elastomeric material does not entirely fill all spaces between the one or more fiber strands, such that the elastomer-enhanced fabric has a textured surface.   
     
     
         2 . The fabric of  claim 1 , wherein voids are present in the spaces between the one or more fiber strands. 
     
     
         3 . The fabric of  claim 2 , wherein gas may permeate across the fabric from one side of the fabric to another opposite side of the fabric through the voids in the spaces between the one or more fiber strands. 
     
     
         4 . The fabric of  claim 1 , wherein the one or more fiber strands including at least one fiber comprises a strand of interlocked fibers. 
     
     
         5 . The fabric of  claim 4 , wherein the elastomeric material is infused into the spaces between the interlocked fibers of the strand. 
     
     
         6 . The fabric of  claim 1 , wherein the fabric comprises woven fiber strands. 
     
     
         7 . The fabric of  claim 1 , wherein the fabric comprises non-woven fiber strands. 
     
     
         8 . The fabric of  claim 1 , wherein the fabric comprises one or more knitted fiber strands. 
     
     
         9 . The fabric of  claim 1 , wherein the one or more fiber strands are not laminated to, sandwiched with, or submerged in a continuous sheet of the elastomeric material. 
     
     
         10 . The fabric of  claim 1 , wherein the elastomeric material comprises a material selected from the group consisting of a gelatinous elastomer, a thermoplastic elastomer, rubber, a synthetic elastomer, and combinations thereof. 
     
     
         11 . The fabric of  claim 1 , wherein a ratio of a weight of the elastomeric polymer to a weight of the plasticizer is from about 0.1 to about 8. 
     
     
         12 . The fabric of  claim 1 , wherein the elastomeric polymer comprises an A-B-A triblock copolymer. 
     
     
         13 . An article of manufacture comprising a fabric as recited in  claim 1 . 
     
     
         14 . The article of manufacture of  claim 13 , wherein the article of manufacture is selected from the group consisting of an article of clothing and a cover for or a component within a pillow, mattress, or cushion. 
     
     
         15 . A method of forming an elastomer-enhanced fabric, comprising:
 providing an elastomeric material on at least one fiber of one or more fiber strands of a fabric, the elastomeric material comprising an elastomeric polymer and a plasticizer; and   causing the elastomeric material to not entirely fill all spaces between the one or more fiber strands, such that the fabric has a textured surface.   
     
     
         16 . The method of  claim 15 , wherein providing an elastomeric material on the at least one fiber of the one or more fiber strands of a fabric comprises:
 disposing a liquid comprising an elastomeric material on the one or more fiber strands; and   removing a portion of the liquid comprising the elastomeric material from the one or more fiber strands.   
     
     
         17 . The method of  claim 16 , wherein removing the portion of the liquid comprising the elastomeric material from the one or more fiber strands comprises compressing the one or more fiber strands to expel at least some of the liquid comprising the elastomeric material from the one or more fiber strands. 
     
     
         18 . The method of  claim 15 , further comprising:
 selecting the one or more fiber strands to include a strand of interlocked fibers; and   infiltrating the interlocked fibers of the strand with the elastomeric material.   
     
     
         19 . The method of  claim 15 , wherein providing an elastomeric material on one or more fiber strands of a fabric comprises:
 providing the elastomeric material on the one or more fiber strands; and   subsequently forming the one or more fiber strands into the fabric.   
     
     
         20 . The method of  claim 15 , wherein providing an elastomeric material on one or more fiber strands of a fabric comprises:
 forming the fabric comprising the one or more fiber strands; and   subsequently providing the elastomeric material on the one or more fiber strands of the fabric.