Fabrication Process for Garments and Other Fabric Products

Abstract

Fabrication processes are provided for a fabric product that provide a continuous moisture and/or thermal barrier around the fabric product, eliminating moisture and thermal leakage through seams and other stitching perforations, and creating an equal barrier quality throughout the structure of the fabric product. A fabric product is also provided.

What is claimed is: 
     
         1 . A multi-layered fabric product comprising:
 an outer shell fabric comprising a plurality of fabric pattern panels, at least one seam formed along edges of fabric pattern panels to join the fabric pattern panels together, the outer shell fabric having an inner side and an outer side;   a barrier layer comprising a plurality of pattern panels fused to the inner side of the outer shell fabric, the pattern panels overlapping in an area extending along the seam of the outer shell fabric, wherein the barrier layer extends across the inner surface of the outer shell fabric and the at least one seam between the outer shell fabric pattern panels.   
     
     
         2 . The product of  claim 1 , wherein the at least one seam comprises a sewn seam or an ultrasonically welded seam. 
     
     
         3 . The product of  claim 1 , wherein the barrier layer comprises a hydrophobic polymer membrane. 
     
     
         4 . The product of  claim 3 , wherein the hydrophobic polymer membrane comprises a material selected from the group consisting of microporous polytetrafluoroethylene (PTFE), nanoporous PTFE, expanded PTFE, polyurethane, cross-linked polyurethane, polypropylene, and polyester. 
     
     
         5 . The product of  claim 1 , wherein the barrier layer comprises activated carbon particles with microporous structures. 
     
     
         6 . The product of  claim 1 , wherein the barrier layer is capable of withstanding a hydrostatic pressure of at least 1 psi, including across the at least one seam. 
     
     
         7 . The product of  claim 6 , wherein the barrier layer is capable of withstanding a hydrostatic pressure of at least 45 psi, including across the at least one seam. 
     
     
         8 . The product of  claim 1 , wherein the barrier layer is equally resistant to hydrostatic pressure across the inner surface of the outer shell fabric and the at least one seam. 
     
     
         9 . The product of  claim 1 , wherein the barrier layer is resistant to at least one of pathogenic microorganisms, blood borne pathogens, viruses, bacteria, liquid chemical agents, and gaseous chemical agents. 
     
     
         10 . The product of  claim 1 , wherein the barrier layer is resistant to heat loss. 
     
     
         11 . The product of  claim 1 , wherein the barrier layer comprises an insulation material. 
     
     
         12 . The product of  claim 11 , wherein the insulation material comprises a natural or synthetic filament material. 
     
     
         13 . The product of  claim 1 , further comprising an inner lining fabric pattern panel fused to the barrier layer and overlapping in the area extending along the seam of the outer shell fabric. 
     
     
         14 . The product of  claim 13 , wherein the inner lining fabric comprises a fleece material or a tricot material. 
     
     
         15 . The product of  claim 13 , wherein the inner lining fabric comprises multiple layers quilted together. 
     
     
         16 . The product of  claim 13 , wherein the inner lining fabric comprises a material selected from the group consisting of polyester, polyamide, polyvinylchloride, polyketone, polysulfone, polycarbonate, fluoropolymer, polyacrylate, polyurethane, co-polyetherester, polypropylene, and co-polyetheramide. 
     
     
         17 . The product of  claim 1 , wherein the adhesive is selected from the group consisting of powder adhesive, web adhesive, microdot adhesive, and nanodot adhesive. 
     
     
         18 . The product of  claim 1 , wherein the outer shell fabric comprises a material selected from the group consisting of polyester, polyamide, polyvinylchloride, polyketone, polysulfone, polycarbonate, fluoropolymer, polyacrylate, polyurethanes, co-polyetherester, polypropylene, and co-polyetheramide. 
     
     
         19 . The product of  claim 1 , wherein the outer shell fabric comprises multiple layers quilted together. 
     
     
         20 . The product of  claim 1 , wherein the product is an article of clothing, a portion of an article of clothing, a jacket, a coat, a parka, a raincoat, a cloak, a poncho, a shirt, a blouse, pants, a shoe, a boot, a glove, a hat, a hood, underwear, an undershirt, briefs, a bra, socks, a diaper, a protective suit for handling of hazardous materials, a protective suit for a firefighter, military personnel, or medical personnel, a blanket, a towel, a sheet, pet bedding, a tent, a sleeping bag, a tarp, a boat cover, carpeting, a rug, a mat, a window covering, or upholstery. 
     
     
         21 . A composite material comprising:
 a first layer comprising a high melt membrane film, the high melt membrane film comprising a material selected from the group consisting of polyester, polyether, polypropylene, polyurethane, thermoplastic polyurethane, PTFE, and expanded PTFE;   a second layer disposed on a first side of the first layer, the second layer comprising a low melt membrane film, the low melt membrane film comprising a material selected from the group consisting of polyester, polyether, polypropylene, and polyurethane;   wherein the low melt membrane film has a melting temperature lower than a melting temperature of the high melt membrane film.   
     
     
         22 . The composite material of  claim 21 , further comprising:
 a third layer disposed on a second side of the first layer, the third layer comprising a lower melt film, the lower melt film comprising a material selected from the group consisting of polyester, polyether, polypropylene, and polyurethane;   wherein the lower melt membrane film has a melting temperature lower than the melting temperature of the low melt membrane film.