Textile constructs formed with fusible filaments

Abstract

A textile construct with a performance film formative built into a textile structure. The textile construct needs only to be subject to a fusing agent to cause the performance film formative to convert from its lattice structure (e.g., knit or woven structure) into a film that is built into a retained lattice structure of the textile. More particularly, the formation of the textile construct is based on fusion of selected filaments, e.g., thermoplastic fibers or yarns, to selectively create a film on one side or layer in the construct while substantially preserving the lattice structure of an opposing side or adjacent layer of non-fusible filaments in a lattice structure. This creates a hybrid film/lattice textile construct. Both open-faced and sandwiched constructions of the film in a unitary structure with the retained lattice structure of another side or layer(s) are possible.

1 . A textile construct, comprising:
 a unitary, hybrid structure of a textile lattice formed from filaments and a thermoplastic film;   the thermoplastic film forming a first side or layer of the textile construct comprising a film of fused material having a substantially solid surface area of at least 50%; and   a second side or layer of the textile construct comprising a discrete knit or woven lattice structure of filaments, the second side or layer being adjacent to and coextensive with the first side or layer and fused to it; and the lattice structure is formed from shrinkable filaments that are non-fusible relative to the fused, thermoplastic film material.   
     
     
         2 . The construct of  claim 1  wherein the shrinkable filaments comprise multifilament filaments having one or more core filaments comprising a shrinkable filament. 
     
     
         3 . The construct of  claim 2  wherein the core filament(s) comprise one or more bicomponent filaments, the bi-component filaments comprising first and second parallel components having differing shrinkability. 
     
     
         4 . The construct of  claim 2  wherein the core filament(s) are wrapped and thereby sheathed by a plurality of textured filaments. 
     
     
         5 . The construct of  claim 4  wherein the textured filaments comprise polyester. 
     
     
         6 . The construct of  claim 1  wherein the non-fusible filament comprises multiple filaments arranged in a core-sheath, multi-filament structure, the core being a monofilament wrapped with multiple textured yarns forming the sheath. 
     
     
         7 . The construct of  claim 1  wherein the film comprises a thermoplastic material having a glass transition temperature in the range of 110 degrees C. to 160 degrees C. or thereabout. 
     
     
         8 . The construct of  claim 1  wherein the non-fusible filaments comprise a shrinkable filament capable of shrinking in length 5%-40% or thereabout when subjected to temperatures of from 110 degrees C. to 160 degrees C. or thereabout. 
     
     
         9 . The construct of  claim 1  wherein the fused thermoplastic film comprises one or more of TPU, polyamide, polyester, polypropylene, and/or polyolefin. 
     
     
         10 . The construct of  claim 1  wherein the non-fusible filament for the discrete lattice is selected from the group of polyester, nylon, wool, cotton and/or silk. 
     
     
         11 . The construct of  claim 1  wherein the construct has an elasticity of 1% to about 30%. 
     
     
         12 . The construct of  claim 11  wherein the film has a thickness of from about 0.5 mm to about 3 mm. 
     
     
         13 . The construct of  claim 6  wherein the construct has an elasticity of 1% to about 30%. 
     
     
         14 . The construct of  claim 13  wherein film has a thickness of from about 0.5 mm to about 3 mm. 
     
     
         15 . The construct of  claim 1  wherein the film comprises a porous membrane of fused material having a pore density of at least 9 billion pores per square inch and/or average pore size of 0.2 microns or less. 
     
     
         16 . The A textile construct, comprising:
 a unitary, hybrid structure of a textile lattice formed from filaments and a thermoplastic film   the thermoplastic film forming a first side or layer of the textile construct comprising   a film of fused material having a substantially solid surface area of at least 50%;   a second side or layer of the textile construct comprising a discrete knit or woven lattice structure of filaments, the second side or layer being adjacent to and coextensive with the first side or layer and fused to it, and the lattice structure is formed from shrinkable filaments that are non-fusible relative to the fused, thermoplastic film material; and   wherein the membrane provides waterproofness or water resistance and/or breathability to the construct according to any one of the following standards:
 Low range hydrostatic—AATCC127 (Option 2) or JIS L1092; 
 High range hydrostatic—ASTM D751 (Fed Std 191-A55); 
 MVTR (upright)—ASTM E96B; 
 MVTR (inverted)—JIS L 1099 (Method B); and 
 Air Permeability—ASTM D737. 
   
     
     
         17 . The construct of  claim 1  wherein the construct has an elasticity of 1% to about 30%, and wherein the fused thermoplastic film and the non-fusible filaments have stretchability values within 40% of each other. 
     
     
         18 . A method of forming a textile construct, comprising:
 forming a composite textile lattice structure comprising an arrangement of (i) a first group of fusible filaments in a first lattice structure and (ii) a second group of non-fusible filaments in a second lattice structure, the non-fusible filaments comprising shrinkable filaments that are non-fusible relative to the fusible filaments, the first and second lattice structures being coextensively intermeshed to form the composite lattice structure, with the fusible filaments being selectively disposed primarily on one side of the composite lattice structure;   subjecting the composite lattice structure to a fusing agent sufficient to selectively cause the fusible filaments in the first lattice structure to fuse into a film substantially on one side or layer of the construct while maintaining the second lattice structure substantially in a discrete lattice structure, the fused film and the discrete lattice structure being coextensively fused together; and   in the forming of the composite lattice structure, matching the shrink or stretch ratio of the non-fusible filaments and fusible filaments so that the shrinking or stretching of one of the lattice structures will not cause delamination, separation, tearing or other significant damage to the composite structure during the step to fuse the non-fusible filaments into a film of fused material, the film having a substantially solid surface area of at least 50%.   
     
     
         19 . The method of  claim 18  further comprising assembling the construct into an article selected from the group of an article of apparel, footwear, tent, and backpack. 
     
     
         20 . The method of  claim 19  further comprising the step of imparting a non-planar, 3D shape to the composite structure.