Laminates, Bladders, and Garments Including Laminates and Bladders

Abstract

Garments include one or more fluid-filled bladder chambers for providing thermal insulation to a wearer. The bladder chamber(s) may be convertible between a deflated condition and an inflated condition. The bladder chamber(s) may be integrally formed with the fabric forming the garment, e.g., with the bladder chamber(s) defined between an exterior laminated component (e.g., formed from a fabric layer and a film layer) and an interior component (e.g., including at least a film layer). The film layers are selectively fixed together, e.g., at a perimeter bond and/or one or more internal bonded regions, to form fluid-tight bladder chamber portions within the overall garment structure. The garments may be equipped with a pump (for adding air to the garment bladder chamber(s)) and/or a release system (for removing air from the garment bladder chamber(s)). In this manner, a wearer can change the garment between the deflated condition and the inflated condition.

1 . A laminate structure for a washable and reusable garment, comprising:
 a first knit fabric having an inner face and an outer face, wherein the first knit fabric includes a double jersey knit structure, has a basis weight of at least 20 grams per square meter and less than 120 grams per square meter, and is formed by a first yarn having a linear mass density of at least 10 denier and less than 100 denier; and   a first film having an inner surface and an outer surface and a thickness of less than 120 micron, wherein the first film includes at least one fluid impervious layer chosen from a polyurethane layer and a thermoplastic polyurethane layer, wherein the first film is bonded to the inner face of the first knit fabric to form the laminate structure.   
     
     
         2 . The laminate structure according to  claim 1 , wherein the first film is bonded to the first knit fabric with a peel strength of at least 1 kg/cm. 
     
     
         3 . The laminate structure according to  claim 1 , wherein the double jersey knit structure comprises a drawn textured yarn. 
     
     
         4 . The laminate structure according to  claim 1 , wherein the first knit fabric comprises a nylon material forming the double jersey knit structure. 
     
     
         5 . The laminate structure according to  claim 1 , wherein the first knit fabric comprises a durable water resistant material provided on at least one of the inner face or the outer face. 
     
     
         6 . The laminate structure according to  claim 1 , wherein the thickness of the first film is at least 40 micron and less than 100 micron. 
     
     
         7 . The laminate structure according to  claim 1 , wherein the first film is formed from a thermoplastic polyurethane material. 
     
     
         8 . The laminate structure according to  claim 1 , wherein the first film comprises a first layer and a second layer joined together, wherein the first layer is formed from a thermoplastic polyurethane material, wherein the second layer is bonded to the inner face of the first knit fabric and is formed from a polyurethane material or a thermoplastic polyurethane material, and wherein first layer is engaged with the second layer on an opposite side of the second layer from the first knit fabric. 
     
     
         9 . The laminate structure according to  claim 8 , wherein the first layer is between 20 micron and 50 micron thick, and wherein the second layer is between 20 micron and 50 micron thick. 
     
     
         10 . The laminate structure according to  claim 1 , wherein the first film comprises a first layer and a second layer joined together, wherein the first layer is formed from a first thermoplastic polyurethane material having a first melt temperature, wherein the second layer is bonded to the inner face of the first knit fabric and is formed from a second thermoplastic polyurethane material having a second melt temperature, wherein the second melt temperature is greater than the first melt temperature, and wherein the first layer is engaged with the second layer on an opposite side of the second layer from the first knit fabric. 
     
     
         11 . The laminate structure according to  claim 10 , wherein the first layer is between 20 micron and 50 micron thick, and wherein the second layer is between 20 micron and 50 micron thick. 
     
     
         12 . The laminate structure according to  claim 10 , wherein the second melt temperature is at least 10 degrees C. higher than the first melt temperature. 
     
     
         13 . A laminate structure for a garment, comprising:
 a first knit fabric comprising a plurality of loops, the first knit fabric having two opposite fabric surfaces, wherein the first knit fabric includes a double jersey knit structure and has a basis weight of at least 15 grams per square meter and less than 150 grams per square meter; and   a first film comprising at least one air-impermeable layer, the first film having two opposite film surfaces and a thickness of more than 30 micron and less than 100 micron, wherein:
 the at least one air-impermeable layer comprises at least one of: (i) a polyurethane layer and/or (ii) a thermoplastic polyurethane layer, and 
 the first film is bonded to the first knit fabric such that one film surface has a bond with one fabric surface. 
   
     
     
         14 . The laminate structure according to  claim 13 , wherein the first knit fabric is formed by a first yarn having a linear mass density of at least 10 denier and less than 100 denier. 
     
     
         15 . The laminate structure according to  claim 14 , wherein the linear mass density is within a range of 35 denier and 65 denier. 
     
     
         16 . The laminate structure according to  claim 14 , wherein the linear mass density is within a range of 10 denier and 25 denier. 
     
     
         17 . The laminate structure according to  claim 13 , wherein the double jersey knit structure comprises a drawn textured yarn. 
     
     
         18 . The laminate structure according to  claim 13 , wherein the at least one air-impermeable layer is formed from a thermoplastic polyurethane material. 
     
     
         19 . The laminate structure according to  claim 13 , wherein the at least one air-impermeable layer is formed from a first layer and a second layer joined together, wherein the first layer is formed from a thermoplastic polyurethane material, wherein the second layer is bonded to the first knit fabric and is formed from a polyurethane material or a thermoplastic polyurethane material, and wherein the second layer is engaged with the first layer on an opposite side of the first layer from the first knit fabric. 
     
     
         20 . The laminate structure according to  claim 19 , wherein the first layer is between 20 micron and 50 micron thick, and wherein the second layer is between 20 micron and 50 micron thick.