Coating processes – Solid particles or fibers applied – Applying superposed diverse coatings or coating a coated base
Reexamination Certificate
2002-09-23
2004-11-30
Singh, Arti R. (Department: 1771)
Coating processes
Solid particles or fibers applied
Applying superposed diverse coatings or coating a coated base
C442S152000, C442S153000, C442S164000, C442S228000, C442S148000, C442S093000, C442S094000, C008S495000, C427S205000, C427S214000, C427S412000
Reexamination Certificate
active
06824819
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to metallized fabrics which are durable to washing and wear. They can be used to down-proof articles in which they are used as linings, e.g., down and fiber filled, insulated articles of clothing and sleeping bags.
BACKGROUND OF THE INVENTION
Metallized fabrics are utilized to reflect radiant heat emitted by the body and thus provide effective heat insulation, particularly for outdoor use and in cold weather climates, e.g., winter apparel and sleeping bags.
U.S. Pat. No. 4,569,874 to Kuznetz discloses lightweight sportswear fabric for cold climates which comprises a composite fabric having vapor-permeable laminate formed by a core layer of hollow fibers acting as a thermal blanket between inner and outer skins. Both faces of the inner skin and the inside face of the outer skin are metallized to render them reflective while the outside face of the outer skin is blackened to absorb solar energy. Radiant heat from the wearer is reflected by the outside face of the inner skin while convection heat from the wearer's body passes by conduction through the inner skin of the laminate to be absorbed by the core layer. Solar heat absorbed by the blackened face is conducted through the outer skin to be absorbed by the core layer. Infrared energy loss from the core layer is minimized by internal reflection from the reflective inside faces of the skins.
U.S. Pat. No. 5,750,242 to Culler discloses a fabric which provides thermal image masking in mid and far infra-red region without compromising the effectiveness of visual and near IR camouflage or comfort level. The material incorporates a metallized microporous membrane into a typical article of clothing or covering, e.g., tents, which suppresses thermal imaging. An air permeable, moisture vapor transmitting, waterproof material having a metallized membrane is laminated to a textile backing and the metal in the metallized membrane forms a discontinuous layer at the surface and on the pore walls adjacent the surface of the microporous membrane. This provides an air permeable, vapor transmissive, waterproof material which suppresses thermal imaging of objects behind the metallized membrane.
U.S. Pat. No. 5,271,998 to Duckett discloses a lightweight metallized fabric which can be used in an automobile cover. The fabric is made by vacuum metallizing with aluminum and applying a finishing solution comprising a urethane, acrylic, fluorocarbon polymer emulsion, drying the fabric at 320° to 400° F. and optionally calendering the fabric after drying.
U.S. patent application Ser. No. 09/148,182, filed Sep. 4, 1998, (Case No. 2049) discloses a metallized fabric of improved washfastness which comprises discrete metal particles encapsulated within a cross-linked polyurethane latex. U.S. patent application Ser. No. 09/400,511, filed Sep. 20, 1999, (Case No. 2097) discloses a metallized fabric of improved washfastness which comprises discrete metal particles encapsulated within a cross-linked polyurethane latex, wherein the metal particles are treated with a primer coating composition comprising the reaction product of a copolymer comprising at least two different monomers: (i) a phosphate-containing vinyl monomer and (ii) a second, separate vinylic monomer containing at least one reactive group capable of covalently reacting with the cross-linking agent present within the polyurethane latex coating.
It would be desirable to provide insulated metallized fabric articles suited to use in cold weather applications such as insulated apparel, sleeping bags, etc. which comprise a fabric having a metal-coated side and an uncoated side which fabric is of improved washfastness. Moreover, it would be desirable to provide metallized fabric articles that do not allow the migration of natural and synthetic insulations, such as hollow fibers or down, through the fabric so as to contain the insulation within the article during normal use and washing.
SUMMARY OF THE INVENTION
In one aspect, the present invention relates to a durable, lightweight metallized fabric which can be used as a lining for insulated articles and which is resistant to migration of insulating materials through its thickness. The fabric comprises: a metallic side having a metal coating containing discrete metal particles, a non-metallic side, and a cross-linked polyurethane latex coating over both sides which encapsulates said metal particles. The fabric can be calendered to an extent sufficient to reduce migration of insulation through its thickness.
In another aspect, the present invention relates to a method of preparing a metallized fabric which comprises
i) providing a fabric,
ii) coating one side of said fabric with metal particles,
iii) coating both sides of said fabric in a cross-linked polyurethane latex comprising a polyurethane dispersion, a cross-linking agent, an inhibitor, and optionally, a catalyst to initiate cross-linking of said polyurethane dispersion, to encapsulate said metal particles within said polyurethane latex; and
iv) calendering said fabric to an extent sufficient to reduce migration of insulation through its thickness.
In yet another aspect, the present invention relates to an article of clothing containing insulation and having an interior lining of metallized fabric resistant to passage of said insulation through its thickness, which comprises a metallic side coated with metal particles, a non-metallic side, and a cross-linked polyurethane latex coating over both sides to encapsulate said metal particles within said polyurethane latex, wherein the metallic side faces a body surface of a wearer. The resistance of the fabric to passage of the insulation can be increased by calendering the metallized fabric.
DETAILED DESCRIPTION OF THE INVENTION
Without limiting the scope of the invention, the preferred embodiments and features are hereinafter set forth.
The present invention relates to a metallized fabric of improved washfastness which comprises a metallic side, a non-metallic side and a cross-linked polyurethane latex coating on both sides. The metallic side comprises a metal coating containing discrete metal particles encapsulated within the cross-linked polyurethane latex. The encapsulated metal coating serves to resist corrosion of the metal particles adhered to the fabric surface to substantially eliminate removal of such metal particles from the fabric substrate due to abrasion encountered during fabric use, atmospheric conditions and/or harsh laundering conditions.
Any fabric can be utilized in this invention provided that the polyurethane latex thoroughly coats the metal particulate coating of the fabric so as to substantially prevent contact between the metal and atmospheric oxygen or harsh oxidizing (and thus corrosive) chemicals present within laundry applications. Fabric comprising polyamide yarn, e.g., nylon, is most preferred. However, any natural fabrics such as cotton and ramie, or any synthetic fiber material such as, polyester, other polyamide, polypropylene, polyester-polyurethanes such as Lycra (Tradename), available from E. I. duPont deNemours and Company, Wilmington, Del., and the like; or any blends of synthetic fibers may be utilized within the inventive fabric. While plain weave construction is preferred, fabrics may be woven in plain, rip-stop, twill, satin or crepe constructions. The fabric yarns may range from single to double ply, 30 to 300 denier and 34 to 150 filaments. The preferred yarn in both the warp and filling direction is single ply, 40 denier with 34 filaments. It is preferred to use a flat warp yarn and textured filling yarn, but either type may be used in either the warp or filling. The preferred finished fabric yarn count when using 40 denier yarn is 170 warp yarns per inch and 140 filling yarns per inch. However, the warp yarn count when using 40 denier may vary from 80 to 200 and the filling from 80 to 200. Additionally, the yarn count can vary considerably depending on the yarn denier.
Prior to metallizing, the fabric can be scoured clean and dried. At this point, the fabric
Goulet Robert J.
Still Jimmie A.
Vogt Kirkland W.
Current Sara M.
Milliken & Company
Moyer Terry T.
Singh Arti R.
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