Multilayer textile assemblies for reversible water vapor absorption

Abstract

Described herein are multilayer moisture management assemblies for reversible absorption of water vapor where the assemblies regulate relative humidity in microclimates proximate the assemblies. The moisture management assemblies absorb water vapor from air when the relative humidity level in the air is at or above a threshold level, thus retarding further elevation of the relative humidity. Articles incorporating the assemblies are also disclosed.

Description

MULTILAYER TEXTILE ASSEMBLIES FOR REVERSIBLE WATER VAPOR ABSORPTIONFIELD

[0001] Described herein are multilayer moisture management assemblies for use as humidity-regulating layers in a variety of consumer products, such as bedding components and performance apparel.BACKGROUND

[0002] Thermal management properties have become desirable in textile-based products used for bedding components, personal protective equipment, athletic accessories, performance apparel, and other products that include textiles and contact individuals. Poor thermal management in such products can lead to a sense of discomfort for the individual. Efforts to improve thermal management properties of textile-based products have focused on managing temperature and moisture dissipation through evaporative cooling.

[0003] Phase change materials (“PCMs”) have been used in many commercial products, including protective clothing and bedding components, to improve the temperature experienced by the person using the product. PCMs have a high heat of fusion and are capable of storing and releasing energy at known consistent temperatures. The amount of heat absorbed by a PCM, and thus the effect of the PCM on the heat transfer rate of a material, depends on the mass of PCM present, which is limited by technical and practical considerations, such as the weight of the finished garment, application technique, and desired tactile properties (e.g., how the finished material will feel to an individual). Any microencapsulation increases the effective mass of the PCM without proportionate increase in the amount of heat that can be absorbed and also causes a super cooling effect. PCM-based products have been found to be effective for short-time frames of 2 hours or less, but the cooling effect is ultimately exhausted and does not provide any further benefit.

[0004] Wicking fabrics are utilized to facilitate the dissipation of moisture (such as sweat) by moving the moisture through and / or across the fabric to promote evaporative cooling. While the evaporative cooling promoted by wicking fabrics provides improved cooling effects, the benefit is only had when the wicking fabric is exposed to an open environment into which the moisture can be dissipated.

[0005] Other efforts to improve thermal management properties include using textiles and foams that promote air flow. This approach has some benefit because it provides a means of dissipating heat into the environment. The benefits of such technologies, however, have only shown marginal value.

[0006] It is desirable to further improve thermal management properties of textile-based products, such as bedding components, upholstered articles, protective gear, medical or athletic equipment, and apparel. Ideally, the assemblies would increase an individual’s sense of thermal comfort when using the product.SUMMARY

[0007] Multilayer moisture management assemblies (“MMMAs”) described herein are useful in consumer products, such as bedding components, upholstered articles, personal protective equipment, medical devices, athletic equipment, performance apparel, and other articles, to increase a user’s (or wearer’s) sense of thermal comfort. The assemblies include at least one water vapor absorbing layer (“WVAL”) that can reversibly convert water vapor to liquid water as a function of relative humidity. The WVAL is between two water resistant layers (WRLs) that allow for minimal liquid water transport or absorption. At least one of the WRLs is water vapor permeable. The MMMAs are used as, or incorporated into, articles that are consumer products. In use, water vapor, such as from perspiration, passes through a WRL and is absorbed by the WVAL, which converts the water vapor to liquid water, when the relative humidity proximate the WVAL is at or above a minimum value, or threshold level. Absorption of water vapor by the WVAL retards further elevation of the relative humidity within the user’s microclimate without compromising flexibility, comfort, or performance-related properties of the article. The WRLs ensure the condensed liquid water is localized to the MMMA. The WRLs inhibit wicking of the condensed liquid through the WRL to avoid wetting other components of the consumer product into which the MMMA is incorporated. Thus, the MMMAs effectively maintain local relative humidity at a comfortable level.

[0008] Disclosed herein are MMMAs comprising at least two WRLs and at least one WVAL located between two WRLs, where both WRLs are water resistant and at least one WRL is watervapor permeable, and where the WVAL includes a substrate and a deliquescent material disposed in or on the substrate. In any MMMA disclosed herein, the two WRLs independently can be a textile, fabric, foam, leather, vinyl, plastic, rubber, foil, film, or latex material. Optionally, the substrate of the WVAL includes a textile, fabric, foam, leather, vinyl, plastic, rubber, foil, film, or latex material.

[0009] In any MMMA disclosed herein, the deliquescent material can have an upper threshold value for absorbing water vapor of 30 % relative humidity or more, for example an upper threshold value for absorbing water vapor of about 30% relative humidity, 35% relative humidity, 40% relative humidity, 45% relative humidity, 50% relative humidity, 55% relative humidity, 60% relative humidity, 65% relative humidity, 70% relative humidity, 75% relative humidity, 80% relative humidity, 85% relative humidity, or 90% relative humidity. In any MMMA disclosed herein,the deliquescent material optionally can include a sodium salt, potassium salt, ammonium salt, lithium salt, magnesium salt, calcium salt, urea or derivative thereof, acrylic polymer, polyurea, polyurethane, epoxy polymer, or silicone polymer.

[0010] In any MMMA disclosed herein, the WVAL optionally can be secured to the two WRLs using adhesive, fusing, or stitching. Alternatively, however, the WVAL need not be secured to the WRLs.

[0011] In some MMMAs disclosed herein, the substrate is a textile, and the WVAL comprises the deliquescent material in a concentration of 5 % to 300 % by weight relative to the weight of the textile, such as a concentration of 5 % to 250 %, 5 % to 200 %, 5 % to 150 %, 5 % to 100 %, 50 % to 300 %, 100 % to 300 %, 150 % to 300 %, 200 % to 300 %, 50 % to 250 %, 50 % to 200 %, 100 % to 200 %, 100 % to 250 %, or 100 % to 300 %, all by weight relative to the weight of the textile.

[0012] Also disclosed herein is a cushioning component including any MMMA dislosed herein and at least one compressible layer, wherein the compressible layer comprises a textile, fabric, foam, leather, vinyl, plastic, rubber, or latex.

[0013] Also disclosed herein is a product, such as a consumer product, where the product includes any MMMA disclosed herein. Optionally, the product comprises a bedding component, an upholstered article, personal protective equipment, a medical device, athletic equipment, or performance apparel. In some specific examples, the product is a pillow or a mattress. In other specific examples, the product is a body armor vest or firefighter apparel.

[0014] Also disclosed herein is a method of making a MMMA including applying a deliquescent material to a textile to form a WVAL, and placing the WVAL between two WRLs, wherein the two WRLs are water resistant and at least one WRL is water-vapor permeable. Optionally, the method further includes securing the WVAL to the two WRLs, wherein securing includes applying adhesive, fusing, or stitching. Optionally, applying the deliquescent material includes padding, knife coating, spraying, foaming, or screen printing. Optionally, applying the deliquescent material to the textile includes forming a textile with a fiber comprising the deliquescent material. Optionally the method includes treating a fiber with the deliquescent material to form the fiber comprising the deliquescent material. Optionally the method includes incorporating the deliquescent material into a synthetic fiber during extrusion or polymerization of the synthetic fiber to form the fiber comprising the deliquescent material.DETAILED DESCRIPTION

[0015] Provided herein are MMMA for use in consumer products, such as bedding components, upholstered articles, personal protective gear, medical or athletic equipment, performance apparel, and other articles. An MMMA can be incorporated into a consumer product as a humidity-regulating layer either directly or first into a cushioning component before the cushioning component is incorporated into the consumer product. In some examples, the MMMA itself is a consumer product.

[0016] The MMMAs include at least one WVAL between at least two WRLs. The two WRLs are liquid water resistant and allow for minimal liquid water transport or absorption. At least one of the WRLs is air and water-vapor permeable, which allows the WVAL to absorb water vapor from adjacent air. Active water vapor absorption by the WVAL facilitates active humidity management in a user’s microclimate by the MMMA. The two WRLs which sit on either side of the WVAL serve two functions. First, at least one WRL is air permeable to permit water vapor to readily migrate through the WRL to the WVAL. Second, both WRLs are liquid water resistant, substantially non-wicking and non-absorbing materials. Because they allow only minimal or no liquid water transport, the WRLs prevent water that condenses on the WVAL from wicking through a WRL to other parts of the consumer product.

[0017] As described herein, the MMMAs impart beneficial thermal management properties to articles into which they are incorporated without adversely affecting the flexibility, comfort, and mechanical properties provided by the article. Thus, assemblies described herein are suitable for use as or in consumer products where they will contact a user (directly or indirectly through other layers or articles) and where flexibility, comfort, and mechanical properties of the product are important for user comfort and / or safety. In some non-limiting examples, the MMMAs described herein can be incorporated into bedding components, including mattresses, pillows, mattress toppers, sheets, or blankets; upholstered articles, such as sofas, stationary chairs, recliners, and other types of seating; protective garments, such as body armor and firefighter apparel; medical devices or athletic equipment, such as braces, supports, immobilizing devices, weighted vests, helmets, pads, or footwear; or other specialty or performance apparel. Additionally or alternatively, the MMMA can be incorporated into an article that is an intermediate product, such as a cushioning component that is part of or that can be incorporated into the consumer products described herein.

[0018] As used herein, the term “textile” means, unless otherwise stated, any combination of fibers, including but not limited to woven, non-woven, or knitted fabrics and cloths. As used herein, the term “fiber” means, unless otherwise stated, any natural or synthetic polymer suitable forproducing textiles. As used herein, the term “foam” means a solid organic material with pockets of gas trapped inside. Typically, the foam is a polymer, but in some examples the solid need not be a polymer. In any case, however, the term “foam” as used herein does not include metal foam.

[0019] In a first aspect, an MMMA includes at least one WVAL between two WRLs. In any assembly described herein, adjacent layers can be secured together by an adhesive, sewn or fused together. Optionally, however, any two layers or all of the layers may be unsecured.

[0020] FIG. 1A is an exploded view of an MMMA 1000 according to one example described herein. In FIG. 1A, the MMMA 1000 includes, from top to bottom, a first WRL 1100, a WVAL 1200, and a second WRL 1120. Optionally, the WVAL 1200 can be secured to one or both of the WRLs 1100, 1120 by an adhesive (not shown), by stitching (not shown) or fused (not shown). Both WRL 1100 and WRL 1120 are air permeable.

[0021] FIG. IB is an exploded view of an MMMA 1500 according to one example described herein. In FIG. IB, the MMMA 1500 includes, from top to bottom, a first WRL 1100, a WVAL 1200, and a second WRL 1130. Optionally, the WVAL 1200 can be secured to one or both of the WRLs 1100, 1130 by an adhesive (not shown), by stitching (not shown) or fused (not shown). Both WRL 1100 and WRL 1130 are water resistant but only WRL 1100 is air permeable.

[0022] In any assembly described herein, the WVAL includes a substrate and a deliquescent material in or on the substrate. The substrate can be a fiber, textile, film or membrane, foam, or combination thereof. In some examples, the substrate is a textile.

[0023] The deliquescent material will absorb and release water vapor. By definition, a deliquescent material can absorb so much water vapor that it dissolves in the absorbed water. The deliquescent material can be an inorganic compound, an organic compound, or any combination thereof. Deliquescent materials absorb water vapor when relative humidity reaches or exceeds a value referred to herein as a “upper threshold value” and release sorbed water when relative humidity drops to or below a value referred to herein as a “lower threshold value.” Deliquescent materials useful in the MMMAs described herein have an upper threshold value for absorbing water vapor of about 30% relative humidity, 35% relative humidity, 40% relative humidity, 45% relative humidity, 50% relative humidity, 55% relative humidity, 60% relative humidity, 65% relative humidity, 70% relative humidity, 75% relative humidity, 80% relative humidity, 85% relative humidity, or 90% relative humidity. The deliquescent materials release sorbed water by a process called efflorescence when the percent relative humidity is at or below the lower threshold value for the deliquescent materials. Deliquescent materials useful in the MMMAs described herein have a lower threshold value for releasing sorbed water of about 60% relative humidity, 55% relative humidity, 50%relative humidity, 45% relative humidity, 40% relative humidity, 35% relative humidity, 30% relative humidity, 25% relative humidity, 20% relative humidity, 15% relative humidity, or 10% relative humidity. In some examples, a deliquescent material useful in the MMMA’s described herein has a upper threshold value of about 75 % and a lower threshold value of about 55%, a upper threshold value of about 85 % and a lower threshold value of about 65%, or a upper threshold value of about 80% and a lower threshold value of about 50%.

[0024] Examples of suitable deliquescent materials include, but are not limited to inorganic salts, organic salts, organic compounds, organic polymers, polyelectrolytes, minerals, or ceramics. Mixtures of these compounds may also be used. In some examples, suitable deliquescent materials include, but are not limited to materials formed from sodium salts, potassium salts, ammonium salts, urea or its derivatives, acrylic polymers, polyureas, polyurethanes, epoxy polymers, or silicone polymers.

[0025] The WVAL described herein can be formed by applying a deliquescent material to a substrate, such as a fiber or textile, via known techniques. For example, standard textile application methods can be used to produce a substrate finished with the deliquescent material. Examples of methods that can be used to apply the deliquescent material to a substrate are pad applications, knife coating, spraying, foaming, and screen printing. The deliquescent material can be applied to a textile itself or to a fiber that is subsequently formed into the textile. Optionally the deliquescent material can be infused into a synthetic fiber during extrusion of the fiber. The amount of deliquescent material applied to the textile can range from 5% or more relative to the untreated weight of the substrate. The percent add on of deliquescent material can be as high as 300% relative to the untreated weight of the substrate. Optionally, the deliquescent material can be applied to any substrate in an amount from 5 % to 300 % relative to the untreated weight of the substrate, such as 5 % to 250 %, 5 % to 200 %, 5 % to 150 %, 5 % to 100 %, 50 % to 300 %, 100 % to 300 %, 150 % to 300 %, 200 % to 300 %, 50 % to 250 %, 50 % to 200 %, 100 % to 200 %, 100 % to 250 %, or 100 % to 300 %, all by weight relative to the weight of the untreated substrate. Optionally, the substrate itself may have deliquescent or hygroscopic properties that can contribute to the overall performance of the MMMA.

[0026] In any assemblies described herein, each of the WRLs includes a substrate. Optionally, a WRL can further include a treatment or coating, such as a treatment or coating that improves the water resistance of the material. The substrate can be a textile, fabric, foam, leather, vinyl, plastic, rubber, foil, film, latex material, or combination thereof. In some examples, one or both of the WRLs are textiles. If the WRL substrate is not inherently water resistant, it is made waterresistant by coating the surface with a water repellent treatment. Optionally, the WRL is a substrate that has minimal liquid water absorption or liquid water transport ability. Optionally, the WRL is liquid water impermeable. Polymeric materials useful in WRLs include but are not limited to fluoropolymers, such as polytetrafluoroethylene (PTFE), expanded PTFE, and other fluoropolymers; polyurethanes; polyolefins, such as polyethylene and polypropylene; polyimides; polyesters; silicone, or a combination thereof. The polymeric materials may be in any useful form, including but not limited to fibers, textiles, films, and other forms. When a treatment or coating is included to improve water resistance of the WRL, the treatment or coating can be any water resistant treatment or coating known in the art, including fluorinated and non-fluorinated water repellents.

[0027] Substrates suitable for use as or in a WRL or WVAL include, but are not necessarily limited to textiles, fabrics, foams, leathers, vinyls, plastics, rubbers, foils, films, latex materials, and combinations thereof. When the substrate is a foil, it can be a metal foil, such as aluminum foil.

[0028] A textile suitable for use as a WRL or WVAL in any MMMA described herein can be woven, non-woven, or knitted and can include plant fibers (e.g., ramie or linen), cellulosic fibers (e.g., cotton, bamboo, or hemp); synthetic fibers (e.g., polyester, nylon, rayon, or polyolefin), animal-derived fibers (e.g., wool or silk), glass fibers, any other known fibers, or combinations thereof. In some examples, a textile comprises cotton, linen, rayon, polyester, polyethylene, polypropylene, nylon, or a combination thereof. Optionally, a useful textile includes a flame resistant textile or a textile including at least some flame resistant fibers, such as glass fibers, aramid fibers, or FR cotton / natural fibers.

[0029] A film or membrane suitable for use as a WRL or a WVAL in the MMMAs described herein can be any film / membrane known for use in the consumer products described herein. In some examples, the film / membrane includes is a polymer, such as polyester, polyvinylalcohol, acrylic, ABS, nylon, polystyrene, polyvinylchloride, polycarbonate, polyurethane, or polyolefin.

[0030] A polymeric foam suitable for use as a WRL or a WVAL in the MMMAs described herein can be any polymeric foam known for use in the consumer products described herein. In some examples, the polymeric foam includes a polyurethane foam, polyacrylic foam, and / or a latex foam, such as those typically used in mattress assemblies. The term “foam” as used herein does not include metal foam.

[0031] In some examples the WVAL in an MMMA is a textile that has been treated with a deliquescent material. In some examples, one or both of the WRLs are textiles. In alternative examples, one or both of the two WRLs is a foam or a film.

[0032] The dimensions of the MMMA and of each layer will vary depending upon the intended use of the final product. The various layers within the MMMA can be coextensive, i.e., they can have the same peripheral shape and can be superposed, but in some examples they need not be coextensive. The surface area of adjacent layers can vary by 1 %, 5 %, 10 %, or more. In some examples, the WVAL has substantially the same peripheral shape and dimensions as one or both of the WRLs. In some examples, a face of the WVAL has a surface area that is at least 50 % of the size of the surface area of a face of a WRL, e.g., at least 60 %, at least 75%, at least 80 %, at least 85 %, at least, 90 %, at least 95%, at least 99 %, or substantially 100 %. The thickness of the MMMA will range from 1 mm to 500 mm. The dimensions of adjacent layers within the MMMA may be the same, but need not be the same.

[0033] The layers of the MMMA can be unsecured or two or more layers can be secured together, such as with an adhesive, by fusing or by sewing (i.e., with stitching). When adhesive is used, in some examples the adhesive is a pressure sensitive adhesive. Optionally, the adhesive can be an acrylic-based adhesive, a rubber-based adhesive, or a silicone-based adhesive. In some examples, two adjacent layers of the MMMA are secured together. Additionally or alternatively, two non-adjacent layers can be secured together around part of all of their perimeters if the nonadj acent layers are larger than an intervening adjacent layer. As an example, if a WVAL is smaller than two WRLs on either side of the WVAL, the two WRLs can be secured together outside of at least a portion of the perimeter of the WVAL.

[0034] FIG. 2A is a schematic representation of a cross-sectional view of an MMMA 2000 described herein, and FIG. 2B is a schematic representation of a top view of the same MMMA 2000. The MMMA 2000 has a WVAL 2200 between two WRLs 2100, 2120. The WVAL 2200 has a WVAL perimeter 2202 that is inside the WRL perimeters 2102, 2122 of the two WRLs 2100, 2120 so the WRLs 2100, 2120 contact the WVAL 2200 at interfaces 2204 and contact each other at interface 2104. Optionally, an adhesive (not shown) can bond one or both of the WRLs 2100, 2120 to the WVAL 2200 at interface 2204 and / or can bond the two WRLs 2100, 2120 together at interface 2104.

[0035] Persons skilled in the art will recognize that as an alternative to two individual water- resistant materials forming the two WRLs optionally joined together, a single sheet of a water- resistant material can be folded to encase a WVAL. Such folding forms two WRLs with one on each side of the WVAL. FIG. 3 is a schematic representation of a cross-sectional view of an MMMA 3000 with a single sheet of water resistant material 3100 folded to form an upper WRL 3110 and alower WRL 3120. The material 3100 has a fold 3130 that separates the upper WRL 3110 from the lower WRL 3120. A WVAL 3200 is between the upper and lower WRLs 3110, 3120.

[0036] Optionally, temperature or heat management technologies may be integrated in the MMMA or in other elements of a consumer product that includes the MMMA. Those technologies can amplify the comfort benefits of the MMMA. Examples of those technologies include thermal conductive materials (TCMs) or phase change materials (PCMs).

[0037] TCMs are materials with thermal conductivities greater than 100 W / (m-K). A TCM may be a powder, film, foil, textile, or foam that can be integrated into the MMMA or consumer product using the MMMA. Examples of TCMs are inorganic materials such as metals, metal oxides, mineral, or ceramic such as graphite, aluminum, aluminum oxide, diamond, or boron nitride.

[0038] Optionally, a PCM is included in or on at least one of the WRLs or the WVAL. The PCM enhances heat absorption and heat dissipation. Phase change materials are capable of storing and releasing large amounts of energy as they change from one phase of matter to another. The PCMs described herein are encapsulated to form microencapsulated PCMs (“mPCMs”). Heat is absorbed when the material changes from solid to liquid, and heat is released when the material changes from liquid to solid. In some examples, PCMs useful in the assemblies and products described herein have a melting point of 10 to 90 °C (e.g., 27 °C to 37 °C, 27 °C to 32 °C, or 27 °C to 29 °C). In other examples, useful PCMs have a melting point in a desired operating temperature range, which may vary depending on the end use of the treated substrate. The PCMs described herein have a heat of fusion of at least 100 J / g, as measured by ASTM D3418-12el. The PCMs optionally have a heat of fusion of 170-200 J / g, as measured by ASTM D3418-12el. When applied to materials used herein, certain mPCMs provide improved thermal management properties to the final product.

[0039] Including mPCM can increase comfort to the individual by providing a cool-to-the- touch effect. Any mPCM capable of being applied to a fiber, textile, or foam and undergoing a phase change due to heat from a wearer or user can be used in the MMMAs herein. In some embodiments, mPCMs useful in the MMMAs include those where the PCM includes a salt hydrate; fatty acid or derivative thereof (e.g., fatty ester, fatty alcohol, and / or fatty amine); or an alkane (e.g., various oleochemicals and / or paraffins). Optionally, the PCM is an alkane having 12 to 20 carbon atoms, such as dodecane, tetradecane, hexadecane, octadecane, or eicosane. The PCM can be derived from a plant, animal, or petroleum source. The PCM can be derived from a biorenewable source.

[0040] In some examples, the microencapsulation coating on the mPCM may be an acrylic, polyurea, polyurethane, melamine-formaldehyde, or other coating. Coatings on PCMs, such as melamine-formaldehyde coatings, prevent the PCM from dispersing when it melts and therebycontributes to the durability of the mPCM treatment on the substrate. Moreover, combining the mPCM with a binder such as polyurethane and / or acrylic (poly acrylate) can significantly improve the wash durability of a mPCM-treated fiber, textile, or foam. In some examples, the mPCM can include a microencapsulated oleochemical. In some examples, the mPCM can include a microencapsulated octadecane.

[0041] In a second aspect, a cushioning component includes at least one MMMA as described herein and at least one compressible layer. As non-limiting examples, a cushioning component described herein can be incorporated into any of the consumer products described herein. In some examples, the cushioning component is separable from the consumer product into which it is incorporated. In some examples, the cushioning component can include a PCM in or on one or more of the compressible layers and / or in or on the MMMA.

[0042] In some examples, a cushioning component includes two or more compressible layers. Optionally, at least one compressible layer is on each side of the MMMA. The compressible layers can include textile-based layers, foam-based layers, and / or combinations thereof. The MMMA imparts beneficial moisture management properties to the cushioning component without adversely affecting the flexibility and cushioning properties provided by the compressible layers. Thus, cushioning components described herein are suitable for use in articles that will contact a user and where flexibility and / or cushioning is important for user comfort. The MMMA layer facilitates moisture transport and absorption and thereby moderates the level of relative humidity within the cushioning component. Controlling the level of relative humidity in the cushioning components can increase the comfort of clothing, bedding, and other articles into which the components are incorporated by regulating the humidity in a user’s microclimate.

[0043] The compressible layers can include any material known for use in the consumer articles described herein. As non-limiting examples, a compressible layer can be a textile, fabric, foam, leather, vinyl, plastic, rubber, latex, or a combination thereof. Optionally, a compressible layer can be a combination of two or more of the foregoing materials, such as but not limited to a garment liner, mattress cover, carpet, wall panel, or acoustical panel. In some examples, a cushioning component includes at least one compressible layer on each side of the MMMA. Optionally, at least one of the compressible layers is a textile layer or a foam layer. In some examples, at least one compressible layer on each side of the MMMA is a textile. In alternative examples, at least one compressible layer on each side of the MMMA is a foam. Optionally, a cushioning component can include more than one compressible layer on one or both sides of the MMMA. Alternatively, however, a cushioning component can include one or more compressible layers on only one side ofthe MMMA. In any cushioning component described herein, adjacent layers can be secured together by an adhesive, by fusing, and / or by sewing. Optionally, however, any two layers or all of the layers can be unsecured.

[0044] FIGs. 4A-4D are schematic representations of cross-sectional views of various examples of cushioning components consistent with the present disclosure. As shown in FIGs. 4A- 4D, the cushioning components include MMMA 1000, shown in FIG. 1, but alternatively any MMMA disclosed herein can be used. In FIG. 4A, a cushioning component 4000 includes, from top to bottom, a textile layer 4010, a first foam layer 4020, an MMMA 1000, and a second foam layer 4022. Optionally, the MMMA 1000 can be secured to one or both of the adjacent foam layers 4020, 4022 by an adhesive (not shown) or by stitching (not shown). The top layer of FIG. 4A, the textile layer 4010, is intended to be positioned closest to a user and optionally contacts the user, so the top surface 4050 of textile layer 4010 is the user-facing surface 4050 of the cushioning component 4000. The MMMA 1000 is separated from the user-facing surface 4050 by a partial thickness 4060 of the cushioning component 4000. In alternative examples, the cushioning component 4000 need not include the top textile layer 4010. In other examples, the textile layer 4010 can instead be a material other than a textile. In still other examples, the cushioning component can include additional textile and / or foam layers in any position and on either side of the MMMA and / or can include additional MMMAs.

[0045] In FIG. 4B, a cushioning component 4100 includes, from top to bottom, a first textile layer 4110, an MMMA 1000, and a second textile layer 4112. Optionally, the MMMA 1000 can be secured to one or both of the textile layers 4110, 4112 by an adhesive (not shown), by fusing (not shown) or by stitching (not shown). In other examples, the cushioning component 4100 can include additional textile and / or foam layers in any position and on either side of the MMMA 1000 and / or can include additional MMMAs.

[0046] In FIG. 4C, a cushioning component 4200 includes, from top to bottom, a textile layer 4210, an MMMA 1000, and a foam layer 4220. Optionally, the MMMA 1000 can be secured to the adjacent textile layer 4210 and / or the adjacent foam layer 4220 by an adhesive (not shown) or by stitching (not shown). In alternative examples, the cushioning component 4200 can include additional textile and / or foam layers in any position and on either side of the MMMA 1000 and / or can include additional MMMAs.

[0047] In FIG. 4D, a cushioning component 4300 includes, from top to bottom, a first foam layer 4320, a first textile layer 4310, an MMMA 1000, a second textile layer 4312, and a second foam layer 4322. Optionally, the MMMA 1000 can be secured to one or both of the adjacent textilelayers 4310, 4312 with an adhesive (not shown) or by stitching (not shown). Optionally, the first foam layer 4320 and first textile layer 4310 or the second foam layer 4322 and the second textile layer 4312 can be secured together by an adhesive (not shown) or by stitching (not shown). In alternative examples, the cushioning component 4300 can include additional textile and / or foam layers in any position and on either side of the MMMA 1000 and / or can have additional MMMAs.

[0048] In a third aspect, a consumer product includes at least one MMMA as described herein. In some examples, the MMMA itself can be a consumer product, such as a pillow, without requiring any elements in addition to the elements that form the MMMA. In other examples, a consumer product described herein can include an MMMA and at least one other element, such as a compressible layer, a performance layer, or a structural element. In some examples the consumer product includes a cushioning component as described herein, which includes an MMMA as described herein.

[0049] Optionally, the consumer product includes a compressible layer on one or both sides of the MMMA. The compressible layers of the consumer product can be any compressible layer described for the cushioning component. For example, the compressible layer can include textilebased layers and / or foam-based layers. The MMMA imparts beneficial moisture management properties to the consumer product without adversely affecting the flexibility and cushioning properties provided by one or more compressible layers. Thus, consumer products described herein are useful as bedding, upholstered furniture, clothing, and other articles that will contact a user and where flexibility and / or cushioning is important for user comfort. The MMMA in the consumer product facilitates moisture transport and absorption to moderate the level of relative humidity within the product. Controlling the level of relative humidity in the product can increase the comfort of the product, by regulating the humidity in a user’s microclimate.

[0050] The compressible layers can include a textile, fabric, foam, leather, vinyl, plastic, rubber, or latex. Optionally, a compressible layer can be a combination of two or more of the foregoing materials, such as but not limited to a garment liner, mattress cover, a carpet, wall panel, or acoustical panel. In some examples, the consumer product includes at least one of the compressible layers that is a textile layer or a foam layer. In more specific examples, the consumer product includes at least two compressible layers with at least one textile layer on either side of the MMMA. In alternative examples, the consumer product includes at least two compressible layers with at least one foam layer on either side of the MMMA. Optionally, a consumer product can include one or more compressible layers on one side of the MMMA and can include one or more compressible layers on the opposite side of the MMMA. In any consumer product described herein,adjacent layers can be secured together by an adhesive and / or by sewing. Optionally, however, any two layers or all of the layers may be unsecured.

[0051] For ease of reference, in some instances herein the MMMA and consumer products into which they are incorporated are described in the context of a specific consumer product, such as a mattress, pillow, or body armor vest. Those descriptions are not intended to be limiting, and persons skilled in the art will understand how to adjust an MMMA (if necessary) for use with a different type of bedding component, garment, or other consumer product.

[0052] In some examples, an MMMA described herein can be incorporated into any type of commercial mattress, such as a foam-based mattress or an inner-spring mattress, or any type of commercial pillow, such as a foam or fiber filled pillow. While mattresses and pillows are used as exemplary embodiments, one skilled in the art would understand that the assemblies described herein are not limited to the specific embodiments shown, and alternatively could be used in any number of products where comfort, cushioning, and thermal management is desired, as described herein.

[0053] FIGs. 5A-5D are schematic representations of cross-sectional views of a standard mattress assembly and mattress assemblies with MMMA according to examples described herein. FIG. 5A shows a cross-sectional view of a standard mattress assembly 5000 including a ticking fabric 5010, an FR sock 5012, and two polyurethane foam layers 5020, 5022. Figs. 5B-5D are schematic representations of cross-sectional views of three exemplary mattress assemblies 5100, 5200, 5300 according to examples described herein showing the standard mattress assembly of FIG 5 A with MMMA 1000 integrated at different locations within the standard mattress assembly. No adhesive was used to secure adjacent layers, but alternatively any layer can be secured to any other layer, for example, with adhesive (not shown) or stitching (not shown). In each assembly, the MMMA 1000 is that shown in FIG. 1, but alternatively any MMMA described herein could be used.

[0054] FIGs. 6A-6B are schematic representations of cross-sectional views of a standard mattress assembly and a mattress assembly with MMMA according to one example described herein. FIG. 6A shows a cross-sectional view of a standard mattress assembly 6000 including a ticking fabric 6010 and two polyurethane foam layers 6020, 6022. Fig. 6B is a schematic representation of a cross-sectional view of an exemplary mattress assembly 6100 according to an example described herein showing the MMMA 1000 within the standard mattress assembly shown in Fig. 6A. No adhesive was used to secure adjacent layers, but alternatively any layer can be secured to any other layer, for example, with adhesive (not shown) or stitching (not shown). In the examplemattress assembly 6100, the MMMA 1000 shown is that shown in FIG. 1, but alternatively any MMMA described herein could be used.

[0055] FIGs. 7A-7B are schematic representations of cross-sectional views of a standard pillow and a pillow with MMMA according to examples described herein. FIG. 7A shows a cross- sectional view of a standard pillow 7000 including a pillow shell 7010 surrounding a PU foam 7020. The pillow shell 7010 optionally can be treated with a PCM, but alternatively need not include a PCM. FIG. 7B shows a cross-sectional view of an exemplary pillow 7100 according to an example described herein including a pillow shell 7010 surrounding a PU foam 7020 and an MMMA 1000 between the pillow shell 7010 and the PU foam 7020. As in FIG. 7A, the pillow shell 7010 optionally can be treated with a PCM, but alternatively need not include a PCM. In the example pillow 7100, the MMMA 1000 shown is that shown in FIG. 1, but alternatively any MMMA described herein could be used.

[0056] FIGs. 8A-8B are schematic representations of cross-sectional views of a standard fiber-fill pillow and an MMMA fiber-fill pillow according to examples described herein. FIG. 8A shows a cross-sectional view of a standard fiber-fill pillow 8000 including a pillow shell 8010 surrounding standard fiber-fill 8030. The pillow shell 8010 optionally can be treated with a PCM (not shown), but alternatively need not include a PCM. FIG. 8B shows a cross-sectional view of an exemplary MMMA fiber-fill pillow 8100 according to an example described herein. The MMMA fiber-fill pillow 8100 is an example of a consumer product that is also an MMMA as described herein. The MMMA fiber-fill pillow 8100 includes a pillow shell 8110 that is a water-repellant material. The pillow shell 8110 surrounds a treated fiber fill 8140, and forms an upper WRL 8112 and a lower WRL 8114 above and below the treated fiber fill 8140. The treated fiber fill 8140 is a standard fiber-fill substrate (not separately shown) that includes (i.e., has been treated with) a deliquescent material (not separately shown). The pillow shell 8110 optionally can be treated with a PCM, but alternatively need not include a PCM.

[0057] In some examples, an MMMA described herein can be incorporated into garments and protective gear, such as clothing, braces, and body armor. As one example, body armor is protective clothing used primarily by security personnel, such as military, police, security guards, and bodyguards, to absorb or deflect physical attacks. Body armor often includes metallic or ceramic plates and / or multiple layers of tightly woven high strength aramid fibers. Despite advances in materials, effective body armor is very heavy and has insulating properties that trap body heat and increase the risk of dehydration, heat stroke, and performance loss for those who wear it. The MMMAs described herein can be incorporated into body armor to improve personal thermalmanagement of the wearer. For example, the MMMAs can be incorporated into a body armor vest as a humidity -regulating liner.

[0058] While body armor is used as an exemplary embodiment, one skilled in the art would understand that the MMMAs described herein alternatively could be used in any number of garments, protective gear, or other products where comfort, cushioning, and thermal management is desired, as described herein.

[0059] FIGs. 9A-9B are schematic representations of a garment 9000 that includes an MMMA 1000 consistent with the present disclosure. FIG. 9A is a perspective view of the garment 9000, in which the MMMA 1000 is located on the inside of a vest 9100, such as a body armor vest or a weighted exercise vest. The MMMA 1000 functions as a cooling liner for the vest 9100. FIG. 9B is a cross-sectional view of the vest 9100 and MMMA / cooling liner 1000.

[0060] Incorporating the cooling liner 1000, as shown in FIGs. 9A-9B does not require modification of the vest 9100 construction. The cooling liner 1000 can be simply laminated directly to an existing vest 9100. The cooling liner 1000 then acts as an intermediary layer between the vest 9100 and a wearer (not shown).

[0061] In a cushioning component or consumer product described herein, the MMMA can be laminated or otherwise secured to an adjacent layer of the cushioning component or the consumer product. That adjacent layer may be a textile, foam, or any other layer in the component or product. Persons skilled in the art will understand that the same methods of securing together individual layers of the MMMA can also be used to secured the MMMA to a layer of a cushioning component or consumer product. For example, the MMMA can be secured to part of the cushioning component or consumer product using adhesive or stitching.

[0062] Textile and foam-based articles tend to impede the dissipation of heat and humidity. In the consumer products described herein, the heat and humidity can come from an external source or from a user’s body temperature and perspiration. Known products and methods that attempt to improve a user’s thermal comfort by manipulating moisture rely on evaporative cooling. But, evaporative cooling is of limited value when heat and humidity is readily retained by a product, as when multiple layers of cushioning materials are used. The MMMA disclosed herein regulate humidity through moisture absorption and retention and thereby provide improved thermal comfort as compared to products that rely on evaporative cooling.

[0063] The MMMAs described herein reduce the relative humidity of the microclimate between a consumer product and the consumer as compared to an equivalent assembly that lacks the MMMA. Humidity is a measure of the concentration of water vapor in the air and relative humidityis generally expressed as a percentage and indicates a present state of absolute humidity relative to a maximum humidity given the same temperature. A high relative humidity in an environment can cause the environment to feel hotter than the actual temperature, and to feel hotter than it would feel at a lower relative humidity.

[0064] When an MMMA described herein is in use, and the individual using the MMMA sweats, the moisture vapor from the user’s perspiration passes through a WRL and contacts the deliquescent material of the WVAL. When the relative humidity proximate the WVAL rises to an upper threshold level, the deliquescent material begins absorbing the water vapor, converting it to liquid water. That liquid water cannot pass through the WRLs, so it is localized to the MMMA to minimize transport to and wetting of other parts of the product or the user. The condensed water also does not contribute to relative humidity, so converting the water vapor to liquid water retards further elevation of the relative humidity beyond the threshold level. The absorption of moisture by the deliquescent material is reversible, so once the humidity level decreases, for example when the user removes the garment or gets out of bed, the deliquescent material releases the moisture in the form of water vapor, which permeates the WRL and dissipates into the environment.

[0065] The MMMAs described herein rapidly absorb water vapor, and that absorption retards increasing relative humidity levels for the wearer’s microclimate. Because relative humidity is much lower in a system containing MMMA than in a comparable system without MMMA, that difference can be easily measured and converted to a lower heat index for the wearer’s microclimate in the system containing the MMMA than in the comparable system without the MMMA. To calculate the heat index (HI), Formula I is used.HI = ci + c2T + c2r + C4T r + C5T2+ c&r2+ c2T2r + c&T r2+ c9T2r2(I) where ci = -42.379, c2= 2.04901523, c3= 10.14333127, c4= -0.22475541, c5= -6.83783*10’3, c6= -5.481717*10'2, c7= 1.22874*10'3, c8= 8.5282*10’4, c9= -1.99*10’6, T is temperature in Fahrenheit and r is relative humidity as a percent (for example, if relative humidity is 65 %, use 65 in Formula 1).

[0066] In some examples, the MMMAs described herein have a steady state relative humidity that is lower than a comparative assembly that is equivalent, but that lacks any MMMA. For example, the MMMAs described herein can have a steady state relative humidity that is less than the comparative assembly by about 0.5 %, by about 1 %, by about 2 %, by about 3 %, or by about 4 %.Examples

[0067] The following examples are set forth below to illustrate methods and results according to the disclosed subject matter. These examples are not intended to be inclusive of all aspects of the subject matter disclosed herein, but rather to illustrate representative methods and results. These examples are not intended to exclude equivalents and variations of the subject matter described herein which are apparent to one skilled in the art.

[0068] Unless stated otherwise, the relative humidity values identified herein are measured with a standard sensor for humidity using a SWEATOR skin from Inside Climate. This equipment uses a membrane that releases water vapor at a temperature and rate comparable to human skin. Both microclimate temperature and percent relative humidity are measured with temperature and humidity sensors from MSR Electronics GmbH. As the SWEATOR membrane releases water vapor, the relative humidity within the tested article increases over time.Example 1 : Preparation of MMMA

[0069] WRL preparation: A 90 gsm polyester fabric is treated with a non-fluorinated water repellent through a pad application. The percent add-on of the water repellent treatment is 5%.

[0070] WVAL preparation: A 200 gsm cotton fabric is treated with a formulation containing urea as the deliquescent material through a pad application. The formulation is composed of the following: 64.5% water, 5% polyurethane binder, 30% urea, and 0.5% antimicrobial. The fabric has 100% wet pick up. The fabric is dried in an oven at 150 °C until dry.

[0071] MMMA preparation: Two sheets of WRL are cut to the dimensions of a mattress top. One sheet of WVAL is also cut to the same dimensions. The fabrics are assembled as shown in FIG 1 and sewn around the edges with a serger.Example 2: MMMA Performance in a Basic Mattress

[0072] A mattress consistent with embodiments described herein and substantially as shown in Fig. 6B was built with a 450 gsm polyester-based mattress ticking with the MMMA made in Example 1 below the mattress ticking. Beneath these two components are a 1 inch polyurethane visoelastic foam followed by a 6 inch polyurethane base foam. The mattress build was tested with a SWEATOR. The relative humidity results are shown in FIG 10 and the heat index results are shown in FIG 11. For the comparative data without MMMA, the same mattress design was used but the MMMA was excluded.Example 3 : MMMA With Only One Air Permeable WRL

[0073] Textile WRL preparation: A 90 gsm polyester fabric is treated with a non-fluorinated water repellent through a pad application. The percent add-on of the water repellent treatment is 5%.

[0074] Foil WRL preparation: A second WRL is a commercially sourced aluminum foil with 100-micron thickness that is continuous and has no openings.

[0075] WVAL preparation: A 200 gsm cotton fabric is treated with a formulation containing urea as the deliquescent material through a pad application. The formulation is composed of the following: 64.5% water, 5% polyurethane binder, 30% urea, and 0.5% antimicrobial. The fabric has 100% wet pick up. The fabric is dried in an oven at 150 °C until dry.

[0076] MMMA preparation: One sheet of Textile WRL and one sheet of Film WRL are cut to the dimensions of a tactical vest panel. One sheet of WVAL is also cut to the same dimensions. The fabrics are assembled as shown in FIG 1 and the layers are adhered with a pressure sensitive adhesive.

Claims

WHAT IS CLAIMED IS:

1. A multilayer moisture management assembly (“MMMA”) comprising two water-resistant layers (“WRLs”), and at least one water vapor absorbent layer (“WVAL”) located between the twoWRLs, wherein both WRLs are water resistant and at least one WRL is water-vapor permeable, and wherein the WVAL comprises a substrate and a deliquescent material disposed in or on the substrate.

2. The MMMA of claim 1, wherein each of the two WRLs independently comprises a textile, fabric, foam, leather, vinyl, plastic, rubber, foil, film, or latex material.

3. The MMMA of claim 1, wherein the substrate comprises a textile, fabric, foam, leather, vinyl, plastic, rubber, foil, film, or latex material.

4. The MMMA of claim 1, wherein the deliquescent material has a threshold value for absorbing water vapor of 30 % relative humidity or more.

5. The MMMA of claim 1, wherein the deliquescent material comprises a sodium salt, potassium salt, ammonium salt, lithium salt, magnesium salt, calcium salt, urea or derivative thereof, acrylic polymer, polyurea, polyurethane, epoxy polymer, or silicone polymer.

6. The MMMA of claim 1, wherein the WVAL is secured to the two WRLs using adhesive, fusing, or stitching.

7. The MMMA of claim 1, wherein the substrate is a textile, and wherein the WVAL comprises the deliquescent material in a concentration of 5 % to 300 % by weight relative to the weight of the textile.

8. A cushioning component comprising the MMMA of any one of claim 1 to claim 7 and at least one compressible layer, wherein the compressible layer comprises a textile, fabric, foam, leather, vinyl, plastic, rubber, or latex.

9. A product comprising the MMMA of any one of claim 1 to claim 7, wherein the product comprises a bedding component, an upholstered article, personal protective equipment, a medical device, athletic equipment, or performance apparel.

10. The product of claim 9, wherein the product is a pillow or a mattress.

11. The product of claim 9, wherein the product is a body armor vest or firefighter apparel.

12. A method of making a multilayer moisture management assembly (“MMMA”) comprising applying a deliquescent material to a textile to form a water vapor absorbent layer (“WVAL”), and placing the WVAL between two water resistant layers (“WRLs”), wherein the two WRLs are water resistant and at least one WRL is water-vapor permeable.

13. The method of claim 12, further comprising securing the WVAL to the two WRLs, wherein securing comprises applying adhesive, fusing or stitching.

14. The method of claim 12, wherein applying the deliquescent material comprises padding, knife coating, spraying, foaming, or screen printing.

15. The method of claim 12, wherein applying the deliquescent material to the textile comprises forming a textile with a fiber comprising the deliquescent material16. The method of claim 15, further comprising treating a fiber with the deliquescent material to form the fiber comprising the deliquescent material.

17. The method of claim 15, further comprising incorporating the deliquescent material into a synthetic fiber during extrusion or polymerization of the synthetic fiber to form the fiber comprising the deliquescent material.

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