Extensible Laminate

Abstract

To provide favorable stretchable laminates and the like.SOLUTION: The present invention provides stretchable laminates with a flat appearance on a visible surface. The laminates comprise a textile layer, a functional layer, and a plurality of elastic fibers. The elastic fibers are in a substantially parallel arrangement, and the internal distance between adjacent fibers does not exceed a maximum fiber spacing, which depends on laminate thickness in a stretched state. Also provided are garments and footwear comprising the stretchable laminates, and methods of producing the stretchable laminates.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] Priority claim This application claims priority to U.S. Provisional Patent Application No. 62 / 403,805, filed October 4, 2016, which is incorporated by reference in its entirety.

[0002] TECHNICAL FIELD OF THEINVENTION In general, the present invention relates to stretchable laminates. More particularly, the present invention relates to a laminate of a textile and a functional layer that has a flat appearance on the surface of the textile opposite the functional layer when the laminate is in an unstretched state. [Background technology]

[0003] 2. Background of the Invention Waterproof, vapor-permeable laminates with stretch properties are highly desirable for incorporation into articles such as clothing. Stretch properties are desirable when flexibility of movement is required in the garment or to achieve form-fitting garments. Without being tailored, form-fitting garments use stretch properties to fit more snugly without negatively impacting the comfort of the wearer. Gloves, mittens, socks, stockings, skiwear, running suits, athletic clothing, and medical compression are some examples of such garments that benefit from form-fitting properties.

[0004] Currently, stretchability in waterproof applications can be achieved by using elastic or extensible textiles laminated to a functional layer that provides waterproofness and moisture permeability. Elastic or extensible textiles can be made from elastic materials or can be coated with elastic materials to impart extensibility to the textile. By using an elastic or extensible outer textile, these laminates can generally achieve a flat surface appearance. For example, US 2009 / 0227165 discloses an extensible composite fabric that includes a sintered expanded porous polytetrafluoroethylene film and an expanded cloth that are laminated together while remaining flat. US 2013 / 0291293 discloses a waterproof, breathable, stretch-recovery composite that can be used in a footwear assembly and that exhibits a stretch rate in at least one direction of at least 35% at 4 pounds of force and a recovery rate of at least 80%.

[0005] US Patent No. 5,804,011 discloses a stretchable layered fabric laminate that is permeable to water vapor, yet air-impermeable and waterproof. The stretchable fabric laminate includes a stretchable composite layer of a hydrophobic protective layer of a porous polymeric material on each side of a layer of a hydrophilic water vapor permeable synthetic polymer. The composite layer is laminated to at least one layer of stretchable fabric. The stretchable layered fabric laminate has excellent stretch and recovery properties in both the machine and cross directions, making it useful for the manufacture of form-fitting articles of protective clothing and other end uses. Furthermore, conventional stretchable laminates incorporating non-elastic textiles tend to have a rough or non-uniform appearance in the unstretched state, resulting in poor aesthetics and low customer acceptance. For example, surface pleats can increase the thickness of the laminate, making it bulkier and more difficult to wear or incorporate into small applications such as shoe tongues. In the unstretched or relaxed state, the outer surface of conventional stretch laminates incorporating inelastic materials has bunching, rippling, buckling and / or pleats. U.S. Pat. No. 6,713,415 discloses a wash-durable integral composite stretch pleated fabric and a method for making the fabric, based on two nonwoven outer layers and a pre-stretched inner layer of elastomeric fibers of at least 400 dtex and at least 8 threads per inch. Summary of the Invention [Problem to be solved by the invention]

[0006] Various attempts have been made to improve stretchable, breathable laminates. Although improvements have been made, it has not been possible to create flat laminates incorporating non-elastic textiles that are free of bunching, rippling, buckling and / or pleating. Furthermore, many of these fabrics have achieved varying degrees of waterproofness, breathability, stretchability, stretch recovery and comfort. However, there is a continuing need to provide the desired properties for clothing and / or footwear while stretching textile types such as non-elastic or relatively inelastic textiles that have a surface with an aesthetic appearance in the unstretched state and that may be used in stretchable laminates. [Means for solving the problem]

[0007] BRIEF SUMMARY OF THE INVETION In some embodiments, the present disclosure provides a stretchable laminate comprising: a textile layer comprising a non-elastic material having a first surface and a second surface; a functional layer disposed on at least one surface of the textile layer; and a plurality of elastic fibers having an adjacent fiber spacing distance disposed in a substantially parallel configuration on at least one of the textile layer and / or the functional layer, wherein at least 80% of the elastic fibers have an adjacent spacing less than a maximum fiber spacing, and the maximum fiber spacing in millimeters is less than or equal to 3.0 times the thickness in millimeters of the stretchable laminate in a stretched state; i) the plurality of elastic fibers are disposed between the textile layer and the functional layer; ii) the functional layer is disposed on a first surface of the textile layer and the plurality of elastic fibers are disposed on a side of the functional layer opposite the textile layer; or iii) The laminate, wherein the functional layer is disposed on a second surface of the textile layer and the plurality of elastic fibers is disposed on a first surface of the textile layer.

[0008] In another embodiment, a stretchable laminate and garments made therefrom include a textile layer comprising a non-elastic material having a first surface and a second surface, a functional layer disposed on at least one surface of the textile layer, and a plurality of elastic fibers disposed in a substantially parallel configuration on at least one of the textile layer and / or functional layer, wherein a surface of the textile layer opposite the functional layer has an average normalized surface roughness (Ra) of 25 micrometers or less in an unstretched state, wherein: i) the plurality of elastic fibers are disposed between the textile layer and the functional layer; ii) the functional layer is disposed on a first surface of the textile layer and the plurality of elastic fibers are disposed on a side of the functional layer opposite the textile layer; or iii) the functional layer is disposed on a second surface of the textile layer, and the plurality of elastic fibers is disposed on a first surface of the textile layer. Stretch laminates and garments made therefrom are provided.

[0009] In some embodiments, the maximum distance between adjacent fibers does not exceed the maximum fiber spacing of the extensible laminate. In some embodiments, the surface of the textile opposite the functional layer is substantially free of buckling or non-uniform buckling.

[0010] In another embodiment, the elastic fibers can be arranged in a substantially parallel configuration between two functional layers, with or without a textile layer, and the surface of the functional layer opposite the plurality of elastic fibers is substantially free of buckling. In other embodiments, the stretchable laminate comprises a plurality of elastic fibers arranged in a substantially parallel configuration on a first functional layer, and optionally further comprises a second functional layer, where the second functional layer is disposed on the first functional layer, the elastic fibers are disposed between the first functional layer and the second functional layer, or the second functional layer is disposed on the first functional layer on a surface opposite the plurality of elastic fibers, and the plurality of elastic fibers have a fiber density or fiber spacing of at least 7.9 fibers / cm, e.g., at least 8.0 fibers / cm, or at least 10.0 fibers / cm. In some embodiments, the stretchable laminate comprises a textile layer comprising a material having a first surface and a second surface, a plurality of elastic fibers arranged in a substantially parallel configuration between a first functional layer and a second functional layer, where the first functional layer or the second functional layer is disposed on the first surface of the textile layer.

[0011] In yet another embodiment, the elastic fibers can be arranged in a substantially parallel configuration on a surface of the functional layer, particularly on the opposite surface of the functional layer from the textile layer. In some embodiments, a stretchable laminate includes a textile layer including a material having a first surface and a second surface, and a functional layer having a plurality of elastic fibers arranged in a substantially parallel configuration on a surface of the functional layer, the functional layer being disposed between the textile layer and the plurality of elastic fibers.

[0012] In a further embodiment, the elastic fibers may be arranged in a substantially parallel configuration on a first surface of the textile layer and the functional layer may be disposed on a second surface of the textile.A stretchable laminate includes a textile layer comprising a material having a first surface and a second surface, a plurality of elastic fibers arranged in a substantially parallel configuration on the first surface of the textile layer, and a functional layer disposed on the second surface of the textile layer.

[0013] In yet further embodiments, the functional layer or textile layer may be omitted. In one such embodiment, the stretchable laminate may include a textile layer comprising a material having a first surface and a second surface, a plurality of elastic fibers arranged in a substantially parallel configuration on the first surface of the textile layer. In other embodiments, the textile layer may be omitted. In another embodiment, the stretchable laminate may include a functional layer, where a plurality of elastic fibers are arranged in a substantially parallel configuration on a surface of the functional layer, and the plurality of elastic fibers have an internal distance less than or equal to a maximum fiber spacing based on the thickness of the laminate when measured in a stretched state. In some embodiments, the fiber density is at least 7.9 fibers / centimeter.

[0014] In some embodiments, the denier of the elastic fiber is 400 denier or less. In some cases, the denier is 300 denier, 200 denier, 150 denier or less, as described herein. In some examples, the functional layer has a thickness of less than 0.06 mm, e.g., less than 0.05 mm, less than 0.04 mm, or less than 0.03 mm.

[0015] In another embodiment, a garment is provided comprising the laminate disclosed herein, hi one embodiment, the laminate is used in an elbow panel, shoulder area, side panel, or tongue. [Brief description of the drawings]

[0016] BRIEF DESCRIPTION OF THE DRAWINGS Advantages of the present invention will become apparent in light of the following detailed disclosure of the invention, particularly when taken in conjunction with the accompanying drawings.

[0017] [Figure 1] Figure 1A is a photograph of an extensible laminate having a flat appearance in an unstretched state, and Figure 1B is a photograph of an extensible laminate having a buckled surface in an unstretched state, according to an embodiment of the invention.

[0018] [Diagram 2] FIG. 2 is a schematic diagram of a cross-section of an extensible laminate having a flat surface in an unstretched state, according to an embodiment of the present invention.

[0019] [Diagram 3] FIG. 3 is a perspective view of uniformly spaced fibers on a functional layer according to an embodiment of the invention.

[0020] [Figure 4] FIG. 4 is a schematic diagram of a cross-section of an extensible laminate having a flat surface in an unstretched state, according to an embodiment of the present invention.

[0021] [Diagram 5]FIG. 5 is a schematic diagram of a cross-section of an extensible laminate having a flat surface in an unstretched state, according to an embodiment of the present invention.

[0022] [Figure 6] FIG. 6 is a schematic diagram of a cross-section of an extensible laminate having a flat surface in an unstretched state, according to an embodiment of the present invention.

[0023] [Figure 7] FIG. 7 is a schematic diagram of a cross-section of an extensible laminate having a flat surface in an unstretched state, according to an embodiment of the present invention.

[0024] [Figure 8] FIG. 8 is a schematic diagram of a cross-section of an extensible laminate having a flat surface in an unstretched state, according to an embodiment of the present invention.

[0025] [Figure 9] FIG. 9 is a schematic diagram of a stretch laminate incorporated into a garment.

[0026] [Figure 10] FIG. 10A is a photograph of the woven fabric with arrows indicating feature spacing.

[0027] FIG. 10B is a photograph of the knitted fabric with arrows indicating feature spacing.

[0028] [Figure 11] FIG. 11A is a three-dimensional surface plot of a stretchable laminate of the present invention.

[0029] FIG. 11B is a graph of normalized surface roughness (Ra) measurements across the surface of a stretchable laminate of the present invention.

[0030] [Figure 12] FIG. 12A is a three-dimensional surface plot of a comparative extensible laminate having a buckled surface due to inadequate elastic fiber spacing.

[0031] FIG. 12B is a graph of normalized Ra measurements across the surface of an extensible laminate having a buckled surface.

[0032] [Figure 13] FIG. 13A is a three-dimensional surface plot of a stretch laminate of the present invention.

[0033] FIG. 13B is a graph of normalized surface roughness (Ra) measurements across the surface of a stretchable laminate of the present invention.

[0034] [Figure 14] FIG. 14A is a three-dimensional surface plot of a comparative extensible laminate having a buckled surface due to inadequate elastic fiber spacing.

[0035] FIG. 14B is a graph of normalized Ra measurements across the surface of an extensible laminate having a buckled surface.

[0036] [Figure 15] FIG. 15A is a three-dimensional surface plot of a comparative extensible laminate having a buckled surface due to inadequate elastic fiber spacing.

[0037] FIG. 15B is a graph of normalized Ra measurements across the surface of an extensible laminate having a buckled surface.

[0038] [Figure 16] FIG. 16A is a three-dimensional surface plot of a stretchable laminate of the present invention.

[0039] FIG. 16B is a graph of normalized surface roughness (Ra) measurements across the surface of a stretchable laminate of the present invention.

[0040] [Figure 17] FIG. 17 is a table of properties of the inventive and comparative laminates.

[0041] [Figure 18] FIG. 18 is a graph of laminate thickness vs. fiber spacing, correlating fiber spacing to normalized Ra values. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] Detailed Description of the Invention Stretchable laminates are disclosed, and in some embodiments, stretchable laminates having a flat appearance in an unstretched state are disclosed. In general, the stretchable laminates of the present invention include a textile layer and / or a functional layer, and a plurality of elastic fibers. The stretchable laminates are provided by incorporating elastic fibers separate from the textile layer, which may be a non-elastic textile layer. The stretchable laminates are elastic in the direction of the elastic fibers. Some configurations of the layers described herein are also within the scope of the present invention. Additionally, other layers, such as adhesive layers or backing layers, may also be incorporated into the stretchable laminates of the present invention.

[0043] In some embodiments, the present disclosure provides an extensible laminate comprising a textile layer comprising a material having a first surface and a second surface, a functional layer disposed on at least one surface of the textile layer, and a plurality of elastic fibers disposed in a substantially parallel configuration on at least one of the textile layer and / or the functional layer. In some embodiments, the plurality of elastic fibers is disposed between the textile layer and the functional layer. In other embodiments, the functional layer is disposed on a first surface of the textile layer and the plurality of elastic fibers is disposed on a side of the functional layer opposite the textile layer. In yet further embodiments, the functional layer is disposed on a second surface of the textile layer and the plurality of elastic fibers is disposed on the first surface of the textile layer. In another embodiment, the present disclosure provides an extensible laminate comprising a plurality of elastic fibers arranged in a substantially parallel configuration on a first functional layer, and optionally further comprising a second functional layer, where the second functional layer is disposed on the first functional layer, the elastic fibers being disposed between the first and second functional layers, or the second functional layer is disposed on the first functional layer on an opposite side to the plurality of elastic fibers, and the plurality of elastic fibers having a fiber density of at least 7.9 fibers / centimeter. The second functional layer can be selected independently of the first functional layer, and can be selected from the same materials as disclosed for the first functional layer. In yet a further embodiment, the present disclosure provides an extensible laminate comprising a first textile layer having a first surface and a second surface, a second textile layer disposed on at least one surface of the first textile layer, and a plurality of elastic fibers arranged in a substantially parallel configuration between the first textile layer and the second textile layer, or disposed on at least one of the first textile layer or the second textile layer. For the purposes of the present invention, "on" is intended to mean that at least a portion of one layer, e.g. a textile layer, covers at least a portion of an adjacent layer, e.g. a functional layer.

[0044] Advantageously, embodiments of the present invention provide a flat appearance on the textile surface of the laminate opposite the functional layer, which can provide an aesthetic appearance. This eliminates undesirable bunching, rippling, buckling and / or pleating on the surface, which would detract from the aesthetic appearance. A flat appearance is particularly attractive, especially for form-fitting garments. The flat appearance refers to the textile surface of the laminate opposite the functional layer. In some garment embodiments, this is the surface of the laminate that faces the environment and is not next to the wearer, where the textile texture is visible without introducing incompatible areas that would result in undesirable bunching, rippling, buckling and / or pleating on the surface. In other garment embodiments, the functional layer can be an outer layer that faces the environment and is not next to the wearer. In embodiments where the functional layer is the layer that faces the environment, the textile surface can be an inner layer that is adjacent to the wearer's skin or other garments, without introducing bunching, rippling, buckling and / or pleating on the surface, which may cause an unpleasant sensory sensation to the wearer. For the purposes of this disclosure, bunching, rippling, buckling and / or pleating are incongruities that result in undulations on the surface of the textile layer opposite the functional layer, which undulations are different from the texture of the textile layer prior to the formation of the laminate. For example, FIG. 1A is an exemplary laminate according to an embodiment of the present invention in which the surface of the textile layer opposite the functional layer has no visible buckling, while FIG. 1B shows a laminate with unacceptable buckling. As described herein, the buckling in FIG. 1B is caused by an improper arrangement of elastic fibers. An embodiment of the present invention achieves a flat appearance by providing an arrangement of elastic fibers that does not result in bunching, rippling, buckling and / or pleating on the surface of the textile layer opposite the functional layer.

[0045] The determination of the flat appearance may vary depending on the type of textile and the layers of the laminate. Generally, each textile has a natural surface texture. The laminates described herein achieve a flat appearance that does not significantly alter the natural surface texture of the textile, e.g., the natural surface texture of the textile prior to the formation of the laminate. In one embodiment, the surface of the textile layer opposite the functional layer in an unstretched state has an average normalized surface roughness (Ra) of 25 micrometers or less, e.g., 20 micrometers or less, 15 micrometers or less, 10 micrometers or less, or 5 micrometers or less. In terms of ranges, the average normalized Ra can be 1 to 25 micrometers, e.g., 5 to 25 micrometers or 10 to 20 micrometers. By having an average normalized Ra of 25 micrometers or less, the textile surface is substantially free of buckling and other inconformities, e.g., folds. In some embodiments, the maximum normalized surface roughness (Ra) is not more than 50% greater than the average normalized surface roughness (Ra). In another embodiment, the surface of the textile layer has a maximum normalized surface roughness (Ra) of less than or equal to 25 micrometers.

[0046] Surface flatness can be evaluated by profilometry. Briefly, profilometry measures the surface topography of a laminate specimen. The surface topography measurements can be normalized to represent the natural surface roughness of the textile layer. A normalized surface roughness (Ra) can then be calculated from the normalized surface topography data. For example, tweed or fleece can have a natural surface roughness with more texture than plain weave nylon. The normalized Ra uses a filter window of two feature lengths as described in the test procedure. When the normalized Ra is greater than 25 micrometers, the occurrence of mismatch increases, which results in an uneven appearance and poor aesthetics. As used herein, the phrase "substantially free of buckling" means that the normalized Ra is equal to or less than 25 micrometers.

[0047] As shown in FIG. 2, the laminate 1 includes a textile layer 10, a plurality of elastic fibers 20, and a functional layer 40. The textile layer 10 has a first surface 11 and a second surface 12. The second surface 12 is the surface opposite the functional layer 40. The functional layer 40 is disposed on the first surface 11 of the textile layer 10. A plurality of elastic fibers 20 are disposed between the textile layer 10 and the functional layer 40. Each of the elastic fibers 20 is disposed in a substantially parallel configuration relative to each other and has an internal spacing of d. An adhesive layer 30 is disposed between the functional layer 40 and the plurality of elastic fibers 20. The adhesive layer 30 also bonds the textile layer 10 to the functional layer 40. The thickness of the laminate 1 can vary depending on the textile layer 10 and the number of layers. As discussed herein, the internal distance d between the elastic fibers 20 can depend on the thickness of the laminate 1. In some embodiments, the thickness of the laminate 1 in the stretched state is from 0.05 to 4 mm, for example from 0.1 to 2 mm or from 0.1 to 1 mm.

[0048] The present invention can be useful for laminates 1 incorporating textile layers 10 made from non-elastic or relatively non-elastic materials. In some embodiments, laminates 1 can incorporate textiles having elastic materials, and elastic fibers 20 can further increase the elasticity of laminate 1. Non-elastic materials can include materials that are not coated with elastic materials, or materials that do not have elastic materials woven or knitted into the textile layer. Thus, in some embodiments, the material of textile layer 10 is not coated or filled with any elastomer or other material that imparts elasticity. In one embodiment, the material of textile layer 10 has an elasticity that is less than that of elastic fibers 20. For example, the elastic fibers can have an elasticity that is at least 1.5 times greater than the textile layer, at least 2 times, at least 3 times, or at least 4 times greater than the textile layer. In certain embodiments, the textile layer 10 can be made from a non-elastic material such that the textile layer 10, independent of the stretch properties of the laminate 1, has an elongation of 15% or less as measured according to ASTM test method D5035-06. In other embodiments, the elongation of the textile layer can be 10% or less, or 5% or less.

[0049] The textile layer 10 can be a woven, knitted or nonwoven layer. The term "woven" can encompass any textile structure constructed from weft and warp yarns or filaments. The term "knitted" should be broadly understood to include any form of warp knitting and circular knitting in particular, but also encompass any other configuration in which a textile structure is produced by winding one or more yarns or filaments to form loops. Thus, as used herein, knitted fabric can also encompass configurations that may be referred to as braided structures. As shown in FIG. 2, the textile layer 10 is a woven layer. In some embodiments, the textile layer 10 can be a woven or knitted layer. Depending on the pattern, the knitted layer may inherently have some stretchability, but still be made from a non-elastic material. The knitted material can be knitted from yarns that are non-elastic yarns or from yarns that do not include an elastic coating. In some embodiments, a second or subsequent textile layer may be used, with each second or subsequent textile layer being selected independently of the previous textile layer.

[0050] In some embodiments, the material of the textile layer 10 can be a natural fiber or a polymeric fiber or a mixture of these fibers. Natural fibers include, for example, cotton, silk, cellulose, and / or wool. Polymeric fibers include, for example, polyamides, polyolefins, polyacrylates, polyesters, polyurethanes, fluoropolymers, and copolymers thereof. In some embodiments, at least a portion of the material of the textile layer 10 can be a flame retardant or fire resistant textile material, such as aromatic polyamides, NOMEX® polymetaphenylene isophthalamide, flame retardant (FR) cotton, polybenzimidazole (PBI), polybenzoxazole (PBO), FR rayon, modacrylic, modacrylic blends, carbon fiber, glass fiber, polyacrylonitrile, polytetrafluoroethylene, and blends thereof. In some embodiments, the textile layer 10 is a polyamide, such as polyester or nylon. The material weight of the textile layer 10 is between 15 and 500 grams per square meter (g / m 2 ), or 15 to 500 g / m 2 In other embodiments, the material weight of the textile layer can vary from 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, or 50 up to 400, 425, 450, 475, or 500 g / m 2 In other embodiments, lighter or heavier materials may also be used. The thickness of the textile layer 10 may also vary, typically being between 0.05 and 4 mm, for example between 0.1 and 2 mm or between 0.1 and 1 mm.

[0051] In some embodiments, a wear coating may be present on the surface 12 of the textile layer 10 opposite the functional layer. The wear coating may be continuous or discontinuous. In certain embodiments, the wear coating may include one or more layers of silicone, polyamide, polyester, epoxy, polyolefin, or polyurethane. The wear coating may be applied in a manner that does not impair the waterproof and breathable properties of the laminate 1.

[0052] The functional layer 40 may be used to provide breathability and water impermeability while allowing water vapor transmission. In one embodiment, the functional layer 40 may be a porous or non-porous membrane. In another embodiment, the functional layer 40 may be a barrier against chemical gases, liquids and / or particulates. A "membrane" as used herein is a barrier or film that is permeable to water vapor or moisture but has waterproof properties. In some embodiments, the membrane may be further treated, such as surface coating, absorbent coating, node and fibril coating, etc., and may also be referred to as a film. A membrane or film is considered to have waterproof properties if the requirements set forth in DIN EN 343 (2010) are met, i.e., if the test for liquid water resistance against hydrostatic pressure according to EN 20 811 (1992) results in a liquid water resistance (Wp) of 8000 Pa or more.

[0053] In some embodiments, the functional layer 40 and, if present, the optional second or subsequent functional layer, comprise at least one of polyurethane, copolyether-ester, polyolefin, polyester, fluoropolymer, or a combination thereof. Suitable fluoropolymers include, for example, polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), tetrafluoroethylene-hexafluoropropylene copolymer (FEP), and tetrafluoroethylene-(perfluoroalkyl)vinyl ether copolymer (PFA). In some embodiments, the functional layer can be an expanded polytetrafluoroethylene (ePTFE) membrane. Porous membranes that can be used include, for example, one or more layers of ePTFE membranes made according to U.S. Patent No. 7,306,729 to Bacino et al., U.S. Patent No. 3,953,566 to Gore, U.S. Patent No. 5,476,589 to Bacino, U.S. Patent No. 5,183,545 to Branca et al., and U.S. Patent No. 4,902,423 to Bacino. Each of these is incorporated herein by reference in its entirety. In certain embodiments, the functional layer can include a copolymer of tetrafluoroethylene (TFE), and the one or more monomers are vinylidene difluoride (VDF), hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), ethylene, vinylidene fluoride (VF), perfluoroalkoxy (PFA), perfluoroether, and trifluoroethylene, or combinations thereof. Alternatively, the functional layer 40 can include a monolithic membrane made of a hydrophilic polymer, such as polyurethane and / or polyether-polyester, among others. In some embodiments, the stretchable laminate can include a second or subsequent functional layer, and each second or subsequent functional layer can be independently selected from the functional layers described above.

[0054] As with textile materials, some of the functional layers 40 may have elasticity less than that of the elastic fibers 20. In particular, ePTFE may have relatively inelastic properties. The elasticity of the functional layer 40 using ePTFE may be improved by imbibing an elastomer, but this requires an additional step to manufacture the functional layer 40. Furthermore, the imbibing process is not necessary, and the embodiments may use the functional layer 40 with or without imbibing an elastomer.

[0055] To achieve good water vapor permeability while still providing sufficient waterproof properties, in some embodiments the functional layer can be a porous membrane having a mean flow pore size of 0.05 μm to 0.5 μm, particularly 0.1 μm to 0.5 μm, more particularly 0.2 μm to 0.45 μm. In other embodiments, the functional layer can be a breathable polyurethane film, in which case there is no porosity. In still other embodiments, the functional layer can be both non-breathable and non-porous, such as in chemical barrier applications useful in industrial or military grade clothing.

[0056] When the functional layer 40 is incorporated into the laminate, the laminate has a strength of at least 3000 g / m 2 / 24hr, e.g. at least 6000g / m 2 / 24hr, at least 8000g / m 2 / 24hr or at least 12000g / m 2 / 24hr and have a water vapor transmission rate (MVTR) according to DIN EN ISO 15496 (2004) of 3000 to 20000 g / m 2 / 24hr range. To maintain an acceptable MVTR, in some embodiments, the elastic fibers 20 cover no more than 40%, such as no more than 20%, of the surface area of ​​the functional layer 40. Lower surface coverage can avoid a significant decrease in MVTR.

[0057] The functional layer 40 is typically a very thin layer. In one embodiment, the functional layer 40 has a thickness of 0.01 to 0.5 mm, for example, 0.01 to 0.3 mm. In some embodiments, the functional layer has a thickness of less than 0.06 mm, less than 0.05 mm, less than 0.04 mm, or less than 0.03 mm.

[0058] Additional treatments may be provided to impart functionality, such as, but not limited to, oleophobicity and hydrophobicity. In some embodiments, the membrane can be treated with an oleophobic and / or hydrophobic coating. Examples of oleophobic coatings include, for example, polyurethanes, fluoropolymers such as fluoroacrylates, and other materials, such as those taught in U.S. Pat. No. 6,261,678 and U.S. Patent Publication No. 2007 / 0272606, the entire contents and disclosures of which are incorporated herein by reference. Oleophobicity can also be provided by coating at least one surface of the membrane with a continuous coating of an oleophobic, water vapor permeable polymer.

[0059] Turning to the elastic fibers 20, which are added as separate layers to the laminate 1 in a substantially parallel configuration, the elastic fibers 20 have a recovery of at least 80% under at least 20% strain, such as at least 50% strain or at least 100% strain. In some embodiments, the recovery of the elastic fibers can be greater than 80% and can be at least 90% or at least 95% under at least 20% or at least 50% or at least 100% strain. In certain embodiments, the elastic fibers 20 comprise at least one elastomer, such as natural rubber, polybutadiene, elastomeric polyolefins, polyurethanes, polyesters, silicones, fluoroelastomers, elastanes, block copolymers containing polyesters, polyester-polyurethanes, polyamides, or combinations thereof. In some embodiments, the elastic fibers 20 are elastane fibers, spandex, LYCRA® polyester-polyurethane fibers, or combinations thereof. In some embodiments, the plurality of elastic fibers can be or include, at least in part, a flame-retardant or fire-resistant elastomer, such as a silicone elastomer or other fiber treated with a known flame-retardant additive or coating. In some embodiments, the plurality of elastic fibers 20 include a material different from the material of the textile layer 10. The denier of the elastic fibers 20 can be 400, 300, 200, 120, 100 or less, or any value therein. In one exemplary embodiment, the denier of the elastic fibers 20 is 300. In certain embodiments, the denier and / or mass of the elastic fibers 20 is matched to the material mass of the textile layer, with heavier fabrics requiring larger denier elastic fibers. The size of the elastic fibers can also depend on the in-plane textile compressibility, where high pressure-resistant textiles generally use larger denier elastic fibers. In some embodiments, the elastic fiber has a mass of 30 to 400 denier or any value therein, such as 40 to 300 denier, 50 to 200 denier, or 60 to 150 denier. The elastic fiber may be a monofilament elastic fiber or a multifilament elastic fiber.

[0060] Uniform elastic fiber spacing advantageously achieves a flat appearance on the surface of the laminate opposite the functional layer, typically the textile layer. Figure 3 is a perspective view of Figure 2 without the textile layer, showing uniform elastic fiber 20 spacing d in the longitudinal direction. The elastic fibers generally extend in one direction, such as the longitudinal direction of the fabric, and are substantially parallel to one another, although the fibers may occasionally touch or cross one another.

[0061] The internal distance d is the spacing between adjacent elastic fibers 20, also referred to herein as the adjacent spacing. Without intending to be bound by theory, when the internal distance between any two adjacent elastic fibers 20 exceeds a maximum distance determined primarily by the thickness of the laminate, the outermost surface 12 of the laminate 1 tends to buckle, wave, bunch and / or crimp. To avoid undesirable buckling, wave, bunch and / or crimp, the majority of the elastic fibers 20 have an adjacent spacing equal to or less than the maximum fiber spacing (MFS). The MFS in millimeters (mm) may be approximated by the following formula: MFS=3(t) where t is the thickness of the laminate in mm, measured in the stretched state by pulling the laminate to its maximum non-plastic extension using the procedure found in the Examples section. In other embodiments, the MFS in millimeters can be equal to 2.9(t) or 2.8(t) or 2.7(t) or 2.6(t) or 2.5(t) or 2.4(t) or 2.3(t) or 2.2(t) or 2.1(t) or 2.0(t), where t is the thickness of the laminate when measured in the stretched state. In some embodiments, at least 80% of the elastic fibers have an adjacent spacing equal to or less than the MFS based on the thickness of the laminate as disclosed above. In other embodiments, at least 85%, at least 90%, or 91% or 92% or 93% or 94% or 95% or 96% or 97% or 98% or 99% or 100% of the elastic fibers have an adjacent spacing equal to or less than the MFS based on the thickness of the laminate. In yet another embodiment, the maximum distance between adjacent fibers does not exceed the maximum fiber spacing of the extensible laminate.If 20% or more of the elastic fibers have adjacent spacing greater than the MFS, non-uniformity may occur, which leads to undesirable buckling.This also causes the normalized Ra to have a peak greater than 25 micrometers.

[0062] The internal distance d between the elastic fibers 20 depends on the MFS and can vary with the textile material and thickness. In some embodiments, the elastic fibers are spaced apart by an internal distance of 0.1 to 1.5 millimeters (mm). In exemplary embodiments, the elastic fibers are uniformly spaced apart within an MFS of 1.5 mm or less, e.g., 1.1 mm or less, 1 mm or less, 0.9 mm or less, 0.5 mm or less, or 0.4 mm or less. In terms of ranges, in certain embodiments, the MFS can be 0.1 to 1.5 mm, e.g., 0.25 to 1.1 mm, 0.25 to 1 mm, 0.4 to 1 mm, 0.5 to 1 mm, or 0.5 to 0.9 mm. This spacing of the elastic fibers allows for 5 to 40 elastic fibers / linear centimeter laminate in the transverse direction, i.e., perpendicular to the fibers. In some embodiments, the number of elastic fibers per linear centimeter can be 10 to 30 or 15 to 20.

[0063] The stretchable laminate further includes an adhesive layer 30. As used herein, the phrase "adhesive layer" refers to a bonding layer or bonding region. In some embodiments, an adhesive composition is used to bond the layers and / or elastic fibers. In other embodiments, the layers and / or elastic fibers can be bonded using other known bonding techniques, such as welding. The adhesive layer is disposed between the plurality of elastic fibers and the textile layer and / or functional layer, and the adhesive layer is typically used to bond the textile or functional layer to the next layer and / or one textile or functional layer to the plurality of elastic fibers. For example, if a stretchable laminate including the composite structure of textile layer / elastic fiber / functional layer of FIG. 2 is desired, one adhesive layer can be used to bond the textile layer to the plurality of elastic fibers and also to the functional layer, thus producing the desired stretchable laminate. As shown in FIG. 2, the adhesive layer 30 is disposed between the functional layer 40 and the plurality of elastic fibers 20. In some embodiments, the plurality of elastic fibers 20 are adhered to the functional layer 40 on the side opposite the textile layer 10. In other embodiments, the adhesive layer 30 is positioned such that it is first adhered to the textile layer 10 before the plurality of elastic fibers 20 are adhered to the functional layer 40. Depending on the layer arrangement, there can be multiple adhesive layers.

[0064] Any suitable adhesive composition may be used in the embodiments described herein. In some embodiments, the adhesive layer comprises an adhesive composition of polyurethane, styrenic block copolymers, such as styrene / isoprene and styrene / butadiene block copolymers, or combinations thereof. In other embodiments, the adhesive composition may comprise flame retardant or fire retardant additives as known in the art. In other embodiments, the adhesive composition may comprise an expandable carbon / polymer mixture, for example, as described in US 2013 / 0156680, which is incorporated by reference in its entirety.

[0065] The adhesive composition can be applied in any pattern, such as lines, dots, continuous areas, etc., by any method known in the art, such as printing, spraying, stamping, or rolling. In some embodiments, a plurality of elastic fibers 20 are bonded by a discontinuous adhesive layer 30, as shown in FIG. 3. Adhesive dots having a diameter of 100 to 1000 microns can be used. In embodiments where the adhesive layer is discontinuous, the spacing between adjacent adhesive areas when measured end-to-end is generally equal to or less than the MFS. "End-to-end" as used in this context means measuring the distance between two adjacent adhesive areas (i.e., the spacing without the adhesive material). In some embodiments, the end-to-end distance is equal to or less than 100% of the MFS. In other embodiments, the end-to-end distance is less than 80% or less than 70% or less than 60% or less than 50% or less than 40% or less than 30% or less than 20% or less than 10% of the MFS. It has been found that as the end-to-end spacing between adjacent adhesive areas approaches the MFS, the surface of the laminate in the unstretched state becomes less flat. In another embodiment, a plurality of elastic fibers are bonded by a continuous adhesive layer, as shown in FIG.

[0066] The total weight of the adhesive composition is 35% or less, e.g., 30% or less, 25% or less, 15% or less, 10% or less, or 5% or less of the total weight of the laminate. In some embodiments, the functional layer and the adhesive layer may be pre-bonded with a functional / adhesive layer. In one embodiment, the functional / adhesive layer is ePTFE coated with polyurethane. In other embodiments, the elastic fiber 20 and the adhesive layer 30 may be pre-bonded by coating or printing the adhesive layer onto the elastic fiber.

[0067] In other embodiments, no adhesive layer is used and the layers may be welded or otherwise bonded together by compression.

[0068] Optionally, the stretchable laminate may include a backing layer, such as a second textile layer or a second functional layer. In some embodiments, the backing layer may include a woven, nonwoven, or knitted material. In other embodiments, the backing layer may include at least one of woven, nonwoven, or knitted nylon, polyester, cotton, silk, or a combination thereof. In other embodiments, the backing layer may include one or more additional microporous layers. In some embodiments, the stretchable laminate may further include a second textile layer including a non-elastic material having a first surface and a second surface, where the first surface of the second textile is disposed on the first functional layer or the second functional layer if two functional layers are utilized. When a backing layer or a second textile layer is used, one or both of the outwardly facing surfaces of the first and second textiles, i.e., the surface opposite the functional layer, may have an average normalized roughness (Ra) of 25 micrometers or less in the unstretched state.

[0069] Once assembled, the stretchable laminate 1 of FIG. 2 has a flat appearance that can achieve a desired aesthetic appearance. The flat appearance can be evaluated by measuring the stretchable laminate in an unstretched state by profilometry as described herein. Additionally, the majority of the elastic fibers 20 of the stretchable laminate 1 of FIG. 2 are spaced apart by an internal distance d that is equal to or less than the MFS. Advantageously, by incorporating elastic fibers into the stretchable laminate, embodiments of the present invention can achieve a flat appearance and provide a stretchable laminate. The stretchable laminate can have an elasticity that is greater than the elasticity of the textile material prior to incorporation into the stretchable laminate. In one embodiment, the stretchable laminate has at least 80% recovery after at least 10% elongation. In other embodiments, the stretchable laminate has at least 80% recovery after at least 20% elongation, or at least 25% elongation, or at least 50% elongation. The textile materials and functional layers used to make the stretch laminates can have an elongation of 15% or less, or 10% or less, or 5% or less, as measured by ASTM D 5035-06. The disclosed stretch laminates can have an elongation of up to 150%, such as greater than 5%, or greater than 10%, or greater than 15%, or in the range of 5% to 150%, as measured by ASTM D 5035-06. In each case, the % elongation of the laminate is greater than the elongation of any individual layer alone. In other embodiments, the stretchable laminate can have an elongation of 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 100%, 105%, 110%, 115%, 120%, 125%, or any value between any of these recited elongations. Depending on the selection of the functional layer, the stretchable laminate can also be waterproof and breathable in both the unstretched and stretched states.

[0070] In addition to the configuration shown in FIG. 2, embodiments can have different arrangements of layers that include elastic fibers.

[0071] 4 shows a laminate 2 having two functional layers 40, 42 with a plurality of elastic fibers 20 disposed between the functional layers 40, 42. A first adhesive layer 30 bonds the elastic fibers 20 to one of the functional layers and may also bond the functional layers 40, 42 together. A second adhesive layer 32 bonds one of the functional layers 40 and the textile layer 10.

[0072] 5 shows a stretchable laminate 3 having a plurality of elastic fibers 20 disposed on a side of a functional layer 40 opposite the textile layer 10. A second adhesive layer 32 bonds the functional layer 40 and the textile layer 10. Although not shown, a backing layer may be provided. This allows the stretchable film including the functional layer 40 and elastic fibers 20 to be used with a wide variety of textile layers 10, since the elastic fibers 20 are adhered to the opposite side of the textile layer 10.

[0073] 6 shows a stretch laminate 4 having a plurality of elastic fibers 20 disposed on the side of the textile layer 10 opposite the functional layer 40. A second adhesive layer 32 bonds the functional layer 40 and the textile layer 10.

[0074] 7 shows a stretch laminate 5 having a plurality of elastic fibers 20 disposed on a textile layer 10. No functional layer is incorporated into the laminate 5. The textile layer 10 is inelastic and can be a material that provides waterproof and / or breathability.

[0075] The present disclosure also relates to a stretchable laminate comprising a plurality of elastic fibers disposed in a substantially parallel configuration between a first textile layer and a second textile layer. The first and second textile layers and the plurality of elastic fibers can be any of those previously described. One or both of the first and second textile layers can be a material that is inelastic and provides waterproof and / or breathability.

[0076] The present disclosure also relates to extensible laminates comprising a plurality of elastic fibers arranged in a substantially parallel configuration on a first functional layer, and optionally further comprising a second functional layer, where the second functional layer, if present, is disposed on the first functional layer and the plurality of elastic fibers are disposed between the first and second functional layers, or the second functional layer is disposed on the first functional layer on an opposite side to the plurality of elastic fibers, and where the plurality of elastic fibers have a fiber density of at least 7.9 fibers / centimeter. FIG. 8 shows an extensible laminate 6 having a plurality of elastic fibers 20 disposed on a functional layer 40. In embodiments without a textile layer, the elastic fibers can have a fiber density of at least 7.9 fibers / centimeter (20 fibers / inch) and up to about 40 fibers / centimeter (about 100 fibers / inch). In other embodiments, the fiber density can range from 12 fibers / centimeter to 32 fibers / centimeter, or from 15 fibers / centimeter to 30 fibers / centimeter.

[0077] In one embodiment, the stretch laminates described herein can be used to manufacture an entire garment. The garment can include any of outerwear, undergarments, footwear, gloves, hats, and accessories. As shown in FIG. 9, the laminates described herein can also be used to manufacture one or more portions 51 of an entire garment 50, such as elbow panels, shoulder areas, cuff areas, or side panels. This can provide elasticity to areas of the garment to benefit the wearer, or make the garment more form-fitting. In some embodiments, the stretch laminates described herein can be used to manufacture one or more portions of a shoe structure or shoe insert, such as a toe portion, a shank portion, or a tongue portion. A garment as disclosed herein can be manufactured such that the functional layer faces away from the wearer, e.g., the functional layer can be on the outermost surface of the garment. In other embodiments, the garment can be manufactured such that the textile layer faces away from the wearer, e.g., the textile layer can be on the outermost surface of the garment.

[0078] Also disclosed is a method for producing a stretchable laminate having a flat appearance from a plurality of elastic fibers and one or more textile layers, one or more functional layers, or a combination thereof, wherein the elastic fibers are incorporated under tension into the stretchable laminate as separate layers arranged in a substantially parallel configuration.

[0079] Next, a method for producing a stretchable laminate comprising a textile layer and a functional layer is described. It should be understood that any of the other embodiments described above can be produced according to this method. While maintaining tension on the elastic fibers, the adhesive layer, the textile layer and the functional layer are fed through a lamination nip, and the resulting laminate is wound onto a roll and cured. After curing, the laminate is unwound and allowed to relax, thereby returning to an unstretched state. Stretchable laminates comprising three or more layers, for example, two textile layers and one functional layer, one textile layer and two functional layers, can also be produced using this method.

[0080] The advantage of this method is that the elastic fibers do not have to be woven into the textile, but rather are introduced as a separate layer. Thus, off-the-shelf non-elastic textiles can be used in the stretch laminate. Another advantage is that the elastic fibers do not have to be incorporated into the textile and woven or knitted into the textile, allowing for faster prototyping and faster production.

[0081] The details of one or more embodiments are described in the description herein. Other features, objects and advantages will be apparent from the description and claims. The following examples are intended to further illustrate certain aspects of the methods and compositions described herein, but are not intended to limit the scope of the claims. EXAMPLES

[0082] Test Method Although particular methods and apparatus are described below, it should be understood that any method or apparatus determined to be suitable by one of ordinary skill in the art may alternatively be used.

[0083] Stretch and Recovery Test Protocol ASTM Test Method D 5035-06 "Standard Test Method for Breaking Force and Elongation of Textile Fabrics (Strip Method)" was used to measure the elongation and recovery of extensible laminate specimens. Specimens 1 inch wide by 6 inches long were cut along the warp direction. Elongation was measured using an Instron® machine using a 4 inch gauge length. Measurements were recorded at 4 lbf, at which point the load was removed. Total elongation was defined as the total increase in gauge length when force was applied. % elongation was defined as the percentage increase in gauge length when force was applied. The following equation was used to calculate the % recovery after the load was removed: % Recovery = 100-100*(Final Length - Initial Length) / Total Elongation

[0084] Moisture Vapor Transmission Rate Test Protocol (MVTR) MVTR is measured according to DIN EN ISO 15496 (2004). Since this is a standard test used in the textile industry, reference is made to the detailed description of the MVTR test disclosed in DIN EN ISO 15496 (2004). For a description of the MVTR test, reference is also made to WO 90 / 04175 A1.

[0085] The basic principle is summarized as follows: The sample to be tested is inserted into an annular sample support together with a highly water vapor permeable but waterproof microporous membrane. The support is then immersed in water (deionized water at 23 ° C) for 15 minutes so that the membrane is in contact with the water. The cup is filled with a saturated solution of potassium acetate in water to produce a relative humidity of 23% at the surface of the sample and covered with a second piece of the same waterproof microporous membrane. The cup containing the potassium acetate solution and the second membrane is weighed and then placed on the sample support so that the second membrane is in contact with the sample. This leads to the transfer of water vapor through the sample from the water side to the cup containing potassium acetate. After 15 minutes, the cup containing potassium acetate is removed and its weight is measured. To measure the water vapor permeability of the test device without the sample, the same procedure is carried out with the first and second membranes without the sample. The MVTR of the sample can then be determined from the difference of both measurements, also taking into account the influence of the two additional microporous membranes.

[0086] The moisture vapour transmission rate (MVTR) of the laminate according to the invention is measured according to EN ISO 15496 (2004) and is in g / m 2 / 24hr. To be considered water vapor permeable as used herein, a laminate generally has a surface area of ​​at least 3000 g / m 2 / 24hr, preferably at least 8000g / m 2 / 24hr, more preferably at least 12000g / m 2 It should have a water vapor transmission rate of 20,000 g / m2 / 24 hr. 2 / 24hr or so.

[0087] The Suter test for liquidproof fabrics. The Suter test method was used to determine whether the samples were liquidproof. The procedure is generally based on the description in ASTM D 751-00, Standard Test Methods for Coated Fabrics (Hydrostatic Resistance Procedure B2). The procedure tests a low pressure load on the sample by forcing water against one side of the test sample and observing the other side for indications that the water has penetrated the sample.

[0088] The test sample was clamped and sealed between rubber gaskets in a fixture that held the sample so that water was applied to a specific area. The circular area to which the water was applied was 4.25 inches in diameter. Water was pressurized to one side of the sample at a pressure of 1 psig (0.07 bar). When testing laminates with one textile layer, the pressurized water was incident on the film side.

[0089] The unpressurized side of the sample was visually observed for three minutes for signs of water. If no water was observed, the sample was considered to have passed the test and was considered liquidproof. Values ​​reported were the average of three measurements.

[0090] Normalized Surface Roughness (Ra) Test Protocol The face surface profile was measured using a non-contact surface profilometer. A 50 mm x 50 mm square sample of the material to be tested was cut with one edge oriented parallel to the mean elastic fiber axis direction. The non-face side of the untensioned sample was attached to a flat 50 mm x 50 mm sample mount using non-foam based double sided tape (3M ID 7000122521) and a uniform pressure of 1.72 Newtons per centimeter (N / cm). The sample mount was placed in the detection area with edges parallel to the x and y directions of travel of the profilometer stage, and the surface profile of the sample was measured within a 30 mm x 30 mm area with an xy resolution of 50 μm or less. The accuracy of the measurements was confirmed by measuring appropriate calibration standards using the same profilometer setup.

[0091] The feature spacing of the face layers of the laminate was determined by the outermost textile layer. For woven fabrics, the feature spacing is the average spacing (center to center, mm) between adjacent yarns, as shown by the open arrows 100 in Figure 10A. For knitted fabrics, the feature spacing is the average spacing (center to center, mm) between adjacent loops, as shown by the open arrows 100 in Figure 10B.

[0092] A normalization procedure was applied to the surface profile to adjust for surface roughness due to the inherent roughness of the textile layer. This normalization procedure included only relevant textile surface data. Non-surface features (such as holes in the textile layer) were omitted from the data. A two-dimensional moving average of the surface height data was calculated using a window size of twice the face layer feature spacing. Normalized surface roughness (Ra) was calculated in the direction of the average elastic fiber axis for each pixel column in the normalized surface profile. Examples of normalized surface roughness can be seen in Figures 11B, 12B, 13B, 14B, 15B, and 16B. The average normalized surface roughness and maximum normalized surface roughness were then calculated from the normalized surface roughness data.

[0093] Laminate Thickness Testing Protocol Now, the laminate is stretched maximally in the direction of its average elastic fiber axis (where the laminate still exhibits ≧90% recovery and ≦5% shrinkage across the width) and stretched for 5 cm. 2 The sample was placed between two rigid surfaces with an area of ​​0.11 N / cm and measured using a digital micrometer (Model XLI 40002, Mahle Federal, Providence, RI). 2 The thickness of the laminate was measured by measuring the separation of the surfaces at a pressure of 100 .mu.m.

[0094] Example 1. Stretchable Laminates of the Present Invention 67g / m of a certain length 2 of woven nylon material (Style 130970 (MI187R) from Milliken and Company, Spartanburg, SC), a quantity of elastane fiber (120 denier, Type 902C from Invista, Wichita, KS), and a length of polyurethane-coated ePTFE membrane were obtained. The ePTFE membrane had the following properties: thickness = 0.043 mm, density = 0.41 grams per cubic centimeter (g / cc), matrix tensile strength in the length direction = 31 x 10 6 Megapascals (MPa), matrix tensile strength across width = 93 x 10 6 MPa, bubble point = 1.5 x 10 5MPa. Polyurethane (PU) was applied to the ePTFE membrane by coating it, allowing it to at least partially penetrate the pores of the membrane, and then curing.

[0095] The elastane fiber was placed on a beam and fed through two leads, each spaced 20 dents per centimeter (cm). Another polyurethane was obtained and loaded into the printer to add adhesive dots to the ePTFE side of the polyurethane-coated ePTFE membrane. Dots measuring 335 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 54%. The elastane fiber was stretched to 250% elongation and inserted between the ePTFE membrane and the woven material, which was placed on the adhesive side of the membrane. The first lead was attached approximately 7 cm from the lamination nip, adjacent to the woven material. The second lead was attached approximately 15 cm from the lamination nip and offset 5 cm laterally relative to the first lead. The resulting laminate was wound on a roll and cured while maintaining tension on the elastane fiber. This took approximately 2 days. After curing, the laminate was unwound and relaxed, thereby returning to an unstretched state.

[0096] The surface topography of the outermost surface of the laminate is shown in Figure 11A. The normalized Ra was determined and is shown in Figure 11B. As shown in Figure 17, the thickness of the stretched laminate was 0.252 mm and the average MVTR was 133305.9 g / m 2 / 24hr, the Suta test results were pass / pass / pass, % elongation was 60.6%, and % recovery was 96.9%.

[0097] Example 2. Comparative functional laminates 67g / m of a certain length 2of woven nylon material (Style 130970 (MI187R) from Milliken and Company, Spartanburg, SC), a quantity of elastane fiber (120 denier, Type 902C from Invista, Wichita, KS), and a length of polyurethane-coated ePTFE membrane were obtained. The ePTFE membrane had the following properties: thickness = 0.043 mm, density = 0.41 grams per cubic centimeter (g / cc), matrix tensile strength in the length direction = 31 x 10 6 Megapascals (MPa), matrix tensile strength across width = 93 x 10 6 MPa, bubble point = 1.5 x 10 5 MPa. Polyurethane (PU) was applied to the ePTFE membrane by coating it, allowing it to at least partially penetrate the pores of the membrane, and then curing.

[0098] The elastane fiber was placed on a beam and fed through one reed at 20 dents / centimeter (cm) spacing. Another polyurethane was loaded into the printer and adhesive dots were added to the ePTFE side of the polyurethane-coated ePTFE membrane. Dots measuring 335 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 54%. The elastane fiber was stretched to 250% elongation and inserted between the ePTFE membrane and the woven material, which was placed on the adhesive side of the membrane. The reed was attached approximately 15 cm from the lamination nip, adjacent to the woven material. While maintaining tension on the elastane fiber, the resulting laminate was wound onto a roll and cured. This took approximately 2 days. After curing, the laminate was unwound and relaxed, thereby returning to an unstretched state.

[0099] The outermost surface of the laminate is shown in Figure 12A and shows visible buckling. When the normalized Ra was determined and is shown in Figure 12B, there was a peak above 25 micrometers. This confirms the presence of buckling. The buckling is a result of poor fiber spacing. As shown in Figure 17, the stretched laminate had a thickness of 0.238 mm and an average MVTR of 12199.9 g / m 2 / 24hr, the Suta test results were pass / pass / pass, % elongation was 55.6%, and % recovery was 96.3%.

[0100] Example 3. Stretchable Laminates of the Present Invention 146g / m of a certain length 2 of woven polyester material (Style 758680 (US440) from Milliken and Company, Spartanburg, SC), a quantity of elastane fiber (300 denier, Type 902C from Invista, Wichita, KS), and a length of polyurethane-coated ePTFE membrane were obtained. The ePTFE membrane had the following properties: thickness = 0.043 mm, density = 0.41 grams per cubic centimeter (g / cc), matrix tensile strength in the length direction = 31 x 10 6 Megapascals (MPa), matrix tensile strength across width = 93 x 10 6 MPa, bubble point = 1.5 x 10 5 MPa. Polyurethane (PU) was applied to the ePTFE membrane by coating it, allowing it to at least partially penetrate the pores of the membrane, and then curing.

[0101] The elastane fiber was placed on a beam and fed through two leads, each spaced 20 dents per centimeter (cm). Another polyurethane was obtained and loaded into the printer, and adhesive dots were added to the ePTFE side of the polyurethane-coated ePTFE membrane. Dots measuring 335 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 54%. The elastane fiber was stretched to 250% elongation and inserted between the ePTFE membrane and the woven material, which was placed on the adhesive side of the membrane. The first lead was attached about 7 cm from the lamination nip, adjacent to the woven material. The second lead was attached about 15 cm from the lamination nip and offset 5 cm laterally relative to the first lead. The resulting laminate was wound on a roll and cured while maintaining tension on the elastane fiber. This took about two days. After curing, the laminate was unwound and relaxed, thereby returning to an unstretched state.

[0102] The surface topography of the outermost surface of the laminate is shown in Figure 13A. The normalized Ra was determined and is shown in Figure 13B. As shown in Figure 17, the thickness of the stretched laminate was 0.470 mm and the average MVTR was 12490.5 g / m 2 / 24hr, the Suta test results were pass / pass / pass, the % elongation was 34.4%, and the % recovery was 96.5%.

[0103] Example 4. Comparative functional laminates 146g / m of a certain length 2 of woven polyester material (Style 758680 (US440) from Milliken and Company, Spartanburg, SC), a quantity of elastane fiber (300 denier, Type 902C from Invista, Wichita, KS), and a length of polyurethane-coated ePTFE membrane were obtained. The ePTFE membrane had the following properties: thickness = 0.043 mm, density = 0.41 grams per cubic centimeter (g / cc), matrix tensile strength in the length direction = 31 x 10 6 Megapascals (MPa), matrix tensile strength across width = 93 x 10 6 MPa, bubble point = 1.5 x 10 5 MPa. Polyurethane (PU) was applied to the ePTFE membrane by coating it, allowing it to at least partially penetrate the pores of the membrane, and then curing.

[0104] The elastane fiber was placed on a beam and fed through one reed at a spacing of 13 dents / centimeter (cm). Another polyurethane was loaded into the printer and adhesive dots were added to the ePTFE side of the polyurethane-coated ePTFE membrane. Dots 500 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 39%. The elastane fiber was stretched to 250% elongation and inserted between the ePTFE membrane and the woven material, which was placed on the adhesive side of the membrane. The reed was attached adjacent to the woven material and approximately 15 cm from the lamination nip. While maintaining tension on the elastane fiber, the resulting laminate was wound onto a roll and cured. This took approximately 2 days. After curing, the laminate was unwound and relaxed, thereby returning to an unstretched state.

[0105] The outermost surface of the laminate is shown in Figure 14A and shows visible buckling. When the normalized Ra was determined and shown in Figure 14B, there was a peak above 25 micrometers, confirming the presence of buckling. The buckling is a result of poor fiber spacing.

[0106] Example 5. Comparative functional laminates 88g / m of a certain length 2 of nylon woven material (Style 7820 (NUERO058P) from Toray Textile Europe Ltd., Crown Farm Way, Forest Town, Mansfield NG19 0FT, UK), a quantity of elastane fiber (120 denier, Type 902C from Invista, Wichita, KS), and a length of polyurethane-coated ePTFE membrane were obtained. The ePTFE membrane had the following properties: thickness = 0.043 mm, density = 0.41 grams per cubic centimeter (g / cc), matrix tensile strength in the length direction = 31 x 10 6 Megapascals (MPa), matrix tensile strength across width = 93 x 10 6 MPa, bubble point = 1.5 x 10 5MPa. Polyurethane (PU) was applied to the ePTFE membrane by coating it, allowing it to at least partially penetrate the pores of the membrane, and then curing.

[0107] The elastane fiber was placed on a beam and fed through one reed at 20 dents / centimeter (cm) spacing. Another polyurethane was obtained and loaded into the printer to add adhesive dots to the ePTFE side of the polyurethane-coated ePTFE membrane. Dots measuring 500 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 39%. The elastane fiber was stretched to 250% elongation and inserted between the ePTFE membrane and the woven material, which was placed on the adhesive side of the membrane. The reed was attached approximately 15 cm from the lamination nip, adjacent to the woven material. While maintaining tension on the elastane fiber, the resulting laminate was wound onto a roll and cured. This took approximately 2 days. After curing, the laminate was unwound and relaxed, thereby returning to an unstretched state.

[0108] The surface topology of the outermost surface of the laminate is shown in Figure 15A. The normalized Ra was determined and is shown in Figure 15B. As shown in Figure 17, the thickness of the stretched laminate was 0.388 mm and the average MVTR was 11830.2 g / m 2 / 24hr, the Suta test results were pass / pass / pass, % elongation was 70.1%, and % recovery was 97.6%.

[0109] Example 6. Functional Laminates of the Present Invention 92g / m of a certain length 2A polyester knit fabric material (Style 45627 (PIQE001MO) from MYBE Sri, Via alla Selva 596, Cassina Rizzardi, Italy), a quantity of elastane fiber (120 denier, Type 902C from INVISTA, Wichita, KS), and a length of polyurethane-coated ePTFE membrane were obtained. The ePTFE membrane had the following properties: thickness = 0.043 mm, density = 0.41 grams per cubic centimeter (g / cc), matrix tensile strength in the length direction = 31 x 10 6 Megapascals (MPa), matrix tensile strength across width = 93 x 10 6 MPa, bubble point = 1.5 x 10 5 MPa. Polyurethane (PU) was applied to the ePTFE membrane by coating it, allowing it to at least partially penetrate the pores of the membrane, and then curing.

[0110] The elastane fiber was placed on a beam and fed through two leads, each spaced 20 dents per centimeter (cm). Another polyurethane was loaded into the printer and adhesive dots were added to the ePTFE side of the polyurethane-coated ePTFE membrane. Dots measuring 335 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 54%. The elastane fiber was stretched to 250% elongation and inserted between the ePTFE membrane and the woven material, which was placed on the adhesive side of the membrane. The first lead was attached approximately 7 cm from the lamination nip, adjacent to the woven material. The second lead was attached approximately 15 cm from the lamination nip and offset 5 cm laterally relative to the first lead. The resulting laminate was wound onto a roll and cured while maintaining tension on the elastane fiber. This took approximately 2 days. After curing, the laminate was unwound and relaxed, thereby returning to an unstretched state.

[0111] The flat surface topography of the outermost surface of the laminate is shown in Figure 16A. The normalized Ra was determined and is shown in Figure 16B. As shown in Figure 17, the thickness of the stretched laminate was 0.757 mm and the average MVTR was 12359.8 g / m2 / 24hr, the Suta test results were pass / pass / pass, % elongation was 74.9%, and % recovery was 93.3%.

[0112] Example 7. Maximum fiber spacing Figure 18 shows the maximum fiber spacing for different extensible laminates with different thicknesses: 0.25 mm, 0.39 mm, 0.47 mm and 0.76 mm. The fiber spacing was varied from 0.01 to 1.4 mm. Three trend lines for different maximum fiber spacings 3.0, 2.5 and 2.0 are shown. Laminates with buckling (Ra>25) are indicated with an X, while laminates with substantially no buckling (Ra≦25) are indicated with a dot.

[0113] Example 8. Stretchable Laminates of the Present Invention 88g / m in two lengths 2 of nylon woven material (Style 7820 (NUERO058P) from Toray Textile Europe Ltd, Crown Farm Way, Forest Town, Mansfield NG19 0FT, UK) and a quantity of elastane fiber (120 denier, Type 902C from Invista, Wichita, KS) were obtained.

[0114] The elastane fiber was placed on a beam and fed through two reeds, each spaced 20 dents per centimeter (cm). Another polyurethane was obtained and loaded into the printer, and adhesive dots were added to the first length of woven material. Dots measuring 305 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 83%. A second length of woven material was placed on the adhesive side of the first length of woven material, and the elastane fiber was stretched to 250% elongation and inserted between the first and second woven materials. The first reed was attached adjacent to the woven material, approximately 7 cm from the lamination nip. The second reed was attached approximately 15 cm from the lamination nip and offset laterally by 2 cm relative to the first reed. The resulting laminate was wound on a roll and cured while maintaining tension on the elastane fiber, which took approximately 2 days. After curing, the laminate was unwound and relaxed, thereby returning to an unstretched state.

[0115] The thickness of the stretched laminate was 0.466 mm and the visual surface appearance of the laminate was substantially identical to that of the unlaminated woven material. The % elongation was 41.8% and the % recovery was 98.3%.

[0116] Example 9. Stretchable Laminates of the Present Invention 67g / m of a certain length 2 of nylon woven material (Style 130970 (MI187R) from Milliken & Company, Spartanburg, SC), a quantity of elastane fiber (120 denier, Type 902C from Invista, Wichita, KS), a length of polyurethane coated ePTFE membrane, and a length of 37.3 g / m 2 A polyester knit fabric (style A1012 from Glen Raven, Inc., Glen Raven, NC) was obtained. Polyurethane (PU) was applied to the ePTFE membrane by coating it, allowing it to at least partially penetrate the pores of the membrane, and then curing. The coated ePTFE membrane had a mass of 32 grams per square meter (g / m 2 ) and a thickness of 0.032 mm.

[0117] Additional polyurethane was obtained and loaded into the printer to add adhesive dots to the coating side of the polyurethane coated ePTFE membrane. Dots measuring 335 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 54%. The chevron side of the knitted fabric material was placed on the adhesive side of the membrane. The resulting laminate was wound onto a roll and allowed to cure. This took approximately 2 days.

[0118] The elastane fiber was placed on a beam and fed through two leads, each spaced 20 dents per centimeter (cm). Another polyurethane was obtained and loaded into the printer to add adhesive dots to the ePTFE side of the polyurethane-coated ePTFE membrane and knitted fabric laminate. Dots measuring 335 microns in diameter were applied to the ePTFE membrane at a percent area coverage of 54%. The elastane fiber was stretched to 250% elongation and inserted between the ePTFE membrane and the woven fabric material, which was placed on the adhesive side of the membrane and knitted fabric laminate. The first lead was attached adjacent to the woven fabric material, approximately 7 cm from the lamination nip. The second lead was attached approximately 15 cm from the lamination nip and offset 5 cm laterally relative to the first lead. The resulting laminate was wound on a roll and cured while maintaining tension on the elastane fiber. This took approximately 2 days. After curing, the laminate was unwound and relaxed. The untensioned laminate was then placed in an oven at 170° C. for 60 seconds to allow additional relaxation.

[0119] The thickness of the stretched laminate was 0.398 mm and the visual appearance of the laminate on the woven side was substantially identical to the surface appearance of the unlaminated woven material. The % elongation was 31.4% and the % recovery was 99.8%. (Aspect) (Aspect 1) a textile layer having a first surface and a second surface; a functional layer disposed on at least one surface of the textile layer; a plurality of elastic fibers arranged in a substantially parallel configuration on at least one of the textile layer and / or the functional layer, the elastic fibers having an adjacent fiber spacing distance; 1. An extensible laminate comprising: at least 80% of the elastic fibers have adjacent spacings less than a maximum fiber spacing, the maximum fiber spacing in millimeters being no greater than 3.0 times the thickness in millimeters of the extensible laminate in a stretched state; i) the plurality of elastic fibers are disposed between the textile layer and the functional layer; ii) the functional layer is disposed on a first surface of the textile layer and the plurality of elastic fibers are disposed on a side of the functional layer opposite the textile layer; or iii) an extensible laminate, wherein the functional layer is disposed on a second surface of the textile layer and the plurality of elastic fibers are disposed on a first surface of the textile layer. (Aspect 2) 2. The extensible laminate of claim 1, wherein the surface of the textile opposite the functional layer is substantially free of buckling. (Aspect 3) 3. The extensible laminate of any one of the preceding claims, wherein the maximum distance between adjacent fibers does not exceed the maximum fiber spacing of the extensible laminate. (Aspect 4) 4. The extensible laminate of any one of claims 1 to 3, wherein the plurality of elastic fibers are spaced apart by an internal distance of 0.1 to 1.5 mm. (Aspect 5) 5. The extensible laminate of any one of the preceding claims, further comprising an adhesive layer disposed between the plurality of elastic fibers and the textile layer or the functional layer. (Aspect 6) 6. The extensible laminate of any one of the preceding claims, wherein the textile layer material has an elongation of less than 15% when measured according to ASTM test method D5035-06. (Aspect 7) The stretch laminate of any one of the preceding claims, wherein the textile layer is a non-elastic material. (Aspect 8) 8. The stretchable laminate of any one of the preceding claims, wherein the material of the textile layer is at least one of cotton, silk, cellulose, wool, polyamide, polyolefin, polyacrylate, polyester, polyurethane, fluoropolymer, copolymer, or combination thereof. (Aspect 9) The extensible laminate according to any one of the preceding embodiments, wherein the functional layer is a porous membrane. (Aspect 10) 10. The extensible laminate of any one of the preceding claims, wherein the functional layer is at least one of a fluoropolymer, a polyurethane, a copolyether-ester, a polyolefin, a polyester, or a combination thereof. (Aspect 11) 11. The extensible laminate of any one of embodiments 1 to 10, wherein the functional layer is an expanded polytetrafluoroethylene membrane. (Aspect 12) 12. The extensible laminate of any one of the preceding claims, wherein the plurality of elastic fibers comprises at least one of natural rubber, polybutadiene, elastomeric polyolefin, polyurethane, silicone, fluoroelastomer, elastane, block copolymers containing polyester, polyester-polyurethane, polyamide, or combinations thereof. (Aspect 13) 13. The extensible laminate of any one of embodiments 1 to 12, wherein the plurality of elastic fibers is 400 denier or less. (Aspect 14) The extensible laminate of any one of embodiments 1 to 13, further comprising a second functional layer, the plurality of elastic fibers being disposed between the functional layer and the second functional layer. (Aspect 15) 15. The extensible laminate of embodiment 14, wherein the second functional layer is at least one of a fluoropolymer, a polyurethane, a copolyether-ester, a polyolefin, a polyester, or a combination thereof. (Aspect 16) 16. The extensible laminate of claim 14 or 15, wherein the functional layer and the second functional layer are porous membranes. (Aspect 17) 17. The extensible laminate of any one of embodiments 14 to 16, wherein the functional layer and the second functional layer are expanded polytetrafluoroethylene membranes. (Aspect 18) 18. The extensible laminate of any one of the preceding claims, further comprising a second textile layer, said second textile layer being disposed on said functional layer or on said second functional layer. (Aspect 19) 20. The extensible laminate of claim 18, wherein the surface of the second textile layer opposite the functional layer or the second functional layer has an average normalized surface roughness (Ra) of 25 micrometers or less. (Aspect 20) 20. The extensible laminate of any one of embodiments 1-19, wherein the maximum normalized surface roughness (Ra) is not more than 50% greater than the average normalized surface roughness (Ra). (Aspect 21) 21. The extensible laminate of any one of the preceding claims, wherein the surface of the textile layer opposite the functional layer has a maximum normalized surface roughness (Ra) of 25 micrometers or less. (Aspect 22) An extensible laminate comprising a plurality of elastic fibers arranged in a substantially parallel configuration on a first functional layer, and optionally further comprising a second functional layer, wherein the second functional layer is disposed on the first functional layer and the elastic fibers are disposed between the first functional layer and the second functional layer, or the second functional layer is disposed on the first functional layer on the opposite side to the plurality of elastic fibers, and the plurality of elastic fibers has a fiber density of at least 7.9 fibers / centimeter. (Aspect 23) 23. The extensible laminate of claim 22, wherein the elastic fibers have a fiber spacing of 40 fibers / centimeter or less. (Aspect 24) 24. The extensible laminate of any one of embodiments 22-23, further comprising an adhesive layer disposed between the first functional layer and the plurality of elastic fibers. (Aspect 25) 25. The extensible laminate of any one of embodiments 22 to 24, wherein the first functional layer and the second functional layer are porous membranes. (Aspect 26) 26. The extensible laminate of any one of claims 22 to 25, wherein each of the first functional layer and the second functional layer independently comprises at least one of a fluoropolymer, a polyurethane, a copolyether-ester, a polyolefin, a polyester, or a combination thereof. (Aspect 27) 27. The extensible laminate of any one of embodiments 22 to 26, wherein the first functional layer and the second functional layer are expanded polytetrafluoroethylene membranes. (Aspect 28) 28. The extensible laminate of any one of claims 22-27, wherein the plurality of elastic fibers comprises at least one of natural rubber, polybutadiene, elastomeric polyolefin, polyurethane, silicone, fluoroelastomer, elastane, block copolymer containing polyester, polyester-polyurethane, polyamide, or combinations thereof. (Aspect 29) 29. The extensible laminate of any one of claims 22-28, wherein the plurality of elastic fibers is less than 400 denier. (Aspect 30) 30. The extensible laminate of any one of embodiments 22 to 29, wherein a surface of the functional layer opposite the elastic fiber is substantially free of buckling. (Aspect 31) A garment comprising the stretch laminate according to any one of embodiments 1 to 30. (Aspect 32) 32. The garment of embodiment 31, wherein the functional layer faces away from the wearer. (Aspect 33) 32. The garment of embodiment 31, wherein the textile layer faces away from the wearer.

Claims

1. a textile layer having a first surface and a second surface; a fibrous layer disposed on the first surface of the textile layer, i) the fibrous layer comprises a plurality of elastic fibers; ii) the plurality of elastic fibers are arranged in a substantially parallel configuration on the first surface of the textile layer; iii) a fibrous layer, at least 80% of said plurality of elastic fibers having an adjacent fiber spacing distance less than 2.5 times the thickness of the extensible laminate in a stretched state; an adhesive layer disposed between the plurality of elastic fibers and the textile layer; 1. An extensible laminate comprising: the stretchable laminate having an elasticity greater than that of the textile layer; the extensible laminate having at least 80% recovery after at least 10% elongation in the direction of the elastic fibers; the second surface of the textile layer having a maximum normalized surface roughness (Ra) of 25 micrometers or less; The second surface of the textile layer has a maximum normalized surface roughness that is no more than 50% greater than the average normalized surface roughness.

2. 2. The extensible laminate of claim 1, wherein the maximum distance between adjacent fibers does not exceed 2.5 times the thickness of said extensible laminate.

3. The extensible laminate of any one of claims 1 to 2, wherein the plurality of elastic fibers are spaced apart at an internal distance of 0.1 to 1.5 mm.

4. The stretchable laminate of any one of claims 1 to 3, wherein the textile layer material has an elongation of less than 15% when measured according to ASTM test method D5035-06.

5. The stretchable laminate of any one of claims 1 to 4, wherein the textile layer is a non-elastic material.

6. 6. The stretchable laminate of any one of claims 1 to 5, wherein the textile layer material comprises at least one of the following materials or combinations: cotton, silk, cellulose, wool, polyamide, polyolefin, polyacrylate, polyester, polyurethane, fluoropolymer, copolymer.

7. 7. The extensible laminate of any one of claims 1 to 6, wherein the plurality of elastic fibers comprises at least one of natural rubber, polybutadiene, elastomeric polyolefins, polyurethanes, silicones, fluoroelastomers, elastanes, polyester-containing block copolymers, polyester-polyurethanes, polyamides, or combinations thereof.

8. The extensible laminate of any one of claims 1 to 7, wherein the denier of said plurality of elastic fibers is 400 denier or less.

9. 9. The stretchable laminate of claim 1, further comprising a second textile layer, the second textile layer being disposed on the fibrous layer opposite the textile layer or on the second surface of the textile layer.

10. The extensible laminate of claim 9, wherein the adhesive layer is a continuous or discontinuous layer, and the surface of the second textile layer opposite the textile layer has an average normalized surface roughness (Ra) of 25 micrometers or less.

11. 10. The extensible laminate of claim 9, wherein the maximum normalized surface roughness (Ra) of the surface of the second textile layer opposite the textile layer is not more than 50% greater than the average normalized surface roughness (Ra) of the surface of the second textile layer opposite the textile layer.

12. A garment comprising the stretch laminate of any one of claims 1 to 11.

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