Breathable metal-coated composite fabric

Abstract

The fabric includes an inner layer, a metal-coated film disposed on the inner layer, and an outer layer disposed on the metal-coated film. The metal-coated film includes a base layer including a polymer and a metal layer disposed on a first surface of the base layer. The inner layer is bonded to the metal-coated film via first contact points, and the outer layer is bonded to the metal-coated film via second contact points.

Description

[Technical Field]

[0001] Cross-reference of related applications This application claims the interests of U.S. Provisional Patent Application No. 62 / 941,555, filed November 27, 2019, under Section 119(e) of the U.S. Patent Act, the contents of which are incorporated herein by reference in their entirety.

[0002] This disclosure generally relates to fabrics for clothing, footwear, tents, and sleeping bags, and more particularly to breathable metal-coated composite fabrics for clothing, footwear, tents, and sleeping bags. [Background technology]

[0003] To improve the thermal insulation of buildings, metal-coated polyethylene plexifilament films—fibril sheets—that are permeable to water vapor and air have been used as house wraps. However, these sheets are unsuitable for clothing due to their poor texture, lack of wrinkle resistance, and poor resistance to washing. [Overview of the project]

[0004] This specification describes breathable composite fabrics for use in clothing, footwear, tents, and sleeping bags that are comfortable for human use and durable against washing cycles.

[0005] In one embodiment, a laminated fabric includes an inner layer, a metal coating film disposed on the inner layer, and an outer layer disposed on the metal coating film. The metal coating film includes a base layer containing a polymer and a metal layer deposited on a first surface of the base layer. The inner layer is bonded to the metal coating film via a first contact point, and the outer layer is bonded to the metal coating film via a second contact point.

[0006] In some embodiments, the inner layer is bonded to a second surface of the base layer, which is opposite the first surface of the base layer. In some embodiments, the outer layer is bonded to the surface of the metal layer.

[0007] In some embodiments, each of the inner layer, base layer, metal layer, and outer layer is at least 500 g / m². 2 It has a water vapor transmission rate (MVTR) of 1 / 24hr. In some embodiments, the inner layer has a thermal conductivity of at most 0.6 W / m·K. The inner layer may include one of woven, knitted, or nonwoven fabrics. The inner layer may include synthetic or natural materials. In some embodiments, the synthetic material is selected from one or more of polyester, nylon, elastane, polyurethane, polyethylene, polypropylene, polylactic acid, or polytetrafluoroethylene (PTFE).

[0008] In some embodiments, the fabric has an inner layer, a metal coating, and an outer layer, each with a water vapor permeability of at least 70%. In some embodiments, the first and second contact points are arranged in a dot matrix. In some embodiments, the first and second contact points include an adhesive. In some embodiments, the first contact point includes a molten base layer or a molten inner layer. In some embodiments, the second contact point includes a molten base layer or a molten outer layer. In some embodiments, the first or second contact point is formed by stitching or quilting.

[0009] In some embodiments, the metal layer comprises one or more of the following: aluminum, titanium, silver, gold, copper, zinc, magnesium, germanium, etc. In some embodiments, the metal layer has a thickness of about 10 nanometers to about 200 nanometers. In some embodiments, the metal layer is formed by depositing metal onto a first surface of the base layer. In some embodiments, the metal layer has a reflectivity in the range of 0.76 to 0.97 at a wavelength of 9.5 micrometers.

[0010] In some embodiments, the base layer has a thickness of less than about 50 micrometers or less than about 25 micrometers.

[0011] In some embodiments, the first surface of the base layer has a specular glossiness of at least 28 percent. The second surface has a roughness that is at least twice the roughness of the first surface.

[0012] In some embodiments, the metal coating has a water vapor transmission rate of at least 800 g / m 2 / 24 hr. In some embodiments, the total emissivity of the metal coating and the outer layer is at most 0.85 at a wavelength of 9.5 micrometers.

[0013] In some embodiments, the device includes a fabric. The device may be one of clothing, footwear, a tent, or a sleeping bag.

Brief Description of the Drawings

[0014] Specific features of various embodiments of this technology are described together with the features in the appended claims. A deeper understanding of the features and advantages of this technology can be obtained by referring to the following detailed description of exemplary embodiments utilizing the principles of this disclosure and the accompanying drawings.

[0015] [Figure 1] It is a schematic diagram showing a breathable composite fabric according to an exemplary embodiment.

[0016] [Figure 2] It is a schematic diagram showing another breathable composite fabric according to an exemplary embodiment.

[0017] [Figure 3] It is a diagram showing the heat resistance retention rate and emissivity of a fabric sample according to an exemplary embodiment.

[0018] [Figure 4A] It is a schematic diagram showing a laminate according to an exemplary embodiment. [Figure 4B] It is a schematic diagram showing a laminate according to an exemplary embodiment. [Figure 4C] A schematic diagram showing a laminate according to an exemplary embodiment.

Mode for Carrying Out the Invention

[0019] In the following description, specific specific details are set forth in order to facilitate a thorough understanding of various embodiments of the present disclosure. However, those skilled in the art will understand that the present disclosure may be practiced without these details. Further, although various embodiments of the present disclosure are disclosed herein, numerous modifications and variations may be made within the scope of the present disclosure by those skilled in the art using common general knowledge. Such modifications include substituting any aspect of the present disclosure with known equivalents in order to achieve substantially the same result in substantially the same manner.

[0020] Unless the context requires a different interpretation, throughout this specification and the claims, the term "comprise" and variations such as "comprises" and "comprising" should be interpreted in an open inclusive sense, i.e., "including but not limited to". Throughout this specification, the recitation of a numerical range of values is intended to function as a shorthand for referring individually to each separate value within the range, including the values defining the range, and each separate value is incorporated herein as if it were individually recited herein. Additionally, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

[0021] Throughout this specification, any reference to “one embodiment” or “embodiment” means that any particular feature, structure, or characteristic described in relation to that embodiment is included in at least one embodiment of this disclosure. Therefore, while the phrase “in one embodiment” or “in an embodiment” may appear in various places throughout this specification, not all references necessarily refer to the same embodiment; they may refer to several instances. Furthermore, any particular feature, structure, or characteristic may be combined in any suitable manner in one or more embodiments.

[0022] The various embodiments described herein relate to breathable composite fabrics for use in clothing and footwear. In one embodiment, a breathable composite fabric includes an inner layer, a metal coating film disposed on the inner layer, and an outer layer disposed on the metal coating film. The metal coating film includes a base layer containing a polymer and a metal layer deposited on a first surface of the base layer. The inner layer is bonded to the metal coating film via a first contact point, and the outer layer is bonded to the metal coating film via a second contact point. The metal layer has a thickness of about 10 nanometers to about 200 nanometers.

[0023] Here, the embodiments will be described with reference to the attached drawings. First, refer to Figure 1. Figure 1 is a schematic diagram showing a breathable composite fabric 100 according to an exemplary embodiment. The fabric 100 includes an inner layer 102, a metal coating film 104 disposed on the inner layer 102, and an outer layer 106 disposed on the metal coating film 104. The metal coating film 104 includes a base layer 108 and a metal layer 110 deposited on the first surface 108a of the base layer 108. For example, the metal layer 110 may be formed by vapor deposition of metal onto the first surface 108a of the base layer 108. The inner layer 102 and the metal coating film 104 are bonded to each other by first contact points 112. The first contact points 112 may be arranged in a dot matrix pattern. The first contact points 112 connect the inner layer 102 to the second surface 108b of the base layer 108. The outer layer 106 and the metal coating film 104 are bonded to each other via second contact points 114. The second contact points 114 may be arranged in a dot matrix pattern. The second contact points 114 connect the outer layer 106 to the surface of the metal layer 110. In the configuration shown in Figure 1, the base layer 108 is sandwiched between the inner layer 102 and the metal layer 110.

[0024] Figure 2 is a schematic diagram showing another breathable composite fabric 200 according to an exemplary embodiment. Fabric 200 is similar to fabric 100, but with the modification that a metal layer 110 is sandwiched between an inner layer 102 and a base layer 108. In fabric 200, a first contact point 112 connects the inner layer 102 to the surface of the metal layer 110. A second contact point 114 connects the outer layer 106 to the second surface 108b of the base layer 108. The structure of fabric 200 can better protect the metal layer 110 from scratches or other accidental damage during subsequent processing and use.

[0025] To create clothing and footwear that are more comfortable to wear, the inner layer 102 is configured to provide high breathability to the breathable composite fabrics 100 and 200. Furthermore, to withstand repeated dynamic / mechanical actions such as washing cycles, the inner layer 102 is configured to have sufficient strength when combined with a suitable outer layer 106.

[0026] In some embodiments, the inner layer 102 is at least 500 g / m². 2It has a water vapor transmission rate of / 24hr. In some embodiments, to provide further breathability, the inner layer 102 has a minimum of 750 g / m². 2 / 24hr, at least 1000g / m² 2 / 24hr, or at least 1500g / m² 2 It has a water vapor transmission rate of / 24hr. By including an inner layer 102 in the breathable composite fabrics 100 and 200, a soft feel, good texture, and drape to the human body are also provided for applications that come into direct contact with the skin. In some embodiments, the inner layer 102 has a thickness of at least 60 micrometers to withstand wear during its service life. The thickness of the inner layer 102 may vary depending on where the breathable composite fabric 100 or 200 is applied. For example, the thickness of the inner layer 102 may be about 60 micrometers to about 2400 micrometers, about 60 micrometers to about 1500 micrometers, about 60 micrometers to about 1000 micrometers, about 60 micrometers to about 750 micrometers, or about 60 micrometers to about 500 micrometers.

[0027] In some embodiments, the inner layer 102 comprises one or more woven, knitted, or nonwoven fabrics. In some embodiments, the inner layer 102 comprises synthetic and / or natural materials. For example, synthetic materials for the inner layer 102 are selected from one or more polyester, polyamide, polyurethane, polyolefin, polylactic acid, nylon, elastane, and PTFE. Furthermore, natural materials for the inner layer 102 may include cotton, wool, silk, linen, and other natural fibers.

[0028] In some embodiments, the fabric 100 or 200 may have a low thermal conductivity of typically no more than 0.1 W / m·K, or at most 0.6 W / m·K, to minimize heat loss by conduction.

[0029] In some embodiments, the inner layer 102 has a tensile strength of at least 45 N / 2.54 cm, a tear strength of at least 9 N, and a Mullen burst of at least 350 kPa under ASTM (American Society for Testing and Materials) D5035 test conditions, ASTM 2261 test conditions, and ASTM D774 test conditions, respectively.

[0030] The metal coating 104 is provided as a breathable radiation barrier for heat insulation purposes. For these purposes, the metal coating 104 is configured to have a low emissivity and a high breathability. Optionally, the metal coating 104 is waterproofed. The metal coating 104 may be configured to be a breathable IR reflective layer to improve heat insulation by reflecting radiation.

[0031] In some embodiments, the metal coating 104 has a water vapor transmission rate of at least 500 g / m 2 / 24 hr. In some embodiments, to provide further breathability, the metal coating 104 may have a water vapor transmission rate of at least 800 g / m 2 / 24 hr, at least 1000 g / m 2 / 24 hr, at least 1500 g / m 2 / 24 hr, at least 2000 g / m 2 / 24 hr, or at least 2500 g / m 2 / 24 hr.

[0032] In some embodiments, the base layer 108 of the metal coating 104 contains a polymer. The base layer 108 has a thickness of less than about 50 micrometers, or less than 25 micrometers, or less than about 20 micrometers, or less than about 15 micrometers, or less than about 10 micrometers so as to be effective for its purpose. In some embodiments, the base layer 106 has an infrared transmittance of at least about 40% at a wavelength of 9.5 micrometers. In some embodiments, the base layer 106 has an infrared transmittance of about 40% - 60% at wavelengths of 7 - 14 micrometers.

[0033] The first surface 108a of the base layer 108 is configured to be flat, and as a result, a more effective reflective layer is obtained after the base layer 108 is metal-coated. In some embodiments, the base layer 108 contains polyethylene having a lower melting point than many conventional fabric materials, thereby enabling a flatter surface to be achieved by calendering at lower temperatures. In some embodiments, the base layer 108 may contain one or more other materials such as polyurethane, thermoplastic polyurethane, polyester, polyamide, or ePTFE film. In some embodiments, the base layer 108 may include an IR-transmitting substrate such as a polyolefin, which is beneficial because it only minimally interferes with the reflectivity of the metal layer 110 located on either side of the base layer 108. The structure of the base layer 108 is configured to maximize thermal radiation reflected back towards the body, minimizing the heat consumed to warm the base layer 108 due to absorption. In some embodiments, the base layer 108 may be porous.

[0034] The metal layer 110 may be formed on the base layer 108 by vapor deposition or other plating techniques. For example, the metal can be deposited on the microporous base layer 108 by methods such as physical vapor deposition (PVD), including sputtering and electron beam deposition. The metal forms a discontinuous layer 110 to maintain permeability / porosity. In some embodiments, the metal layer 110 may contain one or more of the following: aluminum, titanium, silver, gold, copper, zinc, magnesium, germanium, etc. In some embodiments, the metal layer 110 may have a thickness of about 10 nanometers to about 200 nanometers, about 10 nanometers to about 100 nanometers, or about 10 nanometers to about 50 nanometers to provide pores for breathability. Other metals and thicknesses are intended so that the metal layer 110 has an emissivity of not more than 0.5 for infrared radiation at a wavelength of 9.5 micrometers.

[0035] In some embodiments, the metal layer 110 is configured to have a thickness and surface coverage that provides reflectivity in the range of 0.76 to 0.97 at a wavelength of 9.5 micrometers, as determined, for example, by Fourier transform infrared spectroscopy (FTIR). In some embodiments, the metal layer 110 has a reflectivity of 0.8 at a wavelength of 9.5 micrometers.

[0036] In one example, each of the nanoporous polyethylene and polypropylene base layers (approximately 40% porosity, 16-25 μm thick) covered with 100 nm aluminum had a density of at least 2500 g / m². 2 A water vapor transmittance of / 24hr can be achieved. Their reflectivity at a wavelength of 9.5 micrometers is at least 0.97 on the aluminum side and at least 0.87 on the polyolefin side.

[0037] The outer layer 106 is configured to be highly durable when combined with a suitable inner layer 102, in order to resist repeated dynamic / mechanical operations, including wet conditions such as mechanical washing, as well as dry conditions such as abrasion, clocking, and mechanical drying.

[0038] In some embodiments, the outer layer 106 is at least 500 g / m². 2 It has a water vapor transmission rate of / 24hr. In some embodiments, to provide further breathability, the inner layer 102 has a minimum of 750 g / m². 2 / 24hr, at least 1000g / m² 2 / 24hr, or at least 1500g / m² 2 It has a water vapor transmission rate of / 24hr.

[0039] In some embodiments, the outer layer 106 includes one of a woven fabric, knitted fabric, nonwoven fabric, film, or membrane. In some embodiments, the outer layer 106 comprises synthetic and / or natural materials. For example, synthetic materials for the outer layer 106 are selected from one or more of polyester, polyamide, polyurethane, polyolefin, polylactic acid, nylon, elastane, and PTFE. Furthermore, natural materials for the outer layer 106 may include cotton, wool, silk, linen, and other natural materials.

[0040] In some embodiments, the combined emissivity of the metal coating 104 and the outer layer 106 may be at most 0.85. This maintains approximately 45% of the thermal resistance of the metal coating sheet 104 without the outer layer. Various selections of the outer layer 106 allow for an appropriate emissivity. For example, if the outer layer 106 is made of a highly IR-permeable material (e.g., polyolefin) and is thin (e.g., less than 400 μm), the outer layer 106 may have a high cover factor (e.g., 90% or more). As used herein, the cover factor is defined as the ratio of the surface area covered by the solid component, such as yarn or fiber, for forming the outer layer 106, to the total surface area of ​​the fabric. For IR-low / IR-impermeable materials (e.g., polyester, nylon, elastane, polyurethane, polylactic acid, PTFE, cotton, wool, silk, linen, etc.), the outer layer 106 may have a lower cover factor (e.g., about 75% or less), thereby exposing a portion of the metal coating reflective sheet 104. For IR-low transmittance / IR-opaque materials, if the surface coverage exceeds 90%, the total emissivity becomes too high (>0.85), and therefore the thermal resistance achieved by the metal coating sheet 104 is significantly reduced.

[0041] Table 1 below summarizes the material selection of the outer layer in relation to the total emissivity (metal coating sheet + outer layer). Samples A-D were prepared using the same metal coating sheet, i.e., an aluminum-coated nanoporous polyolefin film with reflectivity of 0.97 on the aluminum side and 0.87 on the polyolefin side at a wavelength of 9.5 micrometers. Sample A includes an outer layer made of nonwoven polyolefin (IR transparent) with a thickness of 0.16 mm. The outer layer of Sample A has a cover factor of 100%. Sample A has an acceptable total emissivity of 0.47-0.53. Sample B has a coating / finish / print (6 g / m²) on the surface of the outer layer. 2 Sample B is the same as Sample A except that it includes (less than). Sample B has an acceptable total emissivity of 0.58-0.78. Sample C includes an outer layer (low IR transmission) made from knitted polyester raw silk (FDY). The outer layer of Sample C has a thickness of 0.38 mm and a cover factor of 67-71%. Sample C also has an acceptable total emissivity of 0.63. Sample D includes an outer layer (iron impermeable) made from cotton. The outer layer of Sample D has a thickness of 0.38 mm and a cover factor of 94%. Sample D also has a failing total emissivity of 0.89 due to the use of an iron impermeable material with a high cover factor. [Table 1]

[0042] Figure 3 shows the thermal resistance retention and emissivity of samples A to D shown in Table 1. As shown in Figure 3, the thermal resistance retention of samples A to D are 69%, 62%, 47%, and 29%, respectively.

[0043] As shown in Table 1, the outer layer is not limited to a single-component material and may have a thin coating / finish. For example, Sample B is a lightweight print on a 0.16 mm polyethylene nonwoven film (e.g., added weight <6 g / m²). 2These materials contain ), which have a minor effect on the IR reflectivity of the composite. In some embodiments, it has been found that adding small amounts (<2%) of additives such as color pigments to the IR-transmitting material also has only a minimal effect on the IR reflectivity of the composite. These fabrics offer greater flexibility and color / pattern options for the manufacture of clothing, footwear, and the like.

[0044] The inner layer 102 and the metal coating film 104 are bonded to each other via a plurality of first contact points 112. In some embodiments, the metal coating film 104 can be bonded to the inner fabric with an adhesive such as a water-based adhesive, a solvent-based adhesive, a heat-activated adhesive, or a pressure-activated adhesive. The adhesive is placed on one or both of the inner layer 102 and the metal coating film 104 to bond them to each other. The adhesive is applied in a manner that does not significantly reduce the breathability of the breathable composite fabric 100 or 200. For example, this can be achieved by applying the adhesive as first contact points 112 in a dot matrix pattern instead of a seamless film pattern.

[0045] In some embodiments, the inner layer 102 and the metal coating 104 may be joined by ultrasonic or laser welding. Alternatively, the metal coating 104 may be bonded to the underlying inner layer 102 by heating the contact point above the melting point of the base layer 108 and / or the inner layer 102. For example, a portion of the base layer 108 may be melted to form a first contact point 112 and connected to the inner layer 102. Or, a portion of the inner layer 102 may be melted to form a first contact point 112 and connected to the base layer 108 (Figure 1) or the metal layer 110 (Figure 2). In some embodiments, both a portion of the inner layer 102 and a portion of the base layer 108 may be melted to form a first contact point 112 between the inner layer 102 and the metal coating 104. In some embodiments, the first contact point 112 may be formed by stitching or quilting.

[0046] The first contact point 112 is interposed between the inner layer 102 and the metal coating 104 to minimize its impact on the breathability of the fabric 100 or 200. For example, the first contact point 112 has an area that covers less than 80% of the inner layer 102 (or metal coating 104). To obtain improved breathability, the first contact point 112 covers less than 50%, less than 40%, or less than 30% of the inner layer 102 (or metal coating 104). In one embodiment, to obtain even better breathability, the first contact point 112 covers less than 20% of the inner layer 102 (or metal coating 104).

[0047] The first contact points 112 interposed between the inner layer 102 and the metal coating film 104 may be arranged in any form of dot matrix. The density of the first contact points 112 may be uniform throughout the breathable composite fabric 100 or 200. In some embodiments, the density of the first contact points 112 may vary from region to region. For example, the density of the first contact points 112 may be increased in areas where heavy wear is expected.

[0048] The outer layer 106 and the metal coating film 104 are bonded to each other via a plurality of second contact points 114. In some embodiments, the metal coating film 104 can be bonded to the outer layer 106 with an adhesive such as a water-based adhesive, a solvent-based adhesive, a heat-activated adhesive, or a pressure-activated adhesive. The adhesive is placed on one or both of the outer layer 106 and the metal coating film 104 to bond them to each other. The adhesive is applied in a manner that does not significantly reduce the breathability of the breathable composite fabric 100 or 200. For example, this can be achieved by applying the adhesive as second contact points 114 in a dot matrix pattern instead of a seamless film pattern.

[0049] In some embodiments, the outer layer 106 and the metal coating 104 may be joined by ultrasonic or laser welding. Alternatively, the metal coating 104 may be bonded to the outer layer 106 by heating the contact points above the melting points of the base layer 108 and / or the outer layer 106. For example, a portion of the base layer 108 may be melted to form a second contact point 114 and connected to the outer layer 106. Or, a portion of the outer layer 106 may be melted to form a second contact point 114 and connected to the metal layer 110 (Figure 1) or the base layer 108 (Figure 2). In some embodiments, both a portion of the outer layer 106 and a portion of the base layer 108 may be melted to form a second contact point 114 between the outer layer 106 and the metal coating 104 (Figure 2). In some embodiments, the second contact point 114 may be formed by stitching or quilting.

[0050] The second contact point 114 is interposed between the outer layer 106 and the metal coating 104 to minimize its impact on the breathability of the fabric 100 or 200. For example, the second contact point 114 has an area that covers less than 80% of the outer layer 106 (or metal coating 104). To obtain improved breathability, the second contact point 114 covers less than 50%, less than 40%, or less than 30% of the outer layer 106 (or metal coating 104). In one embodiment, to obtain even better breathability, the second contact point 114 covers less than 20% of the outer layer 106 (or metal coating 104).

[0051] The second contact points 114 interposed between the outer layer 106 and the metal coating film 104 may be arranged in any form of dot matrix. The density of the second contact points 114 may be uniform throughout the breathable composite fabric 100 or 200. In some embodiments, the density of the second contact points 114 may vary from region to region. For example, the density of the second contact points 114 may be increased in areas where heavy wear is expected.

[0052] In some embodiments, the breathable composite fabric 100 or 200 has a breathability (MVTR) of at least 70% of its components, including an inner layer 102, a metal coating film 104, and an outer layer 106.

[0053] In some embodiments, the breathable composite fabric 100 or 200 is constructed such that the metal coating film 104 (reflective layer) is exposed on the outer layer side so as not to block the reflectivity of the fabric.

[0054] In some embodiments, when contact points 112 and 114 are embodied with adhesive, the adhesive is 30 or 60 g / m². 2 A weight less than the specified amount is added.

[0055] In some embodiments, the breathable composite fabric 100 / 200 may be used to manufacture clothing, footwear, tents, sleeping bags, etc. In some embodiments, the breathable composite fabric 100 / 200 may be used together with other materials to manufacture clothing, footwear, tents, sleeping bags, etc. Examples of configurations are shown in Figures 4A to 4C. Figure 4A is a schematic diagram showing a laminate 400 according to an exemplary embodiment. The laminate 400 includes an outer layer made from the breathable composite fabric 100 / 200, an intermediate fiber layer 402, and a single layer of fabric 404. In some embodiments, the intermediate fiber layer 402 may include a fibrous insulating material such as synthetic insulation or cotton.

[0056] Figure 4B is a schematic diagram showing a laminate 410 according to an exemplary embodiment. The laminate 410 includes an outer layer 404 made from a single layer of fabric, an intermediate fiber layer 402, and an inner layer made from a breathable composite fabric 100 / 200.

[0057] Figure 4C is a schematic diagram showing a laminate 420 according to an exemplary embodiment. The laminate 420 includes an outer layer made of breathable composite fabric 100 / 200, an intermediate fiber layer 402, and an inner layer made of breathable composite fabric 100 / 200. It is understood that laminates 400, 410, and 420 are for illustrative purposes only. Other structures using breathable composite fabric 100 / 200 are intended.

[0058] This disclosure also provides a breathable infrared-reflective composite fabric that offers improved thermal insulation through infrared reflection. In the three-layer composite, the intermediate layer is a breathable metal coating layer primarily responsible for infrared reflection, while both the inner and outer layers provide strength and support so that the metal coating layer can withstand repeated abrasion and mechanical actions such as washing. Furthermore, the outer layer is selected not only to protect the metal coating layer from oxidation and thus avoid a reduction in reflectivity, but also to block the outward emissivity of the fabric. It has been demonstrated that an emissivity of at most 0.8 enables effective heating performance (measured by thermal resistance) through IR reflection. The inner layer is also selected to provide a pleasant feel when in direct contact with the skin.

[0059] In one embodiment, the breathable composite fabric disclosed herein has high breathability, which makes it more comfortable to wear than clothing made from non-porous reflective foil.

[0060] In another embodiment, the breathable composite fabric disclosed herein includes a more effective reflective layer using a metal coating. The metal coating includes a base layer made of polyethylene, which has a lower melting point than many conventional fabric materials, thereby enabling a flatter surface to be achieved by calendering at lower temperatures, for example, below 200°C or below about 135°C.

[0061] In yet another embodiment, the breathable composite fabric disclosed herein includes a polyethylene base layer having a thin thickness of about 200 micrometers or less, and the base layer is considerably permeable (about 40-60%) to infrared radiation from the human body (wavelengths of about 7-14 micrometers). Thus, the breathable composite fabric maximizes heat radiation reflected back towards the body, as the heat consumed to heat the layer due to absorption is minimized.

[0062] In another embodiment, the breathable composite fabrics disclosed herein offer better structural integrity and antioxidant capacity than other melt-spun nonwoven materials, making the breathable composite fabrics less prone to disintegration after washing.

[0063] In another embodiment, the breathable composite fabric disclosed herein includes contact points for bonding the inner and outer layers to a metal coating, resulting in high breathability desirable for clothing, footwear, tents, and sleeping bag applications, or other applications requiring fabric material.

[0064] The preceding descriptions in this disclosure are provided for illustrative and explanatory purposes only. They are not intended to be exhaustive or to limit this disclosure to any specific form disclosed. The breadth and scope of this disclosure should not be limited by any of the exemplary embodiments described above. Many modifications and variations will be apparent to those skilled in the art. These modifications and variations include any combination of related features of this disclosure. Embodiments have been selected and described to best illustrate the principles of this disclosure and their practical applications, thereby enabling those skilled in the art to understand this disclosure in terms of various embodiments and modifications suited to specific intended uses. The scope of this disclosure is intended to be defined by the appended claims and other equivalences. The present invention provides, for example, the following items: (Item 1) It is a fabric, The inner layer, A metal coating film disposed in the inner layer, wherein the metal coating film comprises a base layer containing a polymer and a metal layer deposited on a first surface of the base layer, and the inner layer is bonded to the metal coating film via a first contact point, An outer layer disposed on the metal coating film, which is bonded to the metal coating film via a second contact point, and A fabric that possesses these properties. (Item 2) The fabric according to item 1, wherein the inner layer is bonded to a second surface of the base layer, and the second surface is on the opposite side of the first surface. (Item 3) The fabric according to item 1 or 2, wherein the outer layer is bonded to the surface of the metal layer. (Item 4) Each of the inner layer, base layer, metal layer, and outer layer has a density of at least 500 g / m². 2 A fabric as described in any one of items 1 to 3, having a water vapor transmission rate of / 24hr. (Item 5) The fabric is one of the fabrics described in any one of items 1 to 4, having a thermal conductivity of at most 0.6 W / m·K. (Item 6) The fabric according to any one of items 1 to 5, wherein the inner layer includes one of woven, knitted, or nonwoven fabrics. (Item 7) The inner layer is a fabric according to item 6, wherein the inner layer contains synthetic or natural materials. (Item 8) The fabric according to item 7, wherein the synthetic material is selected from one or more of polyester, nylon, elastane, polyurethane, polyolefin, polylactic acid, or polytetrafluoroethylene (PTFE). (Item 9) The fabric according to any one of items 1 to 8, wherein the inner layer, the metal coating film, and the outer layer each have a water vapor transmission rate of at least 70%. (Item 10) A fabric according to any one of items 1 to 9, wherein the first contact point and the second contact point include an adhesive. (Item 11) The fabric according to any one of items 1 to 10, wherein the first contact point includes a molten base layer. (Item 12) The fabric according to any one of items 1 to 11, wherein the first contact point includes a melted inner layer. (Item 13) The fabric according to any one of items 1 to 12, wherein the second contact point includes a molten base layer. (Item 14) The fabric according to any one of items 1 to 13, wherein the second contact point includes a molten outer layer. (Item 15) The fabric according to any one of items 1 to 14, wherein the first contact point or the second contact point is formed by sewing or quilting. (Item 16) The fabric according to any one of items 1 to 15, wherein the metal layer comprises one or more of aluminum, titanium, silver, gold, copper, zinc, magnesium, or germanium. (Item 17) The fabric according to any one of items 1 to 16, wherein the metal layer has a thickness of about 10 nanometers to about 200 nanometers. (Item 18) The fabric according to any one of items 1 to 17, wherein the metal layer has reflectivity in the range of 0.76 to 0.97 at a wavelength of 9.5 micrometers. (Item 19) The metal coating film has a density of at least 800 g / m². 2 A fabric as described in any one of items 1 to 18, having a water vapor transmission rate of / 24hr. (Item 20) The fabric according to any one of items 1 to 19, wherein the total emissivity of the metal coating film and the outer layer is at most 0.85 at a wavelength of 9.5 micrometers. (Item 21) A device comprising a fabric as described in any one of items 1 through 20, wherein the device is one of clothing, footwear, a tent, or a sleeping bag.

Claims

1. It is a fabric, The inner layer, A metal coating film which is an aluminum-coated nanoporous polyolefin film disposed in the inner layer, wherein the metal coating film comprises a base layer containing polyethylene and a metal layer deposited on a first surface of the base layer, the inner layer is bonded to the metal coating film via first contact points, the first density of the first contact points differs depending on the region of the inner layer, and the area covered by the first contact points is less than 20% of the surface of the inner layer, An outer layer comprising a knitted fabric of polyester raw silk (FDY), wherein the outer layer has a cover factor of 67-71% and is arranged on the metal coating film, the outer layer is bonded to the metal coating film via second contact points, the second density of the second contact points differs depending on the region of the outer layer, and the area covered by the second contact points is less than 20% of the surface of the outer layer. A fabric that possesses these properties.

2. The fabric according to claim 1, wherein the inner layer is bonded to a second surface of the base layer, and the second surface is on the opposite side of the first surface.

3. The fabric according to claim 1 or 2, wherein the outer layer is bonded to the surface of the metal layer.

4. Each of the inner layer, base layer, metal layer, and outer layer has a density of at least 500 g / m². ２ A fabric according to any one of claims 1 to 3, having a water vapor permeability of 24hr, wherein the water vapor permeability indicates the degree of breathability.

5. The fabric according to any one of claims 1 to 4, wherein the fabric has a thermal conductivity of at most 0.6 W / m·K.

6. The fabric according to any one of claims 1 to 5, wherein the inner layer comprises one of a woven fabric, a knitted fabric, or a nonwoven fabric.

7. The fabric according to claim 6, wherein the inner layer comprises a synthetic material or a natural material.

8. The fabric according to claim 7, wherein the synthetic material is selected from one or more of polyester, nylon, elastane, polyurethane, polyolefin, polylactic acid, or polytetrafluoroethylene (PTFE).

9. The fabric according to any one of claims 1 to 8, wherein the fabric has a water vapor permeability of at least 70% for each of the inner layer, the metal coating film, and the outer layer.

10. The fabric according to any one of claims 1 to 9, wherein the first contact point and the second contact point contain an adhesive.

11. The fabric according to any one of claims 1 to 10, wherein the first contact point includes a molten base layer.

12. The fabric according to any one of claims 1 to 11, wherein the first contact point includes a molten inner layer.

13. The fabric according to any one of claims 1 to 12, wherein the second contact point includes a molten base layer.

14. The fabric according to any one of claims 1 to 13, wherein the second contact point includes a melted outer layer.

15. The fabric according to any one of claims 1 to 14, wherein the first contact point or the second contact point is formed by sewing or quilting.

16. The fabric according to any one of claims 1 to 15, wherein the metal layer comprises one or more of aluminum, titanium, silver, gold, copper, zinc, magnesium, or germanium.

17. The fabric according to any one of claims 1 to 16, wherein the metal layer has a thickness of 10 nanometers to 200 nanometers.

18. The fabric according to any one of claims 1 to 17, wherein the metal layer has reflectivity in the range of 0.76 to 0.97 at a wavelength of 9.5 micrometers.

19. The metal coating film has a density of at least 800 g / m². ２ A fabric according to any one of claims 1 to 18, having a water vapor transmission rate of 24hr.

20. The fabric according to any one of claims 1 to 19, wherein the total emissivity of the metal coating film and the outer layer is at most 0.85 at a wavelength of 9.5 micrometers, and the total emissivity represents the emissivity of the combination of the metal coating film and the outer layer.

21. An article comprising a fabric as described in any one of claims 1 to 20, wherein the article is one of clothing, footwear, a tent, or a sleeping bag.

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