Bio-Based Composite Fabric for Breathable Waterproof Garments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current outdoor jackets made with extruded ePTFE films or electro-spun polyurethane membranes face issues with breathability, environmental sustainability, and high production costs, as they are not oleophobic and use solvents, necessitating a more environmentally friendly and high-performance composite material.
Innovation Solution
A composite fabric is developed with a first fabric layer and a thin film, both containing at least 15% bio-based carbon content, with the thin film having an average weight of less than 30 GSM and air permeability of less than 1 CFM, enhancing breathability and sustainability while maintaining waterproofness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electro-spun polyurethane membrane is used, then membrane formation is achieved, but environmental sustainability deteriorates due to solvent use and inferior waterproofness
Solution Approach 1:
The patent changes the material composition parameter by incorporating bio-based fibers (至少15%生物基碳含量) into the fabric layer, replacing or supplementing conventional petroleum-based materials. This parameter change improves environmental sustainability while maintaining the membrane formation capability through the lamination process, and enhances waterproofness through the synergistic effect of the bio-based fiber layer with the e-PTFE or polyurethane membrane.
2Reliability
If conventional membranes are used, then waterproofing is achieved, but production cost increases
Solution Approach 1:
The patent employs a composite structure where a relatively thin e-PTFE film or polyurethane membrane (平均重量小于30 GSM) is combined with a bio-based fiber fabric layer. This composite approach achieves effective waterproofing through the membrane component while the bio-based fabric provides structural support and breathability, allowing for cost optimization by using thinner membrane layers that still deliver adequate waterproof performance.
Data Source
AI summary
In a first embodiment, the invention provides a composite fabric which contains a first fabric layer and a thin film. The first fabric layer has an upper and lower side and contains a plurality of synthetic polymer fibers. The synthetic polymer fibers contain at least 15% of bio-based carbon content as measured by ASTM D26866-20 Method B. The thin film is located on the lower side of the first fabric layer and contains at least 15% of biobased carbon content as measured by ASTM D26866-20 Method B. The thin film has an average weight of less than about 30 GSM and has an air permeability of less than about 1 CFM as measured by ASTM D737 @ 125 Pa.