Search

EP-4739498-A1 - WATERPROOF, BREATHABLE NONWOVEN TEXTILES FOR ARTICLES AND METHODS OF MAKING THE SAME

EP4739498A1EP 4739498 A1EP4739498 A1EP 4739498A1EP-4739498-A1

Abstract

A composite textile can include various layers, such as a nonwoven layer and a waterproof, breathable membrane. The composite textile can include various properties, such as waterproofness, water repellancy, and the like. In addition, the composite textile can be manufactured using various techniques, which can be configured to impart desired properties. The composite textile can be suitable to form articles designed for inclement weather.

Inventors

  • HU, CHENG
  • OU, Yang-hua
  • RANALLI, CHRISTOPHER J.
  • WAN, LAI-HUNG

Assignees

  • Nike, Inc.

Dates

Publication Date
20260513
Application Date
20240705

Claims (20)

  1. 1. A composite textile having a first face and an opposite second face, the composite textile comprising: a first nonwoven textile layer having a first side and an opposite second side, the first side of the first nonwoven textile layer comprising the first face of the composite textile, the first nonwoven textile layer comprising a durable water repellant deposit; and a waterproof, breathable membrane bonded to the second side of the first nonwoven textile layer.
  2. 2. The composite textile of claim 1, further comprising a first adhesive layer positioned between the second side of the first nonwoven textile layer and the waterproof, breathable membrane, the first adhesive layer bonding the first nonwoven textile layer to the waterproof, breathable membrane.
  3. 3. The composite textile of claim 1 or claim 2, wherein the first nonwoven textile layer comprises a printed component.
  4. 4. The composite textile of claim 3, wherein the printed component comprises a supercritical CO2 impregnated dye.
  5. 5. The composite textile of any of claims 1 through 4, wherein the first nonwoven textile layer comprises a plurality of chemical bonding sites.
  6. 6. The composite textile of any of claims 1 through 5, wherein the first nonwoven textile layer comprises a spunlace textile.
  7. 7. The composite textile of any of claims 1 through 6, wherein the waterproof, breathable membrane comprises a film comprising recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.
  8. 8. The composite textile of any of claims 1 through 7, further comprising a second nonwoven textile layer having a first side and an opposite second side, the first side of the second nonwoven textile layer comprising the second face of the composite textile, the second side of the second nonwoven textile layer bonded, via a second adhesive layer, to the waterproof, breathable membrane.
  9. 9. The composite textile of claim 8, wherein the second nonwoven textile layer comprises a spunlace textile.
  10. 10. The composite textile of claim 8, wherein the second non woven textile layer comprises a spunbond scrim comprising a basis weight in a range of about 8 gsm to about 16 gsm.
  11. 11. The composite textile of any of claims 1 through 10, wherein the opposite second face of the composite textile comprises a printed component.
  12. 12. The composite textile of any of claims 1 through 11, wherein the first face comprises an outer-facing surface of an apparel article.
  13. 13. A method of manufacturing a composite textile having a first face and an opposite second face, the method comprising: positioning a first adhesive between a first nonwoven textile layer and a waterproof, breathable membrane, the first nonwoven textile layer comprising a first side and an opposite second side, wherein the first adhesive is positioned adjacent the second side of the first non wo ven textile layer; applying one or more of heat and pressure to the first adhesive to bond the first nonwoven textile layer to the waterproof, breathable membrane, wherein subsequent to bonding, the first side of the first nonwoven textile layer comprises the first face of the composite textile; and applying a durable water repellant to the first nonwoven textile layer.
  14. 14. The method of manufacturing the composite textile of claim 13 , wherein the durable water repellant is applied to the first nonwoven textile layer prior to bonding the first nonwoven textile layer to the waterproof, breathable membrane.
  15. 15. The method of manufacturing the composite textile of claim 13 or claim 14, further comprising, prior to bonding, impregnating the first nonwoven textile layer with a colorant via a CO2 medium.
  16. 16. The method of manufacturing the composite textile of any of claims 13 through 15, further comprising, applying a chemical binder to the first side of the first nonwoven textile layer.
  17. 17. The method of manufacturing the composite textile of claim 16, wherein the chemical binder is applied to the first nonwoven textile layer after the first nonwoven textile layer is impregnated with a colorant via a CO2 medium.
  18. 18. The method of manufacturing the composite textile of any of claims 13 through 17, wherein the first nonwoven textile layer is a spunlace textile.
  19. 19. The method of manufacturing the composite textile of any of claims 13 through 18, further comprising: positioning a second adhesive between a second nonwoven textile layer and the waterproof, breathable membrane, the second nonwoven textile layer comprising a first side and an opposite second side, wherein the second adhesive is positioned adjacent the second side of the second nonwoven textile layer; and applying one or more of heat and pressure to the second adhesive to bond the second nonwoven textile layer to the waterproof, breathable membrane, wherein subsequent to bonding, the first side of the second nonwoven textile layer comprises the second face of the composite textile.
  20. 20. The method of manufacturing the composite textile of claim 19, wherein the second nonwoven textile layer comprises a spunlace textile.

Description

WATERPROOF, BREATHABLE NONWOVEN TEXTILES FOR ARTICLES AND METHODS OF MAKING THE SAME FIELD OF THE INVENTION [0001] This specification describes waterproof, breathable nonwoven textiles for articles and methods of making the same. BACKGROUND OF THE INVENTION [0002] Conventional articles (e.g., wearable articles, bags, etc.) designed for inclement weather conditions (e.g., precipitation) generally are formed from a knit or woven textile. In some cases, the knit or woven textile can be combined with a waterproof, breathable membrane. However, knit and/or woven textiles are often manufactured using processes (e.g., knitting, weaving, dyeing, etc.) that are less sustainable and/or that consume relatively high amounts of energy. BRIEF DESCRIPTION OF THE DRAWINGS [0003] Subject matter of this disclosure is related to waterproof, breathable nonwoven textiles and is described in detail below with reference to the attached drawing figures. [0004] FIG. 1 illustrates an example lifecycle for an example first composite textile in accordance with aspects herein. [0005] FIG. 2 illustrates a first nonwoven textile layer for use in the first composite textile of FIG. 1 in accordance with aspects herein. [0006] FIG. 3 illustrates a waterproof, breathable membrane for use in the first composite textile of FIG. 1 in accordance with aspects herein. [0007] FIG. 4 illustrates an optional second nonwoven textile layer for use in the first composite textile of FIG. 1 in accordance with aspects herein. [0008] FIG. 5 illustrates a first face of the first composite textile of FIG. 1 in accordance with aspects herein. [0009] FIG. 6 illustrates an opposite second face of the first composite textile of FIG. 1 in accordance with aspects herein. [0010] FIG. 7 illustrates a first example manufacturing process for forming the first composite textile of FIG. 1 in accordance with aspects herein. [0011] FIG. 8 illustrates a second example manufacturing process for forming the first composite textile of FIG. 1 in accordance with aspects herein. [0012] FIG. 9 illustrates a third example manufacturing process for forming the first composite textile of FIG. 1 in accordance with aspects herein. [0013] FIG. 10 illustrates a waterproof, breathable membrane for use in an example second composite textile in accordance with aspects herein. [0014] FIG. 11 illustrates a nonwoven textile layer for use in the second composite textile in accordance with aspects herein. [0015] FIG. 12 illustrates a first face of the second composite textile in accordance with aspects herein. [0016] FIG. 13 illustrates an opposite second face of the second composite textile in accordance with aspects herein. [0017] FIG. 14 illustrates an example manufacturing process for forming the second composite textile in accordance with aspects herein. [0018] FIGs. 15A- 15B illustrate front and back views respectively of a first example article of apparel for an upper body formed from the first composite textile and/or the second composite textile in accordance with aspects herein. [0019] FIGs. 16A-16B illustrate front and back views respectively of a second example article of apparel for a lower body formed from the first composite textile and/or the second composite textile in accordance with aspects herein. DETAILED DESCRIPTION OF THE INVENTION [0020] This specification describes waterproof, breathable nonwoven textiles and methods of making the same. In at least some instances, the waterproof, breathable nonwoven textiles can be intended for articles (e.g., wearable articles, bags, etc.) used in inclement weather (e.g., precipitation). In examples of this disclosure, one or more nonwoven textile layers can be combined with a waterproof, breathable membrane. For instance, the one or more nonwoven textile layers can include a spunlace layer, entangled fibers (e.g., needle-entangled staple fibers), and/or other type(s) of non wo ven textile(s) such as spunbond, meltblown, and the like. In addition to being water proof, the one or more nonwoven textile layers can include additional properties, such as water repellency, color properties (e.g., via colorant applied or impregnated through various means, such as sublimated or in a CO2 medium as a supercritical fluid), air permeability, anti-pilling, and the like. In contrast to conventional waterproof textiles, the subject matter of the present disclosure can be more sustainable (e.g., by using fewer resources to manufacture, by being conducive to manufacturing with recycled materials - including shredded articles, by being easier to recycle into future products, and the like). These and other examples associated with the present disclosure are described in more detail below. [0021] In contrast to the present disclosure, some conventional textiles designed for inclement conditions (e.g., precipitation) generally are formed from a knit or woven textile on to which a durable water repellant coating is applied. In another example, a waterpro