Insulated Composite Fabric
An insulated composite fabric that includes an inner fabric layer, an outer fabric layer, and an insulating-filler fabric layer enclosed between the inner fabric layer and the outer fabric layer. The insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric. The insulating-filler fabric layer comprises fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
1 . An insulated composite fabric comprising:
an inner fabric layer;
an outer fabric layer; and
an insulating-filler fabric layer enclosed between the inner fabric layer and the outer fabric layer,
wherein the insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric, and
wherein the insulating-filler fabric layer comprises fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
2 . The insulated composite fabric of claim 1 , wherein the fibers have denier of about 0.3 dpf to about 10.0 dpf.
3 . The insulated composite fabric of claim 2 , wherein the fibers have a denier of about 1.5 dpf to about 10.0 dpf.
4 . The insulated composite fabric of claim 1 , wherein the whiskers have an average length of up to about 200% of a diameter of the core.
5 . The insulated composite fabric of claim 1 , wherein the raised surface comprises the fibers having the axial core surrounded by the multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
6 . The insulated composite fabric of claim 1 , wherein the core comprises a polymer and the whiskers comprise another polymer, and wherein the polymer of the core and/or the polymer of the whiskers comprises polyethylene terephthalate (PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the combinations.
7 . The insulated composite fabric of claim 1 , wherein the fibers have about 3 to about 200 whiskers within a cross-sectional surface of the fibers.
8 . The insulated composite fabric of claim 1 , wherein the axially-extending grooves are nanogrooves or microgrooves.
9 . The insulated composite fabric of claim 1 , wherein the whiskers have an average radial length of about 2 nm to about 10 microns.
10 . The insulated composite fabric of claim 1 , wherein the insulating-filler fabric layer comprises a double face warp knit fabric, a double face knit fabric having reverse plaited terry sinker loop knit construction, sliver knit construction, a double face knit fabric having sliver knit construction, or a terry sinker loop fabric in which the terry loop is left un-raised.
11 . A fabric garment comprising:
a first fabric portion formed of a first insulated composite fabric, the first insulated composite fabric comprising:
a first inner fabric layer;
a first outer fabric layer; and
a first insulating-filler fabric layer enclosed between the first inner fabric layer and the first outer fabric layer,
wherein the first insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric, and
wherein the insulating-filler fabric layer comprises fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
12 . The fabric garment of claim 11 , wherein the fibers have denier of about 0.3 dpf to about 10.0 dpf.
13 . The fabric garment of claim 12 , wherein the fibers have a denier of about 1.5 dpf to about 10.0 dpf.
14 . The fabric garment of claim 11 , wherein the whiskers have an average length of up to about 200% of a diameter of the core.
15 . The fabric garment of claim 11 , wherein the raised surface comprises the fibers having the axial core surrounded by the multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
16 . The fabric garment of claim 11 , wherein the core comprises a polymer and the whiskers comprise another polymer, and wherein the polymer of the core and/or the polymer of the whiskers comprises polyethylene terephthalate (PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the combinations.
17 . The fabric garment of claim 11 , wherein the fibers have about 3 to about 200 whiskers within a cross-sectional surface of the fibers.
18 . The fabric garment of claim 11 , wherein the axially-extending grooves are nanogrooves or microgrooves.
19 . The fabric garment of claim 11 , wherein the whiskers have an average radial length of about 2 nm to about 10 microns.
20 . A method comprising:
forming an insulated composite fabric including:
enclosing an insulating-filler fabric layer between an inner fabric layer and an outer fabric layer, wherein the insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric and wherein the insulating-filler fabric layer comprises fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
21 . The method of claim 20 , wherein the fibers have a denier of about 0.3 dpf to about 10.0 dpf.
22 . A method of forming a hybrid composite fabric garment, the method comprising:
forming a first fabric portion out of a first insulated composite fabric, the first insulated composite fabric comprising:
a first inner fabric layer,
a first outer fabric layer, and
a first insulating-filler fabric layer enclosed between the first inner fabric layer and the first outer fabric layer, wherein the first insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric, and wherein the insulating-filler fabric layer comprises fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves;
forming a second fabric portion out of another fabric having an air permeability that is different from, and greater than, an air permeability of the first insulated composite fabric; and
joining together the first and second fabric portions to form the hybrid composite fabric garment.
23 . An insulated composite fabric comprising:
an outer fabric layer; and
an insulating fabric layer attached the outer fabric layer,
wherein the insulating fabric layer is a textile fabric having a raised surface facing towards the outer fabric layer, and
wherein the insulating fabric layer comprises fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
24 . The insulated composite fabric of claim 23 , wherein the fibers have a denier of about 0.3 dpf to about 10.0 dpf.
25 . The insulated composite fabric of claim 24 , wherein the fibers have a denier of about 1.5 dpf to about 10.0 dpf.
26 . The insulated composite fabric of claim 23 , wherein the whiskers have an average length of up to about 200% of a diameter of the core.
27 . The insulated composite fabric of claim 23 , wherein the raised surface comprises the fibers having the axial core surrounded by the multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves.
28 . The insulated composite fabric of claim 23 , wherein the core comprises a polymer and the whiskers comprise another polymer, and wherein the polymer of the core and/or the polymer of the whiskers comprises polyethylene terephthalate (PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the combinations.
29 . The insulated composite fabric of claim 23 , wherein the fibers have about 3 to about 200 whiskers within a cross-sectional surface of the fibers.
30 . The insulated composite fabric of claim 23 , wherein the axially-extending grooves are nanogrooves or microgrooves.
31 . The insulated composite fabric of claim 23 , wherein the whiskers have an average radial length of about 2 nm to about 10 microns.