WO2013043397A2

WO2013043397A2 - Composite fabrics

Info

Publication number: WO2013043397A2
Application number: PCT/US2012/054368
Authority: WO
Inventors: Moshe Rock
Original assignee: Mmi-Ipco, Llc
Priority date: 2011-09-21
Filing date: 2012-09-10
Publication date: 2013-03-28
Also published as: WO2013043397A3

Abstract

A hybrid composite fabric garment includes a first fabric portion and a second fabric portion. The first fabric portion includes a first inner fabric layer, a first outer fabric layer, and a first barrier layer disposed therebetween. The first barrier includes a first nonwoven membrane that has a first hydrophobic material disposed on its surfaces and that has a first predetermined air permeability. The second fabric portion includes a second inner fabric layer, a second outer fabric layer, and a second barrier layer disposed therebetween. The second barrier layer includes a second nonwoven membrane and has a second predetermined air permeability substantially greater than the first predetermined air permeability.

Description

COMPOSITE FABRICS

TECHNICAL FIELD

This disclosure relates to composite fabrics, and in particular to garments formed of composite fabrics.

BACKGROUND

Composite fabric articles are achieved by joining together one or more materials in a fabric body for the purpose of attaining desirable properties that cannot be attained by the fabric body or the individual materials alone. Laminated composites, e.g., those having multiple layers joined, e.g., by an adhesive, are sometimes formed for increasing thermal resistance performance of a composite fabric body.

Composite fabrics can be designed for wind and/or liquid water resistance.

Composite fabrics of this type typically include a barrier membrane adhered to one fabric layer, or adhered or placed between fabric layers. The barrier membrane of such composite fabrics may be constructed to resist, or substantially impede, passage of air and wind through the fabric layers. However, this type of construction can make it difficult for water vapor to escape outwardly through the barrier, causing liquid to build up on the wearer's skin, with resulting discomfort, in particular during exercise or other physical exertion.

Other composite fabrics are designed to enhance water vapor permeability and airflow in order to improve comfort level for the wearer during physical activity. These fabrics, however, are typically poor insulators, and, as a result, during static physical conditions, i.e. when at or near rest, the wearer may experience discomfort due to flow of cool air through the fabric.

SUMMARY

According to one aspect, a hybrid composite fabric garment includes a first fabric portion and a second fabric portion. The first fabric portion includes a first inner fabric layer, a first outer fabric layer, and a first barrier layer disposed therebetween. The first barrier layer includes a first nanofiber membrane. The first barrier layer has a first predetermined air permeability. The second fabric portion includes a second inner fabric layer, a second outer fabric layer, and a second barrier layer disposed therebetween. The second barrier layer includes a second nanofiber membrane. The second barrier layer has a second predetermined air permeability substantially greater than the first predetermined air permeability.

Implementations of this aspect may include one or more of the following additional features. The first predetermined air permeability is between about 0 ft³/ft²/min and about 2 ft³/ft² /min, under a pressure difference of ½ inch of water (125 Pa)

3 2 across the first barrier layer (tested according to ASTM D-737) (between about O m /m /h and 58.6 m³/m²/h at 200 Pa). The first nanofiber membrane has a weight of between about 4 grams per square meter and about 7 grams per square meter. The first nanofiber membrane has a thickness of between about 1 micrometer and about 50 micrometers. The first fabric portion has a water resistance of between about 6,000 mm of water and about 15,000 mm of water (tested according to AATCC 127-2003, option 2). The first fabric portion has a moisture vapor transmission rate of between about 2,000 g/m²/24 hrs and about 6,000 g/m /24 hrs (tested according to ASTM E96 inverted cup). The first fabric portion has an air permeability of between about 0 ft³/ft²/min and about 2

3 2

ft /ft /min, under a pressure difference of ½ inch of water (125 Pa) across the first fabric

3 2 3 2 portion (tested according to ASTM D-737) (between about O m /m /h and 58.6 m /m /h at 200 Pa). In some cases, at least one of the first and second nanofiber membranes has good stretch and recovery. In some implementations, at least one of the first and second nanofiber membranes has low stretch or no stretch. At least one of the first and second nanofiber membranes includes an electrospun nanofiber membrane. At least one of the first and second nanofiber membranes includes a nonwoven web formed from a plurality of nanofibers. The nanofibers have fiber diameters in the range of between about 50 nanometers and about 1,000 nanometers. The nanofibers include polymer fibers (e.g., nylon fibers, polyurethane fibers, etc.). The first barrier layer is bonded to at least one of the first inner fabric layer and the first outer fabric layer with an adhesive. The adhesive is applied in a manner to substantially avoid restriction of moisture vapor transmission through the first barrier layer. The adhesive is applied in a dot coating pattern. The

3 2

second predetermined air permeability is between about 3 ft /ft /min and about 20 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the second barrier layer (tested according to ASTM D-737) (between about 87.9 m /m /h and 586 m³/m²/h at 200 Pa). The second nanofiber membrane has a thickness of between about 1 micrometer and about 50 micrometers. The second nanofiber membrane has a weight of between about 2 grams per square meter and about 4 grams per square meter. The second barrier layer is bonded to at least one of the second inner fabric layer and the second outer fabric layer with an adhesive. The adhesive is applied in a manner to substantially avoid restriction of moisture vapor transmission through the second barrier layer. The adhesive is applied in a dot coating pattern. The second fabric portion has a water resistance of between about 500 mm of water and about 4,000 mm of water (tested according to AATCC 127-2003 option 2). The second fabric portion has a moisture vapor transmission rate of between about 6,000 g/m²/24 hrs and about 12,000 g/m²/24 hrs (tested according to ASTM E96 inverted cup). The second fabric portion has an air

3 2 3 2 *

permeability of between about 3 ft /ft /min and about 20 ft /ft /min, under a pressure difference of ½ inch of water (125 Pa) across the second fabric portion (tested according to ASTM D-737) (between about 87.9 m³/m²/h and 586 m³/m²/h at 200 Pa). At least one of the first outer fabric layer and the second outer fabric layer includes a woven construction. At least one of the first outer fabric layer and the second outer fabric layer includes a knit construction (e.g., single jersey, plated single jersey, double knit, tricot, and terry sinker loop). At least one of the first inner fabric layer and the second inner fabric layer includes a woven construction. At least one of the first inner fabric layer and the second inner fabric layer includes a knit construction (e.g., single jersey, plated single jersey, double knit, tricot, and terry sinker loop). The knit construction includes a raised surface or a brushed surface arranged to face towards a wearer's body during use. At least one of the first outer fabric layer and the second outer fabric layer has at least one- way stretch. At least one of the first outer fabric layer and the second outer fabric layer includes spandex yarn. At least one of the first inner fabric layer and the second inner fabric layer includes spandex yarn. At least one of the first outer fabric layer and the second outer fabric layer includes low stretch or no stretch fabric. The first fabric portion is disposed in one or more first regions of the fabric garment more likely to be exposed to wind and rain during use. The first fabric portion is configured to cover an upper torso region of a wearer's body (e.g., at least a wearer's shoulder regions, upper back region, and/or upper regions of the front of the garments, e.g., upper chest region). In some cases, the first fabric portion is configured to cover a substantial portion of a wearer's back, e.g., the whole back. The second fabric portion is disposed in one more second regions of the fabric garment less likely to be exposed to wind and rain during use. The second fabric portion is configured to cover a lower torso region of a wearer's body (e.g., at least a wearer's lower chest region and below). At least one of the first outer fabric layer and the second outer fabric layer is treated with a durable water repellent. At least one of the first inner fabric layer and the second inner fabric layer includes a moisture wicking fabric. At least one of the first inner fabric later and the second inner fabric layer is formed from a material that is rendered hydrophilic to permit wicking of moisture. At least one of the first and second outer layers is chemically treated for enhanced water repellence and/or for enhanced abrasion resistance. At least one of the first and second fabric portions includes one or more seams which are sealed and/or taped to enhance water resistance. At least one of the first fabric portion and the second fabric portion includes flame retardant fibers or a flame retardant fiber blend. At least one of the first inner fabric layer, the first outer fabric layer, the second inner fabric layer, and the second outer fabric layer includes flame retardant fibers or a flame retardant fiber blend.

In another aspect, a hybrid composite fabric garment includes a first fabric portion and a second fabric portion. The first fabric portion is water repellent, wind resistant, and permits moisture vapor transmission. The first fabric portion includes a first nanofiber membrane. The second fabric portion is less water repellent, less wind resistant, and permits greater moisture vapor transmission than the first nanofiber membrane. The second fabric portion includes a second nanofiber membrane.

Implementations of this aspect of the disclosure may include one or more of the following additional features. The first nanofiber membrane includes a nonwoven web having a weight of between about 4 grams per square meter and about 7 grams per square meter. The first nanofiber membrane has an air permeability of between about 0 ft³/ft²/min and about 2 ft³/ft² /min, under a pressure difference of ½ inch of water (125 Pa) across the first nanofiber membrane (tested according to ASTM D-737) (between about 0

3 2 3 2

m /m /h and 58.6 m /m /h at 200 Pa). The first fabric portion has a water resistance of between about 6,000 mm of water and about 1 ,000 mm of water (tested according to AATCC 127-2003 option 2). The first fabric portion has a moisture vapor transmission rate of between about 2,000 g/m²/24 hrs and about 6,000 g/m²/24 hrs (tested according to ASTM E96 inverted cup). The first fabric portion has an air permeability of between about 0 ft³/ft²/min and about 2 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the first fabric portion (tested according to ASTM D-737) (between about

3 2 3 2

0 m /m /h and 58.6 m /m /h at 200 Pa). The second nanofiber membrane includes a nonwoven web having a weight of between about 2 grams per square meter and about 4 grams per square meter. The second nanofiber membrane has an air permeability of between about 3 ft³/ft²/min and about 20 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the second nanofiber membrane (tested according to ASTM D- 737) (between about 87.9 m³/m²/h and 586 m³/m²/h at 200 Pa). The second fabric portion has a water resistance of between about 500 mm of water and about 4,000 mm of water (tested according to AATCC 127-2003 option 2). The second fabric portion has a moisture vapor transmission rate of between about 6,000 g/m²/24 hrs and about 12,000 g/m /24 hrs (tested according to ASTM E96 inverted cup). The second fabric portion has an air permeability of between about 3 ft³/ft²/min and about 20 ft /ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the second fabric portion (tested according to ASTM D-737) (between about 87.9 m³/m²/h and 586 m³/m /h at 200 Pa). At least one of the first and second nanofiber membranes includes an electrospun nanofiber membrane. At least one of the first and second nanofiber membranes has a thickness of between about 1 micrometer and about 50 micrometers. At least one of the first and second nanofiber membranes has good stretch and recovery. At least one of the first and second nanofiber membranes has low stretch or no stretch. At least one of the first and second nanofiber membranes includes a nonwoven web formed from a plurality of nanofibers. The nanofibers have fiber diameters in the range of between about 50 nanometers and about 1,000 nanometers. The nanofibers include polymer fibers (e.g., nylon fibers, polyurethane fibers, etc.). The first fabric portion includes a first laminate including a first outer fabric layer, and a first inner fabric layer, and the first nanofiber membrane is disposed between the first inner and the first outer fabric layers and is bonded to at least one of the first inner and the first outer fabric layers. The first inner fabric layer includes a raised or brushed surface facing inwardly, away from the first nanofiber membrane. The first nanofiber membrane is bonded to at least one of the first inner and the first outer fabric layers with an adhesive. The adhesive is applied in a manner to substantially avoid restriction of moisture vapor transmission through the first nanofiber membrane. The second fabric portion includes a second laminate including a second outer fabric layer, and a second inner fabric layer, and the second nanofiber membrane is disposed between the second inner and the second outer fabric layers and is bonded to at least one of the second inner and the second outer fabric layers. The second nanofiber membrane is bonded to at least one of the second inner and the second outer fabric layers with an adhesive, and the adhesive is applied in a manner to substantially avoid restriction of moisture vapor transmission through the second nanofiber membrane. The second inner fabric layer includes a raised or brushed surface facing inwardly, away from the second nanofiber membrane. At least one of the first outer fabric layer and the second outer fabric layer includes a woven construction. At least one of the first outer fabric layer and the second outer fabric layer is treated with a durable water repellent. The first outer fabric layer and the second outer fabric layer have the same construction. At least one of the first outer fabric layer and the second outer fabric layer has stretch, e.g., at least one-way stretch. At least one of the first outer fabric layer and the second outer fabric layer includes spandex yarn. At least one of the first inner fabric layer and the second inner fabric layer includes spandex yarn. At least one of the first inner fabric layer and the second inner fabric layer has a construction selected from woven construction; single jersey knit construction, plated single jersey knit construction, double knit construction, tricot knit construction, and terry sinker loop construction. At least one of the first inner fabric layer and the second inner fabric layer includes a moisture wicking fabric. At least one of the first inner fabric later and the second inner fabric layer is formed from a material that is rendered hydrophilic to permit wicking of moisture. At least one of the first and second inner fabric layers includes a raised surface facing inwardly, towards a wearer's body during use. At least one of the first and second inner fabric layers includes a brushed surface facing inwardly, towards a wearer's body during use. The second fabric portion includes a laminate including an outer fabric layer, and an inner fabric layer, and the second nanofiber membrane is disposed between the inner and outer fabric layers and is bonded to at least one of the inner and outer fabric layers with an adhesive. At least one of the first and second outer layers is chemically treated for enhanced water repellence and/or for enhanced abrasion resistance. At least one of the first and second fabric portions includes one or more seams which are sealed and/or taped to enhance water resistance. At least one of the first fabric portion and the second fabric portion includes flame retardant fibers. At least one of the first fabric portion and the second fabric portion includes a flame retardant fiber blend. At least one of the first inner fabric layer, the first outer fabric layer, the second inner fabric layer, and the second outer fabric layer includes flame retardant fibers. At least one of the first inner fabric layer, the first outer fabric layer, the second inner fabric layer, and the second outer fabric layer includes a flame retardant fiber blend.

In yet another aspect of the disclosure, a hybrid composite fabric garment includes a first fabric portion and a second fabric portion. The first fabric portion includes a first inner fabric layer, a first outer fabric layer, and a first barrier layer disposed therebetween. The first barrier layer includes a first nonwoven membrane. The first barrier layer has a first predetermined air permeability. The second fabric portion includes a second inner fabric layer, a second outer fabric layer, and a second barrier layer disposed therebetween. The second barrier layer includes a second nonwoven membrane. The second barrier layer has a second predetermined air permeability substantially greater than the first predetermined air permeability.

Implementations of this aspect of the disclosure may include one or more of the following additional features. At least one of first and second nonwoven membranes includes an electrospun membrane. The electrospun membrane is formed of fibers having fiber diameters in the range of between about 50 nanometers and about 1,000 nanometers. At least one of the first and second nonwoven membranes includes a melt blown membrane. The melt blown membrane is formed of fibers having fiber diameters in the range of between about 500 nanometers and about 2,000 nanometers. At least one of the first and second barrier layers includes multiple nonwoven membrane layers. At least one of the nonwoven membrane layers includes a melt blown membrane. At least one of the nonwoven membrane layers includes an electrospun membrane. At least one of the nonwoven membrane layers includes an electrospun nanofiber membrane. The nonwoven membrane layers include one or more melt blown membrane layers and one or more electrospun membrane layers. The nonwoven membrane layers include a melt blown membrane layer having an air permeability of between about 10 ft³/ft²/min and

3 2

about 70 ft /ft /min, tested according to ASTM D-737 under a pressure difference of ½ inch of water (125 Pa) across the melt blown membrane layer (between about 293

3 2 3 2

m /m /h and 2,050 m /m /h at 200 Pa). The nonwoven membrane layers may also include an electrospun membrane layer connected to the melt blown membrane layer and

3 2 3 2

having an air permeability of between about 2 ft /ft /min and about 20 ft /ft /min, tested according to ASTM D-737 under a pressure difference of ½ inch of water (125 Pa) across the electrospun membrane layer (between about 58.6 m³/m²/h and 586 m³/m²/h at 200 Pa). The electrospun membrane layer includes a nanofiber membrane. The electrospun membrane layer is bonded to the melt blown membrane layer with an adhesive. The first

3 2 ^ 2 predetermined air permeability is between about 0 ft /ft /min and about 2 ft ft /min, under a pressure difference of ½ inch of water (125 Pa) across the first barrier layer (tested according to ASTM D-737) (between about 0 m³/m²/h and 58.6 m³/m²/h at 200 Pa). The first fabric portion has a water resistance of between about 6,000 mm of water and about 15,000 mm of water (tested according to AATCC 127-2003 option 2). The first fabric portion has a moisture vapor transmission rate of between about 2,000 g/m /24 hrs and about 6,000 g/m /24 hrs (tested according to ASTM E96 inverted cup). The second predetermined air permeability is between about 3 ft³/ft²/min and about 20 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the second barrier layer

(tested according to ASTM D-737) (between about 87.9 m³/m²/h and 586 m³/m²/h at 200 Pa). The second barrier layer is bonded to at least one of the second inner fabric layer and the second outer fabric layer with an adhesive. The first barrier layer is bonded to at least one of the first inner fabric layer and the first outer fabric layer with an adhesive. The second fabric portion has a water resistance of between about 500 mm of water and about 4,000 mm of water (tested according to AATCC 127-2003 option 2). The second fabric portion has a moisture vapor transmission rate of between about 6,000 g/m /24 hrs and about 12,000 g/m²/24 hrs (tested according to ASTM E96 inverted cup). The second

3 2

fabric portion has an air permeability of between about 3 ft /ft /min and about 20

3 2

ft /ft /min, under a pressure difference of ½ inch of water (125 Pa) across the second fabric portion (tested according to ASTM D-737) (between about 87.9 m³/m²/h and 586 m /m /h at 200 Pa). The first fabric portion is configured to cover an upper torso region of a wearer's body (e.g., at least a wearer's shoulder regions, upper back region, and/or upper regions of the front of the garments, e.g., upper chest region). In some cases, the first fabric portion is configured to cover a substantial portion of a wearer's back, e.g., the whole back. The second fabric portion is disposed in one more second regions of the fabric garment less likely to be exposed to wind and rain during use. The second fabric portion is configured to cover a lower torso region of a wearer's body (e.g., at least a wearer's lower chest region and below).

In another aspect of the disclosure, a composite fabric includes an inner fabric layer, an outer fabric layer, and a barrier layer disposed between the inner fabric layer and the outer fabric layer. The barrier layer includes a nonwoven membrane.

Implementations of this aspect of the disclosure may include one or more of the following additional features. The nonwoven membrane includes an electrospun membrane. The nonwoven membrane includes a melt blown membrane. The barrier

3 2

layer has a predetermined air permeability of between about 0 ft /ft /min and about 70 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the barrier

3 2 3 2 layer (tested according to ASTM D-737) (between about O m /m /h and 2,050 m /m /h at 200 Pa). The barrier layer includes multiple nonwoven membrane layers. At least one of the nonwoven membrane layers includes a melt blown membrane. At least one of the nonwoven membrane layers includes an electrospun membrane. At least one of the nonwoven membrane layers includes an electrospun nanofiber membrane. The nonwoven membrane layers include one or more melt blown membrane layers and one or more electrospun membrane layers. The nonwoven membrane layers include a melt blown membrane layer having an air permeability of between about 10 ft³/ft²/min and

3 2

about 70 ft /ft /min, under a pressure difference of ½ inch of water (125 Pa) across the melt blown membrane layer (tested according to ASTM D-737) (between about 293

3 2 3 2

having an air permeability of between about 2 ft /ft /min and about 20 ft /ft /min, under a pressure difference of ½ inch of water (125 Pa) across the electrospun membrane layer (tested according to ASTM D-737) (between about 58.6 m³/m²/h and 586 m³/m²/h at 200 Pa). The electrospun membrane layer includes a nanofiber membrane. The electrospun membrane layer is bonded to the melt blown membrane layer with an adhesive. The

3 2 3 2 * barrier layer has an air permeability of between about 0 ft /ft /min and about 2 ft /ft /min, under a pressure difference of ½ inch of water (125 Pa) across the barrier layer (tested according to ASTM D-737) (between about 0 m³/m²/h and 58.6 m³/m²/h at 200 Pa). The composite fabric has a water resistance of between about 6,000 mm of water and about 15,000 mm of water (tested according to AATCC 127-2003 option 2). The composite fabric has a moisture vapor transmission rate of between about 2,000 g/m /24 hrs and about 6,000 g/m²/24 hrs (tested according to ASTM E96 inverted cup). The barrier layer

3 2

has predetermined air permeability of between about 3 ft /ft /min and about 20 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the barrier

3 2 3 2 layer (tested according to ASTM D-737) (between about 87.9 m /m /h and 586 m /m /h at 200 Pa). The barrier layer is bonded to at least one of the inner fabric layer and the outer fabric layer with an adhesive. The composite fabric has a water resistance of between about 500 mm of water and about 4,000 mm of water (tested according to

AATCC 127-2003 option 2). The composite fabric has a moisture vapor transmission rate of between about 6,000 g/m²/24 hrs and about 12,000 g/m²/24 hrs (tested according to ASTM E96 inverted cup). The composite fabric has an air permeability of between about 3 ft³/ft²/min and about 20 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) across the composite fabric (tested according to ASTM D-737) (between about 87.9 m³/m²/h and 586 m³/m²/h at 200 Pa).

According to another aspect of the disclosure, a method of forming a hybrid composite fabric includes forming a first fabric portion, forming a second fabric portion, and joining together the first and second fabric portions to form a hybrid composite fabric garment. Forming the first fabric portion includes disposing a first barrier layer including a first nonwoven membrane having a first predetermined air permeability between a first inner fabric layer and a first outer fabric layer. Forming the second fabric portion includes disposing a second barrier layer including a second nonwoven membrane, having a second predetermined air permeability substantially greater than the first predetermined air permeability, between a second inner fabric layer and a second outer fabric layer. Implementations of this aspect of the disclosure may include one or more of the following additional features. The method may include forming at least one of the first and second barrier layers. Forming at least one of the first and second barrier layers may include stacking multiple nonwoven membranes on top of each other, and mechanically processing the stack of nonwoven membranes. Mechanically processing the stack of nonwoven membranes includes applying pressure to the stack of nonwoven membranes. Pressure is applied by passing the stack of nonwoven membrane through a plurality of rollers. The rollers may be heated. The method may also include disposing an adhesive between the multiple nonwoven membranes. Stacking the multiple nonwoven membranes may include electrospinning a nonwoven membrane onto a carrier nonwoven membrane. The method may also include forming the carrier membrane using a melt blowing operation.

In another aspect of the disclosure, a hybrid composite fabric garment includes a first fabric portion and a second fabric portion. The first fabric portion includes a first inner fabric layer, a first outer fabric layer, and a first barrier layer disposed

therebetween. The first barrier layer includes a first membrane. The first membrane has substantially zero air permeability. The second fabric portion includes a second inner fabric layer, a second outer fabric layer, and a second barrier layer disposed

therebetween. The second barrier layer includes a nonwoven membrane. The nonwoven membrane of the second barrier layer has an air permeability that is substantially greater than the air permeability of the first membrane.

Implementations of this aspect of the disclosure may include one or more of the following additional features. The first barrier layer has an air permeability of between about 0 ft³/ft²/min and about 2 ft³/ft²/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water (125 Pa) across the first barrier layer (between about 0 m³/m²/h and 58.6 m³/m²/h at 200 Pa). The first membrane is a film membrane (e.g., a polytetrafluoroethylene film membrane or a polyurethane film membrane). The first membrane is a nonwoven membrane. The first membrane may include one or more melt blown membrane layers. The first membrane may include one or more electrospun membrane layers. The first membrane may include one or more electrospun nanofiber membrane layers. The first membrane may include multiple nonwoven membrane layers. The first membrane may include one or more melt blown membrane layers and one or more electrospun membrane layers. The first membrane comprises multiple melt blown membrane layers. The first membrane may include multiple electrospun membrane layers. The first membrane may include multiple electrospun nanofiber membrane layers. The first membrane may include a first electrospun nanofiber membrane layer formed from nanofibers having a first fiber diameter, and a second electrospun nanofiber membrane layer formed from nanofibers having a second fiber diameter that is finer than the first fiber diameter. The first membrane may include a first electrospun nanofiber membrane layer formed from nanofibers having fiber diameters of about 500 nanometers, and a second electrospun nanofiber membrane layer formed from nanofibers having fiber diameters of about 200 nanometers. The first membrane may include a first electrospun nanofiber membrane layer formed from nanofibers having fiber diameters of about 800 nanometers, and a second electrospun nanofiber membrane layer formed from nanofibers having fiber diameters of about 300 nanometers. The nonwoven membrane of the second barrier layer may include one or more melt blown membrane layers. The nonwoven membrane of the second barrier layer may include one or more electrospun membrane layers. The nonwoven membrane of the second barrier layer may include multiple nonwoven membrane layers. The nonwoven membrane of the second barrier layer includes one or more melt blown membrane layers and one or more electrospun membrane layers. The nonwoven membrane of the second barrier layer may include multiple melt blown membrane layers. The nonwoven membrane of the second barrier layer may include multiple electrospun membrane layers. The nonwoven membrane of the second barrier layer may include multiple electrospun nanofiber membrane layers. The nonwoven membrane of the second barrier layer may include a first electrospun nanofiber membrane layer formed from nanofibers having a first fiber diameter, and a second electrospun nanofiber membrane layer formed from nanofibers having a second fiber diameter that is finer than the first fiber diameter. The second barrier layer has an air permeability of between about 3 ft /ft²/min and about 20

3 2

ft /ft /min, tested according to ASTM D-737 under a pressure difference of ½ inch of

3 2

water (125 Pa) across the second barrier layer (between about 87.9 m /m /h and 586 m³/m²/h at 200 Pa). In another aspect, the disclosure features a hybrid composite fabric garment that comprises a first fabric portion and a second fabric portion. The first fabric portion comprises a first inner fabric layer, a first outer fabric layer, and a first barrier layer disposed between the first inner fabric layer and the first outer fabric layer. The first barrier layer comprises a first nonwoven membrane having a first hydrophobic material disposed on its surfaces and having a first predetermined air permeability. The second fabric portion comprises a second inner fabric layer, a second outer fabric layer, and a second barrier layer disposed between the second inner fabric layer and the second outer fabric layer. The second barrier layer comprises a second nonwoven membrane and has a second predetermined air permeability substantially greater than the first predetermined air permeability.

Implementations of this aspect of the disclosure may include one or more of the following additional features. At least one of first and second nonwoven membranes comprises an electrospun membrane or a melt blown membrane. The first nonwoven membrane is porous or fibrous and its surfaces comprise wall surfaces defining openings. The first hydrophobic material is disposed on the wall surfaces defining the openings without blocking or significantly restricting a substantial number of the openings. The surfaces of the first nonwoven membrane further comprise an upper surface facing the first outer fabric layer and a lower surface facing the first inner fabric layer, and the first hydrophobic material is disposed on one or more of the upper surface, the lower surface, and the wall surfaces defining the openings. The first hydrophobic material comprises fluorocarbon, wax, or silicone. The first hydrophobic material comprises the form of a porous coating, branches, or dots. The first nonwoven membrane comprises

interconnected fibers and the first hydrophobic material is disposed on surfaces of the interconnected fibers individually. The first nonwoven membrane having the first hydrophobic material disposed on its surfaces has a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm. The first hydrophobic material has a weight percentage of about 0.1% to about 10% of the first nonwoven membrane. The second nonwoven membrane has a second hydrophobic material disposed in its surfaces. The second nonwoven membrane is porous or fibrous and its surfaces comprise wall surfaces defining openings. The second hydrophobic material is disposed on the wall surfaces defining the openings of the second nonwoven membrane without blocking or significantly restricting a substantial number of the openings of the second nonwoven membrane. The surfaces of the second nonwoven membrane further comprise an upper surface facing the second outer fabric layer and a lower surface facing the second inner fabric layer, and the second

hydrophobic material is disposed on one or more of the upper surface of the second nonwoven membrane, the lower surface of the second nonwoven membrane, and the wall surfaces defining the openings of the second nonwoven membrane. The second nonwoven membrane having the second hydrophobic material disposed on its surfaces has a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm. The first and second hydrophobic materials are the same. The first and second hydrophobic materials are different. At least one of the first and second barrier layers comprises multiple nonwoven membrane layers.

In another aspect, the disclosure features a composite fabric that comprises an inner layer, an outer fabric layer, and a barrier layer disposed between the inner fabric layer and the outer fabric layer. The barrier layer comprises a nonwoven membrane having a hydrophobic material disposed on its surfaces.

Implementations of this aspect of the disclosure may include one or more of the following additional features. The nonwoven membrane is an electrospun membrane or a melt blown membrane. The nonwoven membrane is porous or fibrous and its surfaces comprise wall surfaces defining openings. The hydrophobic material is disposed on the wall surfaces defining the openings without blocking or significantly reducing a substantial number of the openings. The surfaces of the nonwoven membrane further comprise an upper surface facing the outer fabric layer and a lower surface facing the inner fabric layer, and the hydrophobic material is disposed on one or more of the upper surface, the lower surface, and the wall surfaces defining the openings. The hydrophobic material comprises a material having low surface tension. The hydrophobic material comprises fluorocarbon, wax, or silicone. The hydrophobic material comprises the form of a porous coating, branches, or dots. The nonwoven membrane comprises

interconnected fibers and the hydrophobic coating is disposed on surfaces of the interconnected fibers individually. The nonwoven membrane having the hydrophobic material disposed on its surfaces has a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm. The hydrophobic material has a weight percentage of about 0.1% to about 10% of the nonwoven membrane. The inner layer is an inner fabric layer. The inner layer is a nonwoven layer. The nonwoven layer is a melt blown membrane.

In another aspect, the disclosure features a method of forming a hybrid composite fabric garment. The method comprises forming a first fabric portion and a second fabric portion. Forming the first fabric portion comprises disposing a first barrier layer between a first inner fabric layer and a first outer fabric layer. The first barrier layer comprises a first nonwoven membrane having a first hydrophobic material disposed on its surfaces and has a first predetermined air permeability. Forming a second fabric portion comprises disposing a second barrier layer between a second inner fabric layer and a second outer fabric layer. The second barrier layer comprises a second nonwoven membrane having a second predetermined air permeability substantially greater than the first predetermined air permeability. The first and second fabric portions are joined together to form the hybrid composite fabric garment.

Implementations of this aspect of the disclosure may include one or more of the following additional features. The first nonwoven membrane is formed by

electrospinning or melt blowing. The electrospun or melt blown first nonwoven membrane comprises interconnected fibers and openings among the interconnected fibers. The first hydrophobic material is deposited onto the surfaces of the first nonwoven membrane without blocking or significantly restricting a substantial number of the openings. The first hydrophobic material is deposited using plasma technology in a chamber in a gas phase or in the form of an aerosol at an atmospheric pressure or at a pressure below the atmospheric pressure. Depositing the first hydrophobic material comprises depositing the first hydrophobic material on surfaces of the interconnected fibers of the nonwoven membrane individually. The first hydrophobic material is deposited after the formation of the first nonwoven membrane. The first hydrophobic material is deposited during the formation of the first nonwoven membrane. The first barrier layer further comprises additional nonwoven membranes and the first hydrophobic material is deposited after the first nonwoven membrane and the additional nonwoven membranes are stacked to form the first barrier layer. The second nonwoven membrane has a second hydrophobic material disposed on its surfaces. The second nonwoven membrane is formed by electrospinning or melt blowing. The electrospun or melt blown second nonwoven membrane comprises interconnected fibers and openings among the interconnected fibers. The second hydrophobic material is deposited onto surfaces of the second nonwoven membrane without blocking or significantly restricting a substantial number of the openings. The second hydrophobic material is deposited using plasma technology in a chamber in a gas phase or in the form of an aerosol at an atmospheric pressure or at a pressure below the atmospheric pressure. Depositing the second hydrophobic material comprises depositing the second hydrophobic material on surfaces of the interconnected fibers of the second nonwoven membrane individually. The second hydrophobic material is deposited after formation of the second nonwoven membrane. The second hydrophobic material is deposited during formation of the second nonwoven membrane. The second barrier layer further comprises additional nonwoven membranes and the method further comprises depositing the second hydrophobic material after the second nonwoven membrane and the additional nonwoven membranes are stacked to form the second barrier layer.

In another aspect, the disclosure features a nonwoven membrane for use in a fabric garment. The nonwoven membrane comprises a substrate defining surfaces rendered hydrophobic, or rendered relatively more hydrophobic. The substrate comprises interconnected fibers and openings among the interconnected fibers. The surfaces of the substrate comprise an upper surface, a lower surface, and wall surfaces defining the openings.

Implementations of this aspect of the disclosure may include one or more of the following additional features. A hydrophobic material is disposed on at least a portion of one or more of the upper surface, the lower surface, and the wall surfaces without blocking or significantly restricting a substantial number of the openings. The surfaces of the substrate having the hydrophobic material disposed thereon comprises a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm. The substrate comprises an electrospun substrate or a melt blown substrate. The substrate comprises a combination of two or more of electrospun substrates and melt blown substrates. The hydrophobic material is in the form of branches, dots, or a continuous coating with pores. The fibers have an average thickness of about 200 nm to about 1 ,000 nm. The openings form tortuous

interconnected, e.g. nano-sized or micron-sized, channels through the nonwoven membrane.

In another aspect, the disclosure features a method comprising providing a nonwoven substrate. The nonwoven substrate comprises interconnected fibers and openings among the interconnected fibers. The substrate defines surfaces comprising an upper surface, a lower surface, and wall surfaces defining the openings. The method also comprises rendering the surfaces of the substrate hydrophobic, or relatively more hydrophobic, without blocking or significantly restricting a substantial number of the openings.

Implementations of this aspect of the disclosure may include one or more of the following additional features. Rendering the surface of the substrate hydrophobic, or relatively more hydrophobic comprises depositing a hydrophobic material on at least a portion of one or more of the upper surface, the lower surface, and the wall surfaces of the substrate. The substrate is formed by electrospinning or melt blowing. The hydrophobic material is deposited using plasma technology in a chamber in a gas phase or in the form of an aerosol at an atmospheric pressure or at a pressure below the atmospheric pressure. Depositing the hydrophobic material comprises depositing the hydrophobic material on surfaces of the interconnected fibers of the nonwoven membrane individually. The hydrophobic material is deposited after formation of the substrate. The hydrophobic material is deposited during formation of the substrate. One or more additional nonwoven substrates are stacked with the nonwoven substrate, and the hydrophobic material is deposited after the additional nonwoven substrates and the nonwoven substrate are stacked. The substrate having the hydrophobic material deposited thereon is laminated between an inner fabric layer and an outer fabric layer. The substrate having the hydrophobic material deposited thereon has a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm. The nonwoven substrate comprises an electrospun membrane over a melt blown membrane, the electrospun membrane having the hydrophobic material deposited thereon. The substrate is laminated to a fabric layer such that the electrospun membrane is between the fabric layer and the melt blown membrane.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a front view of an example of a hybrid composite fabric garment.

FIG. 2 is a cross-sectional view of an example of a fabric laminate for use in a first fabric portion of the hybrid composite fabric garment of FIG. 1.

FIG. 3 is a cross-sectional view of an example of a fabric laminate for use in a second fabric portion of the hybrid composite fabric garment of FIG. 1.

FIG. 4A is a magnified plan view of a nonwoven nanofiber membrane.

FIG. 4B is a magnified cross-sectional view of a nonwoven nanofiber membrane.

FIG. 5 is a schematic view of an electrospinning process for fabricating a nonwoven nanofiber membrane.

FIG. 6 is schematic view of a melt blowing process for fabricating a nonwoven membrane.

FIG. 7A is a schematic top view of a nonwoven nanofiber membrane of this disclosure.

FIGS. 7B-7E are schematic side views of portions of nonwoven nanofiber membranes of this disclosure.

FIGS. 8-10 are schematic representations of systems for processing nonwoven membranes for use in composite fabrics.

FIG. 11 is a schematic cross-sectional view of an example of a fabric laminate for use in a hybrid composite fabric garment.

DETAILED DESCRIPTION

Referring to FIG. 1, a hybrid composite fabric garment 10 in the form of a jacket includes a first fabric portion 20 and a second fabric portion 40. The first fabric portion 20 is formed of a composite fabric (e.g., a laminate) that includes a first outer fabric layer and a first inner fabric layer, with a first barrier layer disposed therebetween. The first barrier layer includes a first membrane, e.g., a film membrane or a nonwoven membrane, e.g., an electrospun nonwoven and/or a melt blown nonwoven membrane. This construction is configured to provide a fabric laminate with high water resistance, e.g., between about 6,000 mm of water and about 15,000 mm of water (tested according to AATCC 127-2003 option 2), and good moisture vapor transmission rate (MVT), e.g., between about 2,000 grams per square meter per 24 hours (g/m /24 hrs) and about 6,000 grams per square meter per 24 hours (tested according to ASTM E-96, inverted cup). This construction is also configured to provide high resistance to the penetration of wind, with a very low air permeability, e.g., between about 0 ft³/ft²/min and about 2 ft³/ft²/min (tested according to ASTM D-737, under a pressure difference of ½ inch of water (125

3 2 3 2

Pa) across the first fabric portion) (between about O m /m /h and 58.6 m /m /h at 200 Pa). Reference is made to the complete disclosures of all the test methods listed herein, including but not limited to, e.g., AATCC 127-2003, ASTM E-96, and ASTM D-737.

The second fabric portion 40 is formed of a composite fabric that includes a second fabric outer layer and a second fabric inner layer, with a second barrier layer (e.g., a second membrane, e.g., a nonwoven membrane, e.g., an electrospun nonwoven and/or a melt blown nonwoven membrane) disposed therebetween. The second barrier layer is generally less water repellent, less wind resistant, and permits greater moisture vapor transmission than the nanofiber membrane of the first barrier layer. This construction can be configured to provide a fabric laminate with higher air permeability, e.g., between

3 2 3 2 *

about 3 ft /ft /min and about 20 ft /ft /min (tested according to ASTM D-737, under a pressure difference of ½ inch of water (125 Pa) across the second fabric portion)

3 2 3 2

(between about 87.9 m /m /h and 586 m /m /h at 200 Pa), low to medium water resistance, e.g., between about 500 mm of water and about 4,000 mm of water (tested according to AATCC 127-2003 option 2), and high moisture vapor transmission rate, e.g., between about 6,000 grams per square meter per 24 hours (g/m²/24 hrs) and about 12,000 grams per square meter per 24 hours (tested according to ASTM E-96, inverted cup). The fabric laminates of the first and second fabric portions 20, 40 are stitched together in a predetermined pattern to form the hybrid composite fabric garment 10. In the example illustrated in FIG. 1, the first fabric portion 20 is configured to cover an upper torso region of a wearer's body, e.g., upper chest and shoulders. The second fabric portion 40 is configured to cover a lower torso region of a wearer's body, e.g., a wearer's lower chest region and below. The seams of the garment may also be sealed to add additional protection against wind and water. For example, a thermoplastic film made of polyurethane can be used to tape the seams. This construction is configured to protect a wearer with a relatively high degree of resistance to liquid water and wind in regions of the garment that are relatively more likely to be exposed to wind and rain, while at the same time still providing for some degree of moisture vapor transmission in those regions. This construction also provides a relatively higher degree of water vapor transmission and air permeability in regions of the garment 10 that are relatively less likely to be exposed to wind and rain, and thus increase the comfort level of the wearer.

First Fabric Portion

Referring to FIGS. 1 and 2, as mentioned above, the first fabric portion 20 is formed of a first fabric laminate 21 including a first inner fabric layer 22, a first outer fabric layer 24, and a first barrier layer 26, positioned between and bonded to the first inner and first outer fabric layers. Due to the construction of the first fabric laminate 21 , the first fabric portion 20 is resistant to penetration by liquid water, e.g., rain, and wind, or is waterproof. For example, the first barrier layer 26 may permit only a relatively low

3 2 3 2 * volume of air flow, e.g., in the range of between about 0 ft /ft /min and about 2 ft /ft /min (tested according to ASTM D-737, under a pressure difference of ½ inch of water (125

3 2 3 2

Pa) across the first barrier layer 26) (between about 90 m /m /h and 58.6 m /m /h at 200 Pa) for enhanced thermal insulation performance in windy conditions. In some implementations, the first barrier layer 26 can have a water column of about 12, 000 mm.

Referring to FIG. 2, the first inner fabric layer 22 has a woven or knit construction (e.g., single jersey knit, plated single jersey knit, double knit, tricot knit, and/or terry sinker loop knit). The first inner fabric layer 22 includes a first surface 27, which faces a wearer's body B during use, and second surface 28, which is bonded to the first barrier layer 26. The first surface 27 can be raised and/or brushed for enhanced user comfort, e.g., softer to touch and enhanced water management.

The first inner fabric layer 22 is designed to wick away moisture, e.g., perspiration, and minimize heat loss. During use, perspiration generated by the user is pulled through the first inner fabric layer 22 and allowed to escape, e.g., as vapor, through the first barrier layer 26 and the first outer fabric layer 24. In some cases, for example, the first inner fabric layer 22 may be formed from a moisture wicking fabric. Alternatively or additionally, the first inner fabric layer 22 may be formed from a material that is rendered hydrophilic to promote wicking of moisture. As a result, liquid moisture, e.g., sweat, is transported away from the wearer's body and toward an outer surface 30 of the garment.

Referring still to FIG. 2, the first outer fabric layer 24 may be a woven material. In some cases, the first outer fabric layer 24 may have stretch in at least one direction, e.g., one-way or two-way stretch. In some examples, the first outer fabric layer 24 may be formed from a low stretch or no stretch fabric. In some cases, the first outer fabric layer 24 is treated with a durable water repellent, thereby inhibiting the transport of liquid water from the outer surface 30 toward an inner surface 27 of the garment 10.

As mentioned above, the first barrier layer 26 is positioned between the first inner and first outer fabric layers 22, 24. The first barrier layer 26 allows water vapor, e.g., a wearer's body humidity, to pass through, but at the same time serves as a liquid barrier that blocks air and liquid water from passing inwardly through the first barrier layer 26 toward the wearer's body B.

The first barrier layer 26 has a weight of between about 4 grams per square meter and about 7 grams per square meter, a thickness of between about 1 micrometer and about 50 micrometers, and an air permeability in the range of between about 0 ft /ft /min and about 2 ft³/ft²/min, under a pressure difference of ½ inch of water (125 Pa) (ASTM D-737) (between about 0 m³/m²/h and 58.6 m³/m²/h at 200 Pa). In some

implementations, the first barrier layer 26 has a weight of about 10 grams per square meter or higher, e.g., about 12 grams per square meter. The barrier layer 26, being relatively heavier, can maintain high water resistance for a long period of time, e.g., after repeated home laundering. Referring again to FIG. 2, first and second adhesive layers 23, 25 secure the first barrier layer 26 to opposed sides of the first inner fabric layer 22 and the first outer fabric layer 24. The first and second adhesive layers 23, 25 can be applied to the opposed surfaces of the first inner and first outer fabric layers 22, 24 and/or to the first barrier layer 26 before joining the layers together. The first adhesive layer 23 is positioned between the first barrier layer 26 and the first outer fabric layer 24 to adhere the first barrier layer 26 to the first outer fabric layer 24. Similarly, the second adhesive layer 25 is positioned between the first barrier layer 26 and the first inner fabric layer 22 for adhering the first barrier layer 26 to the first inner fabric layer 22. The first and second adhesive layers 23, 25 are applied is such a manner as to avoid restriction of the moisture vapor transmission and/or air permeability of the first barrier layer 26. For example, the first and second adhesive layers 23, 25 can be applied in a dot coating pattern. The first and second adhesive layers 23, 25 can be applied, e.g., with rotary printing and/or gravure rolling.

Second Fabric Portion

As discussed above, the second fabric portion 40 of the example hybrid composite fabric garment 10 is constructed to provide a relatively higher level of air permeability as compared to the first fabric portion 20. The second fabric portion 40 is arranged in regions of the hybrid composite fabric garment 10 that are less likely (relative to the first fabric portion 20) to be exposed, in use, to wind and rain, and it is constructed in such a manner as to provide high breathability and air permeability to provide increased comfort for the wearer.

As shown in FIG. 3, and as discussed above, the second fabric portion 40 is formed of a second laminate 41 consisting of a second inner fabric layer 42, a second outer fabric layer 44, and a second barrier layer 46 (e.g., an electrospun membrane and/or a melt blown membrane) disposed therebetween. During use, liquid moisture, e.g., sweat, is absorbed by the second inner fabric layer 42 and transported through the second barrier layer 46 and the second outer fabric layer 44, e.g., in vapor form. The

construction of the second fabric portion 40 also permits air (e.g., wind) to penetrate through the fabric towards a wearer's body, e.g., for cooling. The second inner fabric layer 42 is similar to the first inner fabric layer 22, as described above with regard to FIG. 2. In particular, the second inner fabric layer 42 has a woven or knit construction (e.g., single jersey knit, plated single jersey knit, double knit, tricot knit, and/or terry sinker loop knit). The second inner fabric layer 42 includes a first surface 47, which faces a wearer's body B during use, and second surface 48, which is bonded to the second barrier layer 46. The first surface 47 can be raised and/or brushed for enhanced user comfort, e.g., softer to touch and enhanced moisture absorption.

The second inner fabric layer 42 is formed from a moisture wicking fabric and/or a material that is rendered hydrophilic to promote wicking of moisture. As a result, liquid moisture, e.g., sweat, is transported away from the wearer's body and toward the second barrier layer 46.

The second outer fabric layer 44 is similar to the first outer fabric layer 24. The second outer fabric layer 44 is a woven material. As with the first outer fabric layer 24, the second outer fabric layer 44 may also be treated with a durable water repellent to inhibit the movement of liquid water from an outer surface 50 of the second fabric portion 40 toward the inner surface 47 of the garment 10.

The barrier layer 46 of the second fabric portion 40 has a lower water resistance, higher moisture vapor transmission rate, and higher air permeability properties as compared to the first barrier layer 26. In some implementations, the barrier layer 46 has a water column of about 5,000 mm to about 8,000 mm. The second barrier layer 46 has a weight of between about 2 grams per square meter and about 3 grams per square meter, a thickness of between about 1 micrometer and about 50 micrometers, and an air permeability in the range of between about 3 ft³/ft²/min and about 20 ft³/ft²/min (ASTM D-737, under a pressure difference of ½ inch of water (125 Pa) across the membrane)

(between about 87.9 m /m²/h and 586 m³/m²/h at 200 Pa). In some implementations, the second barrier 46 has a weight of about 4 grams per square meter or higher, e.g., 5 grams per square meter. A relatively heavier second barrier 46 can maintain its water resistance property for a long period of time, e.g., after repeated home laundering. Due at least in part to the construction of the second barrier layer 46, air is permitted to penetrate more easily through the second fabric portion 40 for cooling and providing direct evaporation of liquid moisture, e.g., sweat, from the wearer's body.

Referring still to FIG. 3, the second barrier layer 46 is bound to the second inner and second outer fabric layers 42, 44 with first and second adhesive layers 43, 45. The first adhesive layer 43 is positioned between the second barrier layer 46 and the second outer fabric layer 44 for adhering the second barrier layer 46 to the second outer fabric layer 44. Similarly, the second adhesive layer 45 is positioned between the second barrier layer 46 and the second inner fabric layer 42 for adhering the second barrier layer 46 to the second inner fabric layer 42. The adhesive layers 43, 45 of the second fabric portion 40 are applied in a manner to substantially avoid restriction of moisture vapor transmission and/or air permeability of the second barrier layer 46.

Barrier Layers

The first and/or second barrier layers 26, 46 can include one or more electrospun membrane layers, e.g., one or more electrospun nanofiber membranes such as those commercially available from Finetex Technology, Inc. of Hudson, New Hampshire. For example, FIGS. 4 A and 4B show an electrospun nanofiber membrane 60 that is suitable for use with either or both of the first and second barrier layers 22, 46. As shown in FIGS. 4A and 4B, the electrospun nanofiber membrane 60 includes a plurality of intermingled nanofibers 62 with small pores 64 therebetween. The nanofibers 62 are polymer fibers, e.g., nylon, polyurethane, and/or other synthetic fibers, having fiber diameters in the range of between about 50 nanometers and about 1,000 nanometers. This fibrous and porous structure provides the nanofiber membrane with wind and water resistant, and with vapor permeability properties. The intricate pores 64 of the membrane 60 are sufficiently large enough to allow moisture vapor generated by the wearer's body to escape, yet are small enough to restrict the smallest droplets of water from penetrating the membrane and reaching the wearer's body.

The electrospinning process allows for fine control over the air permeability, water vapor transmission, and water resistance of the nanofiber membrane 60. As illustrated briefly in FIG. 5, in the electrospinning process 70, a polymer solution or melt is pumped from a source 72 to a nanofiber nozzle 73 where a high electrical voltage is applied to the solution or melt (e.g., via a first electrode 74). A jet 75 of the solution or melt is drawn towards a grounded source, e.g., a rotating drum 76, thereby producing a nano sized fiber. Multiple nanofiber nozzles can be run simultaneous to produce a nano- nonwoven membrane. The nanofibers are collected on the rotating drum 76 to produce a continuous nonwoven membrane. Process controls allow for a great deal of command over pore size, thickness, and fiber diameter, thereby allowing for control over air permeability and water repellency properties of the non-woven membrane.

The electrospun nanofiber membranes can have a weight in the range of between about 2 grams per square meter and about 7 grams per square meter, or more, a thickness of between about 1 micrometer and about 50 micrometers, and an air permeability in the

3 2 ^ 2

range of between about 0 ft /ft /min and about 20 ft /ft /min (ASTM D-737, under a pressure difference of ½ inch of water (125 Pa) across the membrane) (between about 0

3 2 3 2

m /m /h and 586 m /m /h at 200 Pa).

Alternatively or additionally, either or both of the first and/or second barrier layers 26, 46 can include one or more melt blown membrane layers. As shown, for example, in FIG. 6, a melt blown nonwoven membrane 80 can be formed by extruding a molten polymer through a die 90 then attenuating and breaking extruded filaments 91 with hot, high-velocity air 92 to form fibers 93, e.g., having a diameter of between about 500 nanometers and about 2,000 nanometers and a length of a few centimeters. The fibers 93 are collected on a moving screen 94 where they bond during cooling. The melt

3 2

blown membrane 80 can have a permeability of between about 10 ft /ft /min and about 70 ft /ft²/min (tested according to ASTM D-737, under a pressure difference of ½ inch of

3 2

water (125 Pa) across the first fabric portion) (between about 293 m /m /h and 2,050 m³/m²/h at 200 Pa).

The different features of the first and second barrier layers 26, 46 can be obtained, e.g., by controlling materials and processes used in forming the membranes, or other factors. For example, one or more nanofiber membranes used for the first barrier layer 26 having a relatively high water resistance, e.g., may be waterproof, or formed of nanofibers having a relatively small diameter, e.g., about 200 nm to about 400 nm or about 300 nm. One or more nanofiber membranes used for the second layer 46 having a relatively low water resistance may be formed of nanofibers having a relatively large diameter, e.g., about 400 nm to about 600 nm or about 500 nm. The first barrier layer 26 can have a relatively higher weight, e.g., about 12 grams per square meter, as compared to the second barrier layer 46, e.g., about 5 grams per square meter, and can have a relatively higher water resistance, e.g., of about 12,000 mm water column, as compared to the water resistance, e.g., of about 5,000 to about 8,000 mm water column, of the second barrier layer 46.

In some implementations, the nanofiber membranes used in the first barrier layer 26 and/or in the second barrier layer 46 of FIGS. 2 and 3 are processed to reduce the surface energy, e.g. after the membranes are made using the methods described previously (e.g., FIGS. 5-6), or other methods, and before the membranes are

incorporated into the first and second fabric portions 20, 40. In particular, one or more surfaces of the nanofiber membrane(s) is rendered hydrophobic, or rendered relatively more hydrophobic, e.g., by reduction of the surface energy reduction of the nanofiber membrane(s) in the first and second barrier layers 26, 46. The surface(s) of the nanofiber membranes rendered hydrophobic, or rendered relatively more hydrophobic, can increase the water resistance of the membrane(s) and thereby reduce the amount of nanofibers necessary for achieving the desired level of performance in the first and second barrier layers 26, 46. The first and second barrier layers 26, 46 can thus be made with reduced costs, while maintaining garment performance and reducing garment weight.

Referring to FIG. 7A, a nanofiber membrane 700 may include electrospun and/or melt blown, e.g., extruded, fibers 702 defining openings (or pores) 704 among the fibers 702. The openings 704 are tortuous, and can be nano-sized or micro-sized. Multiple openings 704 are interconnected within the nanofiber membrane 700, forming channels for air and water vapor to pass the membrane 700. The fibers are coated, e.g., mdividually coated, with a hydrophobic material 706, such as fluorocarbon, wax, silicon, or others, with or without additives, such as cross-linking agents, bonding agents, silane, and etc. The hydrophobic material 706 does not block a substantial number of openings 704 so that the substantial number of channels in the membrane 702 remains unblocked, e.g., for air and/or vapor passage. Referring also to FIG. 7B, the hydrophobic material 706 can be coated on an upper surface 708 of the fiber 702 or on an upper surface of the nanofiber membrane 700 to face the first or second outer fabric layer (e.g., the outer fabric layers 24, 44), and/or on a lower surface 710 of the fiber 702 or a lower surface of the nanofiber membrane 700 to face the first or second inner fabric layer (e.g., the inner fabric layers 22, 42), and walls 712 that defines the openings 704. In some

implementations, referring to FIGS. 7A and 7C, the hydrophobic material 706 may only cover the wall 712 of the opening 704, without substantially covering or being over the upper and the lower surfaces of the fiber 702 or the nanofiber membrane 700.

Alternatively, referring to FIGS. 7 A and 7C, the hydrophobic material 706 may cover the upper and/or lower surfaces 708, 710 of the fiber or the nanofiber membrane 700.

Alternatively, referring to FIG. 7E, the hydrophobic material may be over one or both (not shown) of the upper and lower surfaces 708, 710 of the fiber 706 or the membrane formed of the fibers 706. The walls 712 defining the openings 704 are preferably substantially free of the hydrophobic material 706. The hydrophobic material 706 can also be included in the nanofiber membrane 700 by other methods.

The nanofiber membrane 700 coated with the hydrophobic material 706 maintains desired levels of wind and water resistant and vapor permeability properties, e.g. as discussed for the membrane 60 of FIGS. 4 A and 4B. In particular, the hydrophobic material 706 on the walls 712 of the openings 704 serves to reduce the sizes of the openings without blocking a substantial or significant number of openings so that the nanofiber membrane 700 maintains its fibrous and/or porous structure. The hydrophobic material 706 facilitates, e.g., enhances, the water resistant and vapor permeability properties with controlled air permeability of the nanofiber membrane 700. For example, water is not attracted to, e.g., expelled from, the surfaces and the openings 704 of the nanofiber membrane 700 so that water does not pass into or through the membrane 700 readily. For example, water contacting the hydrophobic material 706 of the membrane 700 has a large contact angle and, as a result, does not readily spread on or through the membrane. (A reduced portion of the vapor may still pass the membrane without contacting the membrane.)

In some implementations, in order to provide desired wind and water resistant and vapor permeability properties, inclusion of hydrophobic material 706 allows use of a relatively reduced amount of nanofibers in the nanofiber membrane 700, e.g. as compared to a nanofiber membrane that does not include the hydrophobic material 706. For example, to achieve the level of properties, e.g., water resistance, vapor permeability, wind resistance and/or air permeability, provided by a nanofiber membrane of this disclosure, the nanofiber membrane treated with hydrophobic material can have a weight reduction of about 0.5 grams per square meter to about 3 grams per square meter compared to a nanofiber membrane of similar construction but without treatment with hydrophobic material. In some implementations, a relatively smaller number of nanofiber membranes 700 may be required in the barrier layers (e.g., barrier layers 26, 46 of FIGS. 2 and 3) as compared to the required number of barrier layers including nanofiber membranes without the hydrophobic material 706. A garment including the nanofiber membrane 700 with a relatively lighter weight can provide use for a long time, e.g., after repeated home laundering. The reduction in weight and volume of nanofibers can reduce the cost for manufacture of the nanofiber membrane and the resulting composite fabric garment (e.g., the garment 10 of FIG. 1) using the membrane. The lighter-weight membrane and the fabric garment can also provide enhanced comfort and reduced fatigue to a wearer of the garment.

The nanofiber membrane configurations of FIGS. 7A-7E can be selected based on the performance features desired for the nanofiber membrane 700. For example, when the nanofiber membrane 700 is to be included in the first fabric portion 20 of FIG. 2 having relatively high water resistance, e.g., the membrane is to be waterproof, the configuration of FIG. 7B and or 7D can be selected to provide a membrane 700 that is highly hydrophobic, e.g., water repellant. The nanofiber membrane 700 for use in the second fabric portion 40 can include relatively less hydrophobic material as compared to the nanofiber membrane 700 for use in the first fabric portion 20. In another example, the nanofiber membrane 700 has the hydrophobic material 706 applied on its outer surface 708 so that the inner surface 710 can absorb water vapor, e.g., sweat, from the first or second inner fabric layer of the first or second fabric portion to facilitate evaporation of the wearer's sweat. The hydrophobic material 706 on the outer surface 708 can restrict or repel water, e.g., rain, from the external environment of the wearer from penetrating the membrane.

The hydrophobic material 706 of the membrane 700 can have different forms. For example, the hydrophobic material 706 can be a continuous porous coating or can be in the form of discontinuous branches, nanobranches, dots, nanodots, or other patterns. The particular forms of the hydrophobic material 706 can be chosen, e.g., based on the desired properties of the nanofiber membrane, and/or the methods and materials used for including the hydrophobic material 706 in the membrane 700. In some implementations, the hydrophobic material covers about 25% to about 100% of the surface area (including the area of the openings or pores 704) of the upper surface and/or the lower surface of the membrane 700. The hydrophobic material 706 can have a fine thickness that does not block a substantial number of openings and keeps a substantial number of air channels (e.g., formed by interconnected openings) through the membrane 700 open. The hydrophobic material 706 can weight about 0.1% to about 10% of the entire membrane 700.

A membrane including hydrophobic material, such as the membrane 700, can be made using various methods. In some implementations, the membrane formed by an electrospinning process (such as the process described in FIG. 5) or by a melt blown process (such as the process described in FIG. 6), e.g., an extrusion process, is coated with the hydrophobic material using nano-coating technologies, e.g., plasma technology or using a pulsed, ionized gas plasma created within a chamber at room temperature. Suitable technologies can include those provided by P2i Ltd. (Milton Park, UK). For example, the hydrophobic material can be introduced in the chamber in a gas phase or in the form of an aerosol at an atmospheric pressure or at a pressure below the atmospheric pressure, e.g., in vacuum. The hydrophobic material coating can be thin, e.g., having a nanometer thickness. Other deposition methods, such as a plasma enhanced chemical vapor (CVD) deposition process, atomic layer deposition, pulsed laser deposition, spin coating, and/or printing can be used. The process of depositing the hydrophobic material can be performed in the same chamber in which the nanofiber membrane is formed, e.g., using electrospinning or extrusion. In some implementations, the electrospun or melt blown nanofiber membrane may be removed from the system in which the membrane is formed and placed into the chamber for depositing the hydrophobic material.

In some implementations, the hydrophobic material in the nanofiber membrane can be deposited onto the nanofiber membrane during the formation of, e.g., during electrospinning or extrusion of, the nanofiber membrane. For example, while the nanofibers are being collected on the rotating drum 76 of FIG. 5, the hydrophobic material may be deposited onto the nanofibers collected on rotating drum. In another example, while the fibers 93 are collected on a moving screen 94 of FIG. 6, the hydrophobic material may be deposited onto the fibers 93. In other implementations, the source 72 for the nanofibers can include a mixture of one or more fiber materials and the hydrophobic material. The hydrophobic material can also be deposited onto the nanofiber membrane at other times (e.g., see discussion below).

Referring next to FIG. 8, prior to lamination with the respective fabric layers, the first and/or second barrier layers 26, 46 can be compressed by calender 100 (hot roll) and/or an adhesive may be applied to the barrier layer 26, 46 to form a suitable bond between the very fine fibers, and/or to control consistency of the barrier layer 26, 46 as well as maintaining its integrity in usage and after repeated laundering. As shown in FIG. 8, in calendering operation, the barrier layer 26, 46 is through the nip of a pair of heated rolls 102 under pressure. In some implementation, the hydrophobic material, e.g., the hydrophobic material 706 of FIGS. 7A-7E, is deposited onto the nanofiber membrane in a plasma application before or after the calendaring operation.

Referring to FIG. 9, in some cases, the first and/or second barrier layer 26, 46 may include two or more membrane layers 60, 80 (e.g., melt blown and/or electrospun membrane layers) or one or more membrane layers 700. For illustrative purposes, one electrospun membrane with (e.g., the membrane 700) or without the hydrophobic material (e.g., the membrane 60) and one melt blown membrane with (e.g., the membrane 700) or without the hydrophobic material (e.g., the membrane 80) are shown in FIG. 9. As illustrated in FIG. 9, the membrane layers 120 can be stacked on top of each other and then pressed together under heat and pressure (e.g., calendering), for enhanced integrity bonding between the membrane layers 60/700, 80/700. To further enhance bond strength between the membrane layers 60/700, 80/700, an adhesive 110, e.g., a thermosetting or thermoplastic adhesive, can be applied between the membrane layers 60/700, 80/700 prior to calendering. In this manner, multiple membrane layers 60/700, 80/700 can be selectively stacked together in order to provide a single nonwoven membrane 120. The stacking of the individual membrane layers provides for precision control of the air permeability of the nonwoven membrane 120. Referring to FIG. 10, in some embodiments, a melt blown nonwoven membrane with (e.g., the membrane 700) or without the hydrophobic material (e.g., the membrane 80) (e.g., one or more melt blow nonwoven membrane layers) can be used as a carrier on which an electrospun membrane with (e.g., the membrane 700) or without the hydrophobic material (e.g., the membrane 60) can be deposited as it is produced to form a combined melt blown-electrospun membrane 130. The combined melt blown- electrospun membrane 130 can then compressed by calendar 100.

In some implementations, the hydrophobic material 706 of FIGS. 7A-7E is not loaded onto the nanofiber membrane. Instead, the hydrophobic material is loaded onto the barrier layers 26, 46 formed or processed using methods described for FIGS. 8-10. For example, when the barrier layers 26, 46 include multiple nanofiber membranes, it may be unnecessary or undesirable to load the hydrophobic material onto each individual membrane. The method of loading the hydrophobic material onto the barrier layers can be similar to, e.g., the same as, the methods for depositing the hydrophobic material onto the nanofiber membranes. Similar to the nanofiber membrane carrying a hydrophobic material, the barrier layers loaded with the hydrophobic material in such a manner also have enhanced water resistance, wind resistance, and vapor permeability properties. The barrier layers can include fewer layers of nanofiber membranes and therefore be relatively lighter, while providing longer-term water resistant properties.

Referring to FIG. 11, a laminate 1100 is formed by laminating fabric layer 1102 and nonwoven layers 1104, 1106. In some implementations, the nonwoven layer 1104 between the fabric layer 1102 includes one or more electrospun membranes having a hydrophobic material disposed thereon, e.g., the nanofiber membranes 700 of FIGS. 7A- 7E. The nonwoven layer 1106 can include one or more melt blown membranes with or without a hydrophobic material. In some implementations, the nonwoven layers 1104, 1106 each has features similar to those of single or stacked membranes 700 of FIGS. 7A- 7E. The fabric layer 1102 can have features similar to the first outer fabric 22 of FIG. 2 or the second outer fabric layer 42 of FIG. 3. In some implementations, the nonwoven layers 1104, 1106 are formed using the methods described for FIG. 10, e.g., before being laminated with the fabric layer 1102. The laminate 1100 provides features, e.g., water resistance, wind resistance, vapor permeability, air permeability, and/or others, similar to those features of first fabric portion 20 of FIG. 2 or second fabric portion 40 of FIG. 3, and can be used in a garment similarly. Desired features of the laminate 1100 can be obtained by controlling the properties, e.g., weight, porosity, hydrophobicity, and/or others, of the layers 1102, 1104, 1106. For example, the nonwoven layer 1104 or the combined nonwoven layers 1104, 1106 can have features similar to the first or second barrier layer 26, 46 of FIGS. 2 and 3. The laminate 1100 is used in the garment 10 without the need for additional layers, such as the first and second inner fabric layers 22, 42 of FIGS. 2 and 3, or additional layers made of a textile fabric, e.g., a knitted fabric, a woven fabric, or a tricot fabric. The fabric layer 1102 serves as an outer layer that faces the external environment and the nonwoven layer 1106 faces the body of a wearer. The nonwoven layer 1106 can protect the nonwoven layer 1104, e.g., containing one or more membranes 700 of FIGS. 7A-7E, from abrasion.

A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, in some embodiments, the first barrier layer 26 is formed from a film membrane, e.g., polyurethane or polytetrafluoroethylene (PTFE) film, having very low, e.g., between about 0 ft³/ft²/min and about 2 ft³/ft²/min, tested according to ASTM D-737 under a pressure difference of ½ inch of water (125 Pa) across the film membrane (between about 0 m³/m²/h and 58.6 m³/m²/h at 200 Pa).

The pattern designs of the first and second fabric portions of the hybrid composite fabric garments are not limited to the particular combinations shown in the figures and described above. Rather, a wide variety of different patterns can be employed in order to achieve the desired results. For example, in other embodiments, the first fabric portion may completely cover the surface of the fabric garment except in high perspiration portions of the body, e.g., under the arms. More extensive coverage by the first fabric portion can provide a hybrid garment which offers enhanced resistance in extremely wet and/or windy environments.

In some embodiments, the inner fabric layers of the first and/or second fabric portions may be finished with raised surfaces in a three-dimensional pattern with raised regions separated by channels, such as grid, box, etc., selected to generate a channeling effect, e.g. as described in U.S. Pat No. 6,927,182, issued August 9, 2005. Such a pattern formed along the inner fabric layers facilitates maintaining a cushion of air along the wearer's body for added warmth during static physical conditions and enhanced air flow during physical activity, thereby creating a heat dissipating or cooling effect.

In some implementations, the first and/or second fabric portions of the hybrid composite fabric garments may be provided with one-way or two-way stretch, e.g., by incorporation of spandex material in one or more of the outer and/or inner fabric layers.

In some embodiments, the first and/or second nanofiber membrane can have good stretch and recovery properties or very low (e.g., almost none).

In some implementations the hybrid fabric composite garment may include, e.g., formed from, flame retardant fibers or fiber blends. For example, either or both of the first and second fabric portions can include flame retardant fibers or flame retardant fiber blends. The flame retardant fibers can be on both sides (i.e., inner and outer surfaces) of the fabric garment, or just on the outside (i.e., the first and/or second outer fabric layers), or just the inside (i.e., the first and/or second inner layers).

In some cases, the first and/or second outer fabric layer(s) is chemically treated to improve water repellence and/or to enhance abrasion resistance.

Furthermore, although one specific example of a hybrid composite fabric garment in the form of a jacket has been described above, it should be noted that the fabric laminate constructions described herein may also be applied to fabric garments of any of the various types of clothing articles, including, but not limited to, coats, shells, pullovers, vests, shirts, pants, etc.

Accordingly, other implementations are within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:

1. A hybrid composite fabric garment, comprising:

a first fabric portion comprising:

a first inner fabric layer;

a first outer fabric layer; and

a first barrier layer disposed between the first inner fabric layer and the first outer fabric layer, said first barrier layer comprising a first nonwoven membrane having a first hydrophobic material disposed on its surfaces and having a first predetermined air permeability; and

a second fabric portion comprising:

a second inner fabric layer;

a second outer fabric layer; and

a second barrier layer disposed between the second inner fabric layer and the second outer fabric layer and comprising a second nonwoven membrane, wherein the second barrier layer has a second predetermined air permeability substantially greater than the first predetermined air permeability.

2. The hybrid composite fabric garment of claim 1, wherein at least one of first and second nonwoven membranes comprises an electrospun membrane or a melt blown membrane.

3. The hybrid composite fabric garment of claim 1 , wherein the first nonwoven membrane is porous or fibrous and its surfaces comprise wall surfaces defining openings.

4. The hybrid composite fabric garment of claim 3, wherein the first hydrophobic material is disposed on the wall surfaces defining the openings without blocking or significantly restricting a substantial number of the openings.

5. The hybrid composite fabric garment of claim 3, wherein the surfaces of the first nonwoven membrane further comprise an upper surface facing the first outer fabric layer and a lower surface facing the first inner fabric layer, and the first hydrophobic material is disposed on one or more of the upper surface, the lower surface, and the wall surfaces defining the openings.

6. The hybrid composite fabric garment of claim 1 , wherein the first hydrophobic material comprises fluorocarbon, wax, or silicone.

7. The hybrid composite fabric garment of claim 1, wherein the first hydrophobic material comprises the form of a porous coating, branches, or dots.

8. The hybrid composite fabric garment of claim 1 , wherein the first nonwoven membrane comprises interconnected fibers and the first hydrophobic material is disposed on surfaces of the interconnected fibers individually.

9. The hybrid composite fabric garment of claim 1 , wherein the first nonwoven membrane having the first hydrophobic material disposed on its surfaces has a weight of about 1 grams per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm.

10. The hybrid composite fabric garment of claim 9, wherein the first hydrophobic material has a weight percentage of about 0.1% to about 10% of the first nonwoven membrane.

11. The hybrid composite fabric garment of claim 1 , wherein the second nonwoven membrane has a second hydrophobic material disposed in its surfaces.

12. The hybrid composite fabric garment of claim 11 , wherein the second nonwoven membrane is porous or fibrous and its surfaces comprise wall surfaces defining openings.

13. The hybrid composite fabric garment of claim 12, wherein the second

hydrophobic material is disposed on the wall surfaces defining the openings of the second nonwoven membrane without blocking or significantly restricting a substantial number of the openings of the second nonwoven membrane.

14. The hybrid composite fabric garment of claim 13, wherein the surfaces of the second nonwoven membrane further comprise an upper surface facing the second outer fabric layer and a lower surface facing the second inner fabric layer, and the second hydrophobic material is disposed on one or more of the upper surface of the second nonwoven membrane, the lower surface of the second nonwoven membrane, and the wall surfaces defining the openings of the second nonwoven membrane.

15. The hybrid composite fabric garment of claim 11, wherein the second nonwoven membrane having the second hydrophobic material disposed on its surfaces has a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm.

16. The hybrid composite fabric garment of claim 11 , wherein the first and second hydrophobic materials are the same.

17. The hybrid composite fabric garment of claim 11 , wherein the first and second hydrophobic materials are different.

18. The hybrid composite fabric garment of claim 1, wherein at least one of the first and second barrier layers comprises multiple nonwoven membrane layers.

19. A composite fabric, comprising:

an inner layer;

an outer fabric layer; and

a barrier layer disposed between the inner layer and the outer fabric layer, the barrier layer comprising a nonwoven membrane having a hydrophobic material disposed on its surfaces.

20. The composite fabric of claim 19, wherein the nonwoven membrane is an electrospun membrane or a melt blown membrane.

21. The composite fabric of claim 19, wherein the nonwoven membrane is porous or fibrous and its surfaces comprise wall surfaces defining openings.

22. The composite fabric of claim 21 , wherein the hydrophobic material is disposed on the wall surfaces defining the openings without blocking or significantly reducing a substantial number of the openings.

23. The composite fabric of claim 21 , wherein the surfaces of the nonwoven membrane further comprise an upper surface facing the outer fabric layer and a lower surface facing the inner layer, and the hydrophobic material is disposed on one or more of the upper surface, the lower surface, and the wall surfaces defining the openings.

24. The composite fabric of claim 19, wherein the hydrophobic material comprises a material having low surface tension.

25. The composite fabric of claim 24, wherein the hydrophobic material comprises fluorocarbon, wax, or silicone.

26. The composite fabric of claim 19, wherein the hydrophobic material comprises the form of a porous coating, branches, or dots.

27. The composite fabric of claim 19, wherein the nonwoven membrane comprises interconnected fibers and the hydrophobic coating is disposed on surfaces of the interconnected fibers individually.

28. The composite fabric of claim 19, wherein the nonwoven membrane having the hydrophobic material disposed on its surfaces has a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm.

29. The composite fabric of claim 28, wherein the hydrophobic material has a weight percentage of about 0.1% to about 10% of the nonwoven membrane.

30. The composite fabric of claim 19, wherein the inner layer is an inner fabric layer.

31. The composite fabric of claim 19, wherein the inner layer is a nonwoven layer.

32. The composite fabric of claim 31 , wherein the nonwoven layer is a melt blown membrane.

33. A method of forming a hybrid composite fabric garment, the method comprising: forming a first fabric portion comprising:

disposing a first barrier layer comprising a first nonwoven membrane having a first hydrophobic material disposed on its surfaces and having a first predetermined air permeability between a first inner fabric layer and a first outer fabric layer;

forming a second fabric portion comprising:

disposing a second barrier layer comprising a second nonwoven membrane having a second predetermined air permeability substantially greater than the first predetermined air permeability between a second inner fabric layer and a second outer fabric layer; and

joining together the first and second fabric portions to form the hybrid composite fabric garment.

34. The method of claim 33, further comprising forming the first nonwoven membrane by electrospinning or melt blowing.

35. The method of claim 34, wherein the electrospun or melt blown first nonwoven membrane comprises interconnected fibers and openings among the interconnected fibers, and the method further comprising depositing the first hydrophobic material onto the surfaces of the first nonwoven membrane without blocking or significantly restricting a substantial number of the openings.

36. The method of claim 35, wherein the first hydrophobic material is deposited using plasma technology in a chamber in a gas phase or in the form of an aerosol at an atmospheric pressure or at a pressure below the atmospheric pressure.

37. The method of claim 36, wherein depositing the first hydrophobic material comprises depositing the first hydrophobic material on surfaces of the interconnected fibers of the nonwoven membrane individually.

38. The method of claim 33, wherein the first hydrophobic material is deposited after the formation of the first nonwoven membrane.

39. The method of claim 33, wherein the first hydrophobic material is deposited during the formation of the first nonwoven membrane.

40. The method of claim 33, wherein the first barrier layer further comprises additional nonwoven membranes and the first hydrophobic material is deposited after the first nonwoven membrane and the additional nonwoven membranes are stacked to form the first barrier layer.

41. The method of claim 33, wherein the second nonwoven membrane has a second hydrophobic material disposed on its surfaces.

42. The method of claim 41 , further comprising forming the second nonwoven membrane by electrospinning or melt blowing.

43. The method of claim 42, wherein the electrospun or melt blown second nonwoven membrane comprises interconnected fibers and openings among the interconnected fibers, and the method further comprising depositing the second hydrophobic material onto surfaces of the second nonwoven membrane without blocking or significantly restricting a substantial number of the openings.

44. The method of claim 43, wherein the second hydrophobic material is deposited using plasma technology in a chamber in a gas phase or in the form of an aerosol at an atmospheric pressure or at a pressure below the atmospheric pressure.

45. The method of claim 44, wherein depositing the second hydrophobic material comprises depositing the second hydrophobic material on surfaces of the interconnected fibers of the second nonwoven membrane individually.

46. The method of claim 41 , comprising depositing the second hydrophobic material after formation of the second nonwoven membrane.

47. The method of claim 41 , comprising depositing the second hydrophobic material during formation of the second nonwoven membrane.

48. The method of claim 41 , wherein the second barrier layer further comprises additional nonwoven membranes and the method further comprises depositing the second hydrophobic material after the second nonwoven membrane and the additional nonwoven membranes are stacked to form the second barrier layer.

49. A nonwoven membrane for use in a fabric garment, the nonwoven membrane comprises:

a substrate defining surfaces rendered hydrophobic, or rendered relatively more hydrophobic, and comprising interconnected fibers and openings among the

interconnected fibers, the surfaces of the substrate comprising an upper surface, a lower surface, and wall surfaces defining the openings.

50. The nonwoven membrane of claim 49, further comprising:

a hydrophobic material disposed on at least a portion of one or more of the upper surface, the lower surface, and the wall surfaces without blocking or significantly restricting a substantial number of the openings,

the surfaces of the substrate having the hydrophobic material disposed thereon comprising a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm.

51. The nonwoven membrane of claim 49, wherein the substrate comprises an electrospun substrate or a melt blown substrate.

52. The nonwoven membrane of claim 51 , wherein the substrate comprises a combination of two or more of electrospun substrates and melt blown substrates.

53. The nonwoven membrane of claim 50, wherein the hydrophobic material is in the form of branches, dots, or a continuous coating with pores.

54. The nonwoven membrane of claim 49, wherem the fibers have an average thickness of about 200 nm to about 1 ,000 nm.

55. The nonwoven membrane of claim 49, wherein the openings form interconnected tortuous channels through the nonwoven membrane.

56. The non-woven membrane of claim 55, wherein the interconnected tortuous channels are nano- or micron-sized.

57. A method comprising:

providing a non-woven substrate comprising mterconnected fibers and openings among the interconnected fibers, the substrate defining surfaces comprising an upper surface, a lower surface, and wall surfaces defining the openings; and rendering the surfaces of the substrate hydrophobic, or relatively more hydrophobic, without blocking or significantly restricting a substantial number of the openings.

58. The method of claim 57, wherein rendering the surface of the substrate hydrophobic, or relatively more hydrophobic comprises depositing a hydrophobic material on at least a portion of one or more of the upper surface, the lower surface, and the wall surfaces of the substrate.

59. The method of claim 57, comprising forming the substrate by electrospinning or melt blowing.

60. The method of claim 58, wherein the hydrophobic material is deposited using plasma technology in a chamber in a gas phase or in the form of an aerosol at an atmospheric pressure or at a pressure below the atmospheric pressure.

61. The method of claim 58, wherein depositing the hydrophobic material comprises depositing the hydrophobic material on surfaces of the interconnected fibers of the nonwoven membrane individually.

62. The method of claim 58, wherein the hydrophobic material is deposited after formation of the substrate.

63. The method of claim 58, wherein the hydrophobic material is deposited during formation of the substrate.

64. The method of claim 58, further comprising stacking one or more additional nonwoven substrates with the nonwoven substrate, and wherem the hydrophobic material is deposited after the additional nonwoven substrates and the nonwoven substrate are stacked.

65. The method of claim 58, further comprising laminating the substrate having the hydrophobic material deposited thereon between an inner fabric layer and an outer fabric layer.

66. The method of claim 58, wherein the substrate having the hydrophobic material deposited thereon has a weight of about 1 gram per square meter to about 10 grams per square meter and a water column of about 2,000 mm to about 20,000 mm.

67. The method of claim 58, wherein the nonwoven substrate comprises an electrospun membrane over a melt blown membrane, the electrospun membrane having the hydrophobic material deposited thereon.

68. The method of claim 67, further comprising laminating the substrate to a fabric layer such that the electrospun membrane is between the fabric layer and the melt blown membrane.