Abstract: A fabric for use in outdoor apparel is disclosed comprising an insulating layer including a multitude of cross fibers disposed between exterior fabric layers, the combination of which creates a temperature regulating material suitable for maintaining a comfortable body temperature in environments where the ambient temperature is low. The fabric is created using a double needle bar knitting technique which allows several fiber choices to be incorporated into a single fabric sample and infuses the enclosed, insulating layer with a multitude of air spaces helpful in the insulating process. In addition to air spaces, the invention uses phase change technology in the insulating layer to regulate and stabilize the temperature of the air spaces that exist between the cross fibers, thus producing a thermal regulation effect greater than would be possible if either technology were used alone.

Abstract: The present invention includes a foam flame bonded fabric laminate that is wind-resistant, breathable, and supple along with a low cost process for producing it. The apparatus of the present invention comprises a foam bonding agent layered between fabrics or other materials where the foam possesses wind-resistant and breathable characteristics independent of the other layers. The process of the present invention involves two-step foam flame bonding with each step accomplished in a separate pass through a laminating device. In one embodiment, the first step includes lightly exposing a thin polymer foam (such as polyester polyurethane or polyether polyurethane) to a flame without preheating, then pressing it against the inner face of mesh or tricot. The second step includes more vigorously exposing the foam face of the foam-mesh or foam-tricot laminate to a flame, then pressing it against the inner face of a berber, pile, or fleece fabric.