Article with moisture resistance properties

Abstract

An article having resistance to moisture includes a base layer, a screening layer, and an outer layer. The screening layer is resistant to penetration by moisture in the liquid phase and may be permeable to moisture in the vapor phase. In one embodiment the screening layer has a moisture vapor transmission rate in the range of 0 to 0.5 g per mil/100 in2 per day as determined according to ASTM D-96 at 90% relative humidity and 100° F. The screening layer may comprise one or more layers. Optionally, a screening layer may be resistant to penetration both by moisture in the liquid and in the vapor phase.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to a composite material and an article made therefrom having moisture resistance properties. More particularly the present invention relates to a composite material and an article made therefrom that is a barrier to water penetration but allows passage of moisture vapor in one aspect of the invention and is a barrier to water penetration and a barrier to moisture vapor in another aspect of the invention.

BACKGROUND OF THE INVENTION

[0002] Certain articles of clothing, such as shoes, hats and gloves; articles of sports clothing, such as baseball and softball fielding gloves, gloves for batters, football players and golfers, sporting shoes; and any other articles of sporting goods, such as game balls (referred to herein as “sports clothing and accessories”) may be subjected to exposure to moisture in the normal course of use. For example, sports clothing commonly comes in contact with the perspiration of the wearer; and dew, rain, and even snow as are commonly found on the playing surface and surrounding areas. During the normal course of use, sports clothing may even be subject to complete immersion in water.

[0003] It is well known that exposure to water can have deleterious effects on sports clothing and accessories. Some of the effects of moisture absorption are immediate and obvious, including increased weight of the article, the sensation of dampness experienced by the wearer, and a general decrease in the performance qualities of the goods.

[0004] In the case of items made of leather, wetting and drying can lead to noticeable stiffness and hardening of the leather. Use of the leather article, particularly when subject to multiple cycles of wetting, drying and subsequent use, can lead to cracking and splitting of the leather. The subsequent performance of the article even when dry may be degraded because of the noticeable stiffness of the recently wetted and dried leather. Other effects of wetting and drying of materials such as shrinkage can occur to materials that are fabric, leather or synthetic leather. For example, shrinkage can not only cause a change in size or shape of the article, but it could also induce tearing of panels of the material at stitches or other locations.

[0005] Imparting water resistance to sports clothing and accessories has been addressed in several ways. One way of making such goods resistant to water is to treat the outer surfaces with substances to impart a water repellant finish. Leather and fabrics have been treated with waxes in an attempt to seal the pores or the weave of the fabric or otherwise repel water. Various waxes such as SNO-SEAL, commercially available from ATSKO/Sno-Seal, Inc., Orangeburg, South Carolina, are commonly used for this purpose. More advanced materials have also been used for treating leather and other materials to impart water repellence, including a polyfluoralkyl material disclosed in U.S. Pat. No. 5,069,935 and silica materials disclosed in U.S. Pat. No. 5,204,088.

[0006] While waxes, oils, polyfluoralkyl and silica materials do provide water repellance, there can be significant drawbacks with the use of each one of these materials. In particular, these water repellant materials reduce the ability of the player to “feel” a club or bat through the sports clothing and accessories. Additionally, the performance of shoes intended to make contact with a ball, such as in soccer, can be degraded when treated with such waterproofing materials. Hence, playability may be changed. Further, the color of sports clothing and accessories is typically darkened by the use of these water repellant substances and thus, the overall appearance of the articles can be negatively impacted. Importantly, waxes and oils can make leather surfaces slippery, lessening the desired “tack” of leather articles such as gloves or game balls that are waterproofed.

[0007] It is further known that water repellant surface treatments, such as waxes, oils, and other chemical materials, are applied to only the outer surface of the article. Therefore, these treatments often have a limited life span due to wear and abrasion the outer surfaces encounter under conditions of normal use.

[0008] Water resistant synthetic materials have been used as a replacement for leather and fabric in various structures. However, materials such as molded rubber, polyvinyl chloride, and certain other synthetic materials do not have the optimal combination of flexibility, feel, tack and appearance, making these materials much less desirable for many uses in sports clothing and accessories.

SUMMARY OF THE INVENTION

[0009] An object of the present invention is to provide a composite material for use in sports clothing and accessories which is resistant to penetration by moisture in liquid form.

[0010] Another object of the present invention is to provide a composite material, which possesses the desirable characteristics of natural leather yet, is resistant to penetration by moisture in liquid form.

[0011] A further object of the invention is to provide a natural leather replacement material for use in sports clothing and accessories which is resistant to penetration by moisture in the liquid state, yet which permits penetration by water vapor.

[0012] These and related objects are achieved in one aspect of the invention by providing a composite material which is resistant to penetration by moisture. The material includes in its structure one or more screening layers. The screening layer is resistant to penetration by moisture in the liquid state but is permeable to moisture in the vapor state.

[0013] In another aspect of the invention the composite material includes a screening layer which is resistant to penetration by moisture in the liquid state and resistant to penetration by moisture in the vapor state.

[0014] The invention also encompasses various sports clothing and accessories manufactured or constructed from the composite material of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings in which:

[0016] FIG. 1 is an enlarged, partially exploded view of a portion of an inventive composite material;

[0017] FIG. 2 is a plan view of a baseball glove incorporating an embodiment of the inventive composite material;

[0018] FIG. 3 is an enlarged, partially exploded view of a portion of one embodiment of a screening layer; and

[0019] FIG. 4 is a partially exploded perspective view of a game ball incorporating an embodiment of the inventive composite material.

DETAILED DESCRIPTION OF THE INVENTION

[0020] FIG. 1 illustrates a portion of composite material 10 that may be used in connection with sports clothing and accessories and which is made in accordance with an aspect of the present invention. The composite material 10 comprises an exterior layer 12, an underlying layer 14 and a screening layer 16. The exterior layer 12 preferably comprises natural leather or synthetic leather. The underlying layer 14 underlies the exterior layer 12. The underlying layer 14 preferably comprises natural leather or synthetic leather.

[0021] The screening layer 16 is disposed between the underlying layer 14 and the exterior layer 12. Preferably the screening layer 16 is coextensive with at least one of the exterior layer 12 and/or the underlying layer 14. The screening layer 16 may be formed solely of a single layer of a sheet-like material or a coating material. Alternatively the screening layer may be formed of multiple layers of sheet-like materials, which may be the same or different, or multiple layers of coating materials, which may be the same or different. The screening layer may optionally be formed from a combination of one or more layers of sheet-like materials in combination with one or more layers of coating materials. In any variation the screening layer 16 comprises one or more layers of a material having a low transmission rate to moisture in the liquid state. In one embodiment, the material of the screening layer 16 resists penetration of moisture in both the liquid and vapor states. In another embodiment, the material of the screening layer 16 resists penetration of moisture in the liquid state, but permits penetration or permeation of moisture which is in the vapor state. In the latter embodiment the screening layer 16 may be said to be “breathable”. The composition and structure of the screening layer used in the present invention will vary according to whether the barrier layer is intended to be permeable to moisture vapor or resistant to penetration by water vapor.

[0022] The screening layer 16 may take the form of one or more layers of a sheet-like material which, as used herein, refers to a material having a heterogeneous, planar structure. In this form, the sheet-like material is relatively thin in cross section, is sufficiently flexible and resilient to conform readily to the shape of the object in which it is incorporated and flex as necessary as the object is flexed. Examples of sheet-like materials, which may be used in the practice of the invention, include polymeric films and metal foils. The polymeric films include, for example, polyolefins, such as polyethylene and polypropylene; halogenated polyolefins, such as polyvinyl chloride; polyesters, such as polyethylene terephthalate; polyamides, such as nylons; and homopolymers, such as polytetrafluoroethylene. Preferred materials for use in this invention include polyethylene terephthalates which are commercially available under the trademark MYLAR from DuPont, Wilmington, Delaware, polytrimethylene terephthalates, polybutadiene terephthalate, and expanded polytetrafluoroethylene materials such as those sold under the trademark GORE-TEX, commercially available from W. L. Gore and Associates, Wilmington, Del. Metal foils for use in this invention should be thin, sufficiently flexible so as to readily conform to the shape of the object to which they are incorporated and to allow the article to flex and move appropriately, and they should also be of sufficiently low mass. Furthermore, the metal material should not readily oxidize or otherwise deteriorate when exposed to moisture or through the normal use of the article in which it is incorporated. Aluminum foil is highly suitable for use in this invention. Other metal foils such as, for example, copper foil may be useful as well. Although the metallic screening layer has been discussed in terms of a metallic foil layer it should be appreciated that a layer of metal may be deposited in a process such as vacuum deposition to provide a metallic screening layer 16 between the underlying layer 14 and exterior layer 12.

[0023] The screening layer 16 may be comprised of multiple layers having different functions. As an example, FIG. 3 illustrates one embodiment of a screening layer 16 having a central moisture resistant layer 26 disposed between two adhesive layers 28, 30. The adhesive layers function to allow bonding of the screening layer 16 to the exterior layer 12 and/or underlying layer 14. Naturally, if the screening layer is intended to be permeable to moisture vapor the adhesive layers 28, 30 should be discontinuous.

[0024] The particular embodiment illustrated in FIG. 1 shows a material wherein the screening layer 16 is permeable to moisture vapor, but resistant to penetration by moisture in the liquid state. The screening layer 16 has discontinuities 20 (such as pores) therein which are of a size sufficient for moisture vapor, for example, to pass through from an area of higher concentration to an area of lower concentration. The discontinuities 20 are small enough so that the screening layer is resistant to penetration of moisture in the liquid state. It will be understood that the screening layer 16 may also be a completely occlusive barrier, that is, it may be a screening layer which resists the penetration of water in either the vapor or the liquid state.

[0025] The underlying layer 14, screening layer 16 and exterior layer 12 are preferably laminated to form a seamless composite material. If the screening layer 16 comprises a thermoplastic material the lamination may be performed by applying heat and pressure to an underlying layer 14, screening layer 16, exterior layer 12 sandwich to securely integrate the discrete layers into a unitary composite material. Alternatively, the underlying layer 14, screening layer 16, exterior layer 12 may be laminated using an adhesive or other binder 22 between the layers. The adhesive may be any type of adhesive or binder which will securely adhere the screening layer to the base layer and outer layer without compromising the integrity, appearance, or performance of the various components of the material. In the case of a material that is intended to be permeable to moisture vapor, care must be taken in the application of the adhesive or binder 22. Completely coating any of the layers of the material with a continuous layer of adhesive will occlude the pores 20 of the screening layer 16 and reduce moisture vapor permeability of the composite material. It is preferred, therefore, that the adhesive or binder 22 be applied in a discontinuous fashion, such as in a dot pattern or other discontinuous pattern to avoid occluding the pores 20 in the screening layer 16. Such care need not be taken when the material is intended to have a screening layer 16 which is resistant to penetration of moisture in both the vapor and liquid states.

[0026] The screening layer 16 may also take the form of one or more layers of a coating material. Typically, the coating material initially is in a fluid form that dries, cures, or otherwise reacts in situ to form a layer of a moisture resistant material. When the screening layer 16 is in the form of a coating material, the coating material must be of sufficient durability and resilience to withstand incorporation into sports clothing and accessories such as for example, a shoe, glove, or game ball. Coating materials which are suitable for forming the screening layer 16 include, for example, polyvinylidene chloride (such as those materials sold under the trademark SARAN, commercially available from Dow Chemical Company, Midland, Mich.), polyamides, epoxy resins, polyurethanes, latex rubber, polyvinyl chloride, and polyvinyl alcohol.

[0027] It will be appreciated that a screening layer which is non-permeable to moisture in both the liquid and vapor states will prevent the penetration of moisture from the outside of an article to the interior of the article. In addition, moisture that is generated within the article, such as through perspiration of the individual wearing a shoe or glove, may be trapped by the screening layer. While such a non-permeable composite material would be suitable for short term wear, or for conditions in which internal moisture generation is not a concern or kept to a minimum, this material and articles made from this material may not provide optimum comfort to the wearer in other situations. Therefore, it is advantageous to use clothing articles and sporting goods which are made from a composite material having a “breathable” screening layer which is resistant to penetration by moisture in the liquid state, while permitting the transmission of moisture in the vapor state. Such a breathable composite material allows the article to be water resistant, while at the same time remaining relatively comfortable to the wearer.

[0028] To be effective a breathable screening layer should have a water vapor transmission rate that is appropriate for the given article or sporting good and the conditions under which it is to be used. For example, a shoe or glove which is intended for use in warm weather and under conditions where perspiration of the wearer is likely should have a relatively high water vapor transmission rate. On the other hand, a shoe, glove or other article which will be used in relatively cool temperatures and under conditions which are not conducive to the wearer producing a great deal of perspiration, may appropriately have a lower water vapor transmission rate. It will be appreciated that the layer (exterior 12, screening 16 or underlying 14) in an article or composite material that has the lowest water vapor transmission controls the overall rate in which water vapor transmission occurs for the entire article.

[0029] A suitable test for determining the water vapor transmission rate of a material layer is set forth in ASTM D-96. This test expresses water vapor transmission rate in terms of units of grams of water transmitted per mil thickness of material per 100 in2 of material per day at 90% relative humidity and 100° F. (g per mil/100 in2 per day). For the purpose of this invention, it is adequate that the screening layer 16 be rated in the range of from about 0 to about 0.5 g per mil/100 in2 per day. Preferably the screening layer 16 may be rated in the range from about 0.0001 g per mil/100 in2 per day to about 0.3 g per mil/100 in2 per day and most preferably from about 0.0002 g per mil/100 in2 per day to about 0.2 g per mil/100 in2 per day.

[0030] In FIG. 2, a fielder's glove 34 is shown incorporating the composite material comprising the underlying layer 14, screening layer 16, and exterior layer 12 described above. The fielder's glove or mitt 34 includes a palm 36, glove fingers 38, a thumb 40, and webbing 42 for catching and trapping a baseball or softball. The layers of material from which the glove is manufactured are pierced to define lacing holes 48 to accommodate lacing 46 that is used to bind the various edges of the material. The screening layer is incorporated within the glove and functions to reduce the transmission of moisture from the exterior to the wearer's hand. While FIG. 2 illustrates a baseball fielder's glove, as discussed above, the present invention may be employed in connection with other sports clothing and accessories.

[0031] In another aspect of the invention the composite material is incorporated into a game ball such as, for example, a basketball, volleyball, soccer ball, baseball, softball, tennis ball, football, golf ball, etc. For clarity of description and ease of understanding, the invention will be described in connection with a football as shown in FIG. 4. It will be noted that other game balls can employ the various features of the present invention. The invention is especially advantageous in connection with game balls having natural or synthetic leather covers as the tendency of such leather covers to absorb water is well known.

[0032] FIG. 4 shows a game ball 52 comprising an air bladder 54 that is commonly made of a highly durable, stretchable, air impermeable material such as butyl rubber or a polyurethane material. The bladder 54 is sealed to retain air pressure within. Disposed directly over the air bladder 54 is the lining 56. The lining is employed in the structure of the game ball to help the ball retain the proper shape and to provide additional strength and mechanical reinforcement to the cover material. Traditionally, the linings of game balls were formed from one or more plies of fabric or scrim made from highly water absorbent natural fibers such as cotton or linen. Synthetic fibers such as polyester, nylon and even glass fibers have more recently been used in forming the lining material. Overlying the lining material is a cover 58. The cover is formed of a material that has been cut into panels. The above described composite material comprising an underlying layer 14, screening layer 16 and exterior layer 12 is used to form the panels of the game ball 52. In this fashion the screening layer 16 will function to reduce moisture infiltration into the game ball 52. The panels are joined to create seams 64. Traditionally, one seam 64 is only partially joined to form an opening between adjacent panels 60, 62 through which the bladder 54 may be inserted. The edges of the panels 60, 62 include lacing holes 66 through which laces 68 can be woven to join the panels 60, 62.

[0033] In a different embodiment, not shown, a cover material comprised of the outer layer 12 and the screening layer 16 is used to form the panels. This embodiment dispenses with the underlying layer, placing the screening layer 16 adjacent the underlying game ball structure. Alternatively, and also not shown, the screening layer 16 is not bonded to the outer layer and can be disposed as a discreet layer between the cover 58 and the lining 56 or bladder 54 to reduce moisture infiltration into the game ball 52.

[0034] While the present invention has been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the present invention is not limited to the disclosed embodiments. Rather, it is intended to cover all of the various modifications and the equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A composite material having resistance to water comprising:

a first layer of leather; and

a screening layer substantially coextensive with and joined to a side of the first layer, the screening layer being resistant to penetration by moisture in the liquid phase.

2. The material of claim 1 further comprising a second layer of leather substantially coextensive with and joined to a free side of the screening layer.

3. The material of claim 1 further comprising a second layer of leather substantially coextensive with and joined to a free side of the screening layer wherein the first layer, screening layer and second layer are bonded to form a laminate.

4. The material of claim 1, wherein the screening layer additionally has a moisture vapor transmission rate in the range of about 0 to 0.5 grams per mil/100 inches2 per day when tested according to ASTM D-96 at 90 percent relative humidity and 100° F.

5. The material of claim 1, wherein the screening layer additionally has a moisture vapor transmission rate in the range of about 0.0001 to 0.3 grams per mil/100 inches2 per day when tested according to ASTM D-96 at 90 percent relative humidity and 100° F.

6. The material of claim 1, wherein the screening layer additionally has a moisture vapor transmission rate in the range of about 0.01 to 0.2 grams per mil/100 inches2 per day when tested according to ASTM D-96 at 90 percent relative humidity and 100° F.

7. The material of claim 1, wherein the screening layer comprises discontinuities.

8. The material of claim 1, wherein the screening layer comprises more than one layer.

9. The material of claim 1, wherein the screening layer comprises a preformed layer.

10. The material of claim 1, wherein the screening layer comprises a coating over the side of the first layer.

11. The material of claim 1, wherein the screening layer comprises at least one material selected from the group consisting of polyolefin, halogenated polyolefin, polyethylene terephthalate, polytrimethylene terephthalate, polybutadiene terephthalate, polyester, polyamide, polyurethane, polyvinylidene chloride, polyvinyl chloride, polyvinyl alcohol, rubber, epoxy, polytetrafluoroethylene and metal.

12. The material of claim 1, wherein the screening layer comprises at least one coating material selected from the group consisting of polyurethane, polyvinyidiene chloride, polyvinyl chloride, polyvinyl alcohol, rubber, epoxy, polytetrafluoroethylene and metal.

13. An article comprising an outer layer of leather; and a screening layer substantially coextensive with and joined to the outer layer, the screening layer being resistant to penetration by moisture in the liquid phase.

14. The article of claim 13, wherein said article is selected from the group consisting of a glove, a fielders glove, a shoe and a game ball.

15. The article of claim 13 further comprising an underlying layer of leather substantially coextensive with a free side of the screening layer and adhesive disposed between the adjacent layers wherein the outer layer, screening layer and underlying layer are bonded to form a laminate.

16. A game ball comprising an outer layer overlying a reinforcing lining and a screening layer substantially coextensive with the outer layer and disposed between the outer layer and the reinforcing lining, wherein the screening layer is resistant to penetration by liquid water.

17. The game ball of claim 16, wherein the outer layer consists essentially of natural leather or synthetic leather.

18. The game ball of claim 16, wherein the screening layer is laminated to an inner surface of the outer layer.

20. A game ball having resistance to water comprising an outer layer and a screening layer substantially coextensive with and joined to an inner side of the outer layer, the screening layer being resistant to penetration by moisture in the liquid phase.