FIELD OF THE INVENTION

The present disclosure relates to articles of manufacture with improved moisture control, as well as methods related thereto.

BACKGROUND OF THE INVENTION

Perspiration is the primary means of thermoregulation for the human body, during which sweat (mainly composed of water) is secreted through the skin and evaporation of the fluid removes the heat from the surface underneath. During intensive activity, accumulated sweat can drastically increase the humidity level surrounding the skin, which can result in a very uncomfortable feeling unless sweat is efficiently removed. Moisture control fabrics can confine the moisture distribution in the fabric structure for various applications. Among them, one application is sweat-proof material that controls and prevents the moisture from showing on the external surface.

There are many methods currently utilized to sweat-proof materials. Common methods include the incorporation of a thin plastic film to prevent water movement across layers (e.g. Thompson Tee, www.thompsontee.com), but thin plastic films tend to inhibit the air flow through the materials and increase the rigidity of the fabric, which can cause wearer discomfort. An alternative method to using plastic materials is the use of hydrophobic coatings (i.e., fluoropolymer, silicone, and wax) to prevent liquid movement through the material. Coatings and fabric finishes provide a more breathable and comfortable alternative to plastic films. Technology such as 3xDRY (Schoeller Textile, see WO2002075038A3) implements hydrophobic treatments only on the outside surface of the material to prevent liquids from penetrating through the thickness of the fabric. The outside coating allows perspiration or other liquids from the inside surface to partially absorb through the thickness of the fabric but not become visible on the outside of the garment. However, the inside of this fabric can reach full saturation and the garment can cling to the wearer and cause discomfort.

Incorporating inherently hydrophobic materials into the overall structure is another method to create sweat-proof materials. In some fabric products, like Silic™ and ThreadSmith™, the fabric is completely non-absorbent (e.g., hydrophobic) and prevents liquid from passing through the fabric. However, this technology leads to wearer discomfort due to perspiration remaining on the skin surface.

Therefore, a need exists for articles with improved moisture control capacity. A fabric structure with sweat-proof function that can prevent full saturation, reduce garment cling and achieve quick drying properties would be ideal and largely improve wearer comfort. Such articles would be able to control the movement of moisture (e.g., a bodily fluid, such as sweat) from the inside to the outside to keep the outside dry while removing the moisture from the surface of the skin and keeping the wearer comfortable. These articles can find use, e.g., in fabrics for garments, sheets, and other accessories.

BRIEF SUMMARY OF THE INVENTION

To meet these and other demands, the present disclosure provides fabrics with improved moisture control capacity, as well as garments and methods of making related thereto. These fabrics have unique structures that control the movement of moisture, allowing the inner surface to remove moisture and keeping the moisture from accumulating on the outer surface. These properties provide fabrics that resist staining, reduce clinging to the body, and lessen drying times, as compared with existing materials.

In certain aspects, the present disclosure provides a fabric, comprising: (a) an outer surface comprising a hydrophobic material; and (b) an inner surface comprising: (i) one or more first regions, wherein the one or more first regions each comprise a hydrophobic material, and (ii) one or more second regions, wherein the one or more second regions each comprise a hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In some embodiments, at least one of the one or more second regions is surrounded by at least one of the one or more first regions. In some embodiments, each of the one or more second regions is surrounded by one or more of the one or more first regions. In some embodiments, the one or more second regions are adjacent to the one or more first regions. In some embodiments, the one or more second regions are patterned in a geometric pattern or logo. In some embodiments, the one or more second regions form a plurality of repeated shapes surrounded by the one or more first regions. In some embodiments, the one or more second regions form a lattice. In some embodiments, at least one of the one or more first regions is surrounded by at least one of the one or more second regions. In some embodiments, each of the one or more first regions is surrounded by the one or more of the one or more second regions. In some embodiments, the one or more first regions are adjacent to the one or more second regions. In some embodiments, the one or more first regions are patterned in a geometric pattern or logo. In some embodiments, the one or more first regions are a plurality of repeated shapes surrounded by the one or more second regions. In some embodiments, the one or more first regions form a lattice. In some embodiments, the outer surface does not comprise the hydrophilic material of the one or more second regions. In some embodiments, a collective surface area of the one or more first regions and a collective surface area of the one or more second regions are substantially equivalent. In some embodiments, the proportion of the collective surface area of the one or more second regions to the surface area of the entire fabric is about 40% to about 95%. In some embodiments, the fabric further comprises an intermediate layer, wherein the intermediate layer is between the outer surface and the inner surface and affixed to one or both of the outer surface and the inner surface. In some embodiments, the intermediate layer comprises a hydrophobic material. In some embodiments, the intermediate layer comprises a hydrophilic material. In some embodiments, at least a portion of the hydrophobic material of the inner surface is in contact with at least a portion of the hydrophobic material of the outer surface. In some embodiments, the inner surface is interconnected with or affixed to the outer surface. In some embodiments, the inner surface is affixed to the outer surface by stitching, bonding, adhesion, lamination, or a combination thereof. In some embodiments, the hydrophilic material of the second region comprises 5% to 95% of the total thickness of the fabric. In some embodiments, the one or more second regions comprise 15% to 85% of the inner surface (e.g., by surface area). In some embodiments, the hydrophobic material of the outer surface resists a hydrostatic pressure of about 150 pa to about 3 kpa. In some embodiments, the hydrophobic material of the one or more first regions resists a hydrostatic pressure of about 150 pa to about 3 kpa. In some embodiments, the hydrophobic materials of the outer surface and the one or more first regions are different. In some embodiments, the hydrophobic materials of the outer surface and the one or more first regions are the same. In some embodiments, the hydrophobic material of the outer surface, the hydrophobic material of the one or more first regions, or both comprises a hydrophobic textile. In some embodiments, the hydrophobic textile is natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the hydrophobic textile is selected from the group consisting of polypropylene, polydimethylsiloxane, a fluoropolymer, olefin, or a blend thereof. In some embodiments, the hydrophobic material of the outer surface, the hydrophobic material of the one or more first regions, or both comprises a porous material with a hydrophobic coating. In some embodiments, the hydrophobic coating comprises fluoropolymer, silicone, hydrosilicone, fluoroacrylate, or wax. In some embodiments, the porous material is a textile, foam, polymer, or mesh. In some embodiments, the textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, lyocell, modal, poly-paraphenylene terephthalamide, elastin fiber, and any blend thereof. In some embodiments, the hydrophilic material of the one or more second regions comprises a hydrophilic textile. In some embodiments, the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof. In some embodiments, the hydrophilic material of the one or more second regions comprises a porous material with a hydrophilic coating. In some embodiments, the hydrophilic coating comprises hydrophilic silicone. In some embodiments, the porous material is a textile. In some embodiments, the textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, lyocell, modal, poly-paraphenylene terephthalamide, elastin fiber, and any blend thereof. In some embodiments, the fabric is a component of bedding, footwear, seat cover, outdoor gear, upholstery, or an accessory.

Further provided herein is a garment comprising a fabric according to any of the above embodiments. In some embodiments, the inner layer is configured to face the skin of the wearer of the garment. In some embodiments, the garment is a coat, a dress, a skirt, a sports bra, undergarment, pant, short, or sock. In some embodiments, the garment is a shirt. In some embodiments, the fabric is localized to one or more of an underarm area, a mid-back area, a lower-back area, a front chest area, a stomach area, and a shoulder area of the garment. In some embodiments, the one or more second regions form an interconnected lattice. In some embodiments, the one or more first regions form an interconnected lattice. In some embodiments, the fabric is localized to the mid-back area and/or to the lower-back area of the garment. In some embodiments, the fabric is surrounded by a hydrophobic material of the garment.

In certain aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a hydrophilic material comprising an outer and an inner surface; (b) screen printing a first hydrophobic material onto one or more portions of the inner surface; and (c) screen printing a second hydrophobic material onto the outer surface to cover the outer surface; thereby making a fabric comprising an outer surface comprising the second hydrophobic material, and an inner surface comprising one or more first regions comprising the first hydrophobic material, and one or more second regions comprising the hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a hydrophilic material comprising an outer and an inner surface; (b) screen printing a first hydrophobic material onto one or more portions of the outer surface such that the first hydrophobic material penetrates through the hydrophilic material to generate an inner surface comprising one or more first regions comprising the first hydrophobic material and one or more second regions comprising the hydrophilic material; and (c) screen printing a second hydrophobic material onto the outer surface such that the second hydrophobic material penetrates through the hydrophilic material to generate an outer surface comprising the second hydrophobic material, thereby making a fabric comprising an outer surface comprising the second hydrophobic material, and an inner surface comprising one or more first regions comprising the first hydrophobic material, and one or more second regions comprising the hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In some embodiments, the first and the second hydrophobic materials of the outer and inner surfaces contact each other. In some embodiments, the outer surface comprises about 50% of the total thickness of the fabric, and the inner surface comprises about 50% of the total thickness of the fabric. In some embodiments, the ratio of the thickness of the outer surface to the thickness of the inner surface is between about 0.1 to about 10. In some embodiments, the first and the second hydrophobic materials are the same. In some embodiments, the first and the second hydrophobic materials are different.

In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a first, a second, and a third hydrophilic material, wherein each of the first, second, and third hydrophilic materials comprises an outer and an inner surface;

(b) screen printing a hydrophobic material onto the outer surface of the first hydrophilic material to cover the outer surface; (c) screen printing a hydrophobic material onto one or more portions of the inner surface of the second hydrophilic material; (d) affixing the inner surface of the first hydrophilic material to the third hydrophilic material; and (e) affixing the outer surface of the second hydrophilic material to the third hydrophilic material; thereby making a fabric with three layers comprising an outer surface comprising a hydrophobic material, a middle hydrophilic layer, and an inner surface comprising one or more first regions comprising a hydrophobic material and one or more second regions comprising a hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In some embodiments, the first hydrophilic material, the second hydrophilic material, and the third hydrophilic material comprise the same material. In some embodiments, the first hydrophilic material, the second hydrophilic material, and the third hydrophilic material comprise different hydrophilic materials. In some embodiments, the first hydrophilic material comprises about 30% to about 45% of the total thickness of the fabric, the second hydrophilic material comprises about 30% to about 45% of the total thickness of the fabric, and the third hydrophilic material comprises about 10% to about 40% of the total thickness of the fabric. In some embodiments, the ratio of the thickness of the first hydrophilic material to the thickness of the second hydrophilic material is between about 0.1 to about 10, and the ratio of the thickness of the second hydrophilic material to the thickness of the third hydrophilic material is between about 1 to about 5. In some embodiments, the first and third hydrophilic materials and the second and third hydrophilic materials are affixed by stitching, bonding, adhesion, lamination, or a combination thereof. In some embodiments, the hydrophobic materials in (b) and (c) are the same. In some embodiments, the hydrophobic materials in (b) and (c) are different. In some embodiments of any of the above embodiments, a collective surface area of the one or more first regions and a collective surface area of the one or more second regions are substantially equivalent.

In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a hydrophobic material comprising an outer and an inner surface; and (b) screen printing a hydrophilic material onto one or more portions of the inner surface; thereby making a fabric comprising an outer surface comprising a hydrophobic material, and an inner surface comprising one or more first regions comprising a hydrophobic material, and one or more second regions comprising a hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In some embodiments, the outer surface comprises about 50% of the total thickness of the fabric, and the inner surface comprises about 50% of the total thickness of the fabric. In some embodiments, the ratio of the thickness of the outer surface to the thickness of the inner surface is between about 0.1 to about 10. In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a first hydrophobic material, a second hydrophobic material, and a first hydrophilic material, wherein the first and second hydrophobic materials and the first hydrophilic material each comprise an outer and an inner surface; (b) screen printing a second hydrophilic material onto one or more portions of the inner surface of the second hydrophobic material; (c) affixing the first hydrophilic material to the outer surface of the second hydrophobic material; and (d) affixing the first hydrophilic material to the first hydrophobic material; thereby making a fabric with three layers comprising an outer surface comprising a hydrophobic material, a middle hydrophilic layer, and an inner surface comprising one or more first regions comprising a hydrophobic material and one or more second regions comprising a hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In some embodiments, the first hydrophilic material and the second hydrophobic material and the first hydrophilic material and the first hydrophobic material are affixed by stitching, bonding, adhesion, lamination, or a combination thereof. In some embodiments, the first hydrophobic material comprises about 30% to about 45% of the total thickness of the fabric, the middle hydrophilic layer comprises about 10% to about 40% of the total thickness of the fabric, and the third hydrophobic material comprises about 30% to about 45% of the total thickness of the fabric. In some embodiments, the ratio of the thickness of the first hydrophobic material to the thickness of the second hydrophobic material is between about 0.1 to about 10, and the ratio of the thickness of the second hydrophobic material to the thickness of the first hydrophilic material is between about 1 to about 5. In some embodiments of any of the above embodiments, a collective surface area of the one or more first regions and a collective surface area of the one or more second regions are substantially equivalent.

In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a material comprising an outer and an inner surface; (b) screen printing a hydrophobic material onto one or more first regions of the inner surface; (c) screen printing a hydrophilic material onto one or more second regions of the inner surface, wherein the one or more first regions and the one or more second regions are different; and (d) screen printing a hydrophobic material onto the outer surface; thereby making a fabric comprising an outer surface comprising a hydrophobic material, and comprising an inner surface comprising one or more first regions comprising a hydrophobic material, and one or more second regions comprising a hydrophilic material. In some embodiments, the hydrophobic materials of the outer and inner surfaces contact each other. In some embodiments, the outer surface comprises about 50% of the total thickness of the fabric, and the inner surface comprises about 50% of the total thickness of the fabric. In some embodiments, the ratio of the thickness of the outer surface to the thickness of the inner surface is between about 0.1 to about 10. In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a first material, a second material, and a hydrophilic material, wherein each of the first and second materials and the hydrophilic material comprise an inner and an outer surface; (b) screen printing a hydrophobic material onto one or more first regions of the inner surface of the second material; screen printing a hydrophilic material onto one or more second regions of the inner surface of the second material, wherein the one or more first regions and the one or more second regions are different; (d) screen printing a hydrophobic material onto the outer surface of the first material; (e) affixing the hydrophilic material to the inner surface of the first material; and (f) affixing the hydrophilic material to the outer surface of the second material; thereby making a fabric with three layers comprising an outer surface comprising a hydrophobic material, a middle hydrophilic layer, and an inner surface comprising one or more first regions comprising a hydrophobic material, and one or more second regions comprising a hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In some embodiments, the hydrophobic materials in (b) and (d) comprise the same material. In some embodiments, the hydrophobic materials in (b) and (d) comprise different materials. In some embodiments, the first material comprises about 30% to about 45% of the total thickness of the fabric, the hydrophilic material comprises about 10% to about 40% of the total thickness of the fabric, and the second material comprises about 30% to about 45% of the total thickness of the fabric. In some embodiments, the ratio of the thickness of the first material to the thickness of the second material is between about 0.1 to about 10, and the ratio of the thickness of the second material to the thickness of the hydrophilic material is between about 1 to about 5. In some embodiments, the first and hydrophilic materials and the second and hydrophilic materials are affixed by stitching, bonding, adhesion, lamination, or a combination thereof. In some embodiments of any of the above, a collective surface area of the one or more first regions and a collective surface area of the one or more second regions are substantially equivalent.

In other aspects, the present disclosure provides a method of making a fabric, the method comprising; (a) knitting an outer layer of the fabric using a hydrophobic yarn; (b) knitting a first region of an inner layer of the fabric using a hydrophilic yarn; and (c) knitting a second region of the inner layer of the fabric using a hydrophobic yarn; thereby making a fabric comprising an outer surface comprising a hydrophobic material, and an inner surface comprising one or more first regions comprising a hydrophobic material, and one or more second regions comprising a hydrophilic material, wherein the one or more first regions and the one or more second regions are different. In some embodiments, the knitting of one or more of (a), (b), and (c) is warp knitting. In some embodiments, the knitting of one or more of (a), (b), and (c) is weft knitting. In some embodiments, the inner layer and the outer layer are connected using a hydrophobic tie-in yarn. In some embodiments, the inner layer is connected to the outer layer across their entire surfaces. In some embodiments, the inner layer is connected to the outer layer with individual loops at one or more discrete points. In some embodiments, the one or more discrete points are at one or more edges of the fabric. In some embodiments, a double needle circular knitting machine is used to knit a multi-layered structure, wherein the outer layer is knit on the dial using hydrophobic yarns; the inner layer is knit on the cylinder; each course of the inner layer uses either hydrophobic or hydrophilic yarns; the courses of the inner layer alternate hydrophobic and hydrophilic yarns to produce a pattern; and a hydrophobic tie-in yarn is used to connect the inner and outer fabric layers. In some embodiments, the first region of the inner layer and the second region of the inner layer of the fabric are knitted in alternating fashion.

In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) weaving hydrophilic and hydrophobic yarns together to form a pattern with interspersed hydrophilic and hydrophobic portions; and (b) applying a hydrophobic coating to an outer surface of the woven pattern, thereby making a fabric comprising an outer layer comprising a hydrophobic material and an inner layer comprising a hydrophobic region interspersed with hydrophilic regions. In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a hydrophobic material; (b) providing a fabric comprising an inner surface comprising one or more first regions comprising a hydrophobic material and one or more second regions comprising a hydrophilic material, wherein the one or more first regions and the one or more second regions are different; and (c) affixing the hydrophobic material to the fabric, thereby making a fabric comprising an outer surface comprising a hydrophobic material, and an inner surface comprising one or more first regions comprising a hydrophobic material and one or more second regions comprising a hydrophilic material. In some embodiments of any of the above embodiments, the hydrophobic material is affixed to the fabric by stitching, bonding, adhesion, lamination, or a combination thereof.

In other aspects, the present disclosure provides a method of making a fabric, the method comprising: (a) providing a hydrophobic material and a hydrophilic material; (b) providing a fabric comprising an inner surface comprising one or more first regions comprising a hydrophobic material and one or more second regions comprising a hydrophilic material, wherein the one or more first regions and the one or more second regions are different; (c) affixing the hydrophobic material to the hydrophilic material; and (e) affixing the hydrophilic material to the fabric; thereby making a fabric comprising an outer surface comprising a hydrophobic material, and an inner surface comprising one or more first regions comprising a hydrophobic material and one or more second regions comprising a hydrophilic material. In some embodiments, the hydrophobic material and the fabric and the hydrophilic material and the fabric are affixed by stitching, bonding, adhesion, lamination, or a combination thereof. In some embodiments, the hydrophobic material of the outer surface, the hydrophobic material of the one or more first regions, or both comprises a hydrophobic textile. In some embodiments, the hydrophobic textile is natural fiber, a synthetic fiber, or a blend thereof.

In some embodiments of any of the above embodiments, the hydrophobic textile is selected from the group consisting of polypropylene, polydimethylsiloxane, a fluoropolymer, olefin, or a blend thereof. In some embodiments, the hydrophobic material of the outer surface, the hydrophobic material of the one or more first regions, or both comprises a porous material with a hydrophobic coating. In some embodiments, the hydrophobic coating comprises fluoropolymer, silicone, hydrosilicone, fluoroacrylate, or wax. In some embodiments, the porous material is a textile, foam, polymer, or mesh. In some embodiments, the textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, lyocell, modal, poly-paraphenylene terephthalamide, elastin fiber, and any blend thereof.

In some embodiments of any of the above embodiments, the hydrophilic material of the one or more second regions comprises a hydrophilic textile. In some embodiments, the hydrophilic textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the hydrophilic textile is selected from the group consisting of cotton, rayon, coconut fiber, cellulose, silk, bamboo, and any blend thereof. In some embodiments, the hydrophilic material of the one or more second regions comprises a porous material with a hydrophilic coating. In some embodiments, the hydrophilic coating comprises hydrophilic silicone. In some embodiments, the porous material is a textile. In some embodiments, the textile is a natural fiber, a synthetic fiber, or a blend thereof. In some embodiments, the textile is selected from the group consisting of cotton, hemp, rayon, coconut fiber, cellulose, wool, silk, bamboo, polyurethane, polypropylene, polyethylene, glass, acetate, polyester, nylon, lyocell, modal, poly-paraphenylene terephthalamide, elastin fiber, and any blend thereof.

In some embodiments of any of the above embodiments, the fabric is a component of bedding, footwear, a seat cover, outdoor gear, upholstery, or accessory.

In other aspects, the present disclosure provides a fabric made by the method according to any one of the above embodiments.

In other aspects, the present disclosure provides a garment comprising the fabric made by the method according to any one of the above embodiments. In some embodiments, the inner layer is configured to face the skin of a wearer of the garment. In some embodiments, the garment is a sports bra, undergarment, shirt, undershirt, coat, dress, skirt, pant, short, or sock.

It is to be understood that one, some, or all of the properties of the various embodiments described above and herein can be combined to form other embodiments of the present invention. These and other aspects of the present disclosure will become apparent to one of skill in the art. These and other embodiments of the present disclosure are further described by the detailed description that follows.

