PCT
`WORLD INTELLECTUAL PROPERTY ORGANIZATION
`WORLD INTELLECTUAL PROPERTY ORGANIZATION
`PCX
`International Bureau
`International Bureau
`INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`WO 98/06891
`WO 98/06891
`(11) International Publication Number:
`(11) International Publication Number: (cid:9)
`(51) International Patent Classification 6 :
`(51) International Patent Classification 6 :
`DO6N 3/04, 3/18, B32B 27/12, A41D
`D06N 3/04, 3/18, B32B 27/12, A41D
`31/02
`31/02
`
`(43) International Publication Date: (cid:9)
`(43) International Publication Date:
`
`19 February 1998 (19.02.98)
`19 February 1998 (19.02.98)
`
`Al (cid:9)
`A1
`
`(81) Designated States: AL, AM, AT, AU, AZ, BA, BB, BG, BR,
`(81) Designated States: AL, AM, AT, AU, AZ, BA, BB, BG, BR,
`BY, CA, CH, CN, CU, CZ, DE, DK, EE, ES, FI, GB, GE,
`BY, CA, CH, CN, CU, CZ, DE, DK, EE, ES, FI, GB, GE,
`GH, HU, IL, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR,
`GH, HU, IL, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR,
`LS, LT, LU, LV, MD, MG, MK, MN, MW, MX, NO, NZ,
`LS, LT, LU, LV, MD, MG, MK, MN, MW, MX, NO, NZ,
`PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR,
`PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR,
`TT, UA, UG, US, UZ, VN, YU, ZW, ARIPO patent (GH,
`TT, UA, UG, US, UZ, VN, YU, ZW, ARIPO patent (GH,
`KE, LS, MW, SD, SZ, UG, ZW), Eurasian patent (AM, AZ,
`KE, LS, MW, SD, SZ, UG, ZW), Eurasian patent (AM, AZ,
`BY, KG, KZ, MD, RU, TJ, TM), European patent (AT, BE,
`BY, KG, KZ, MD, RU, TJ, TM), European patent (AT, BE,
`CH, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL,
`CH, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL,
`PT, SE), OAPI patent (BF, BJ, CF, CG, CI, CM, GA, GN,
`PT, SE), OAPI patent (BF, BJ, CF, CG, CI, CM, GA, GN,
`ML, MR, NE, SN, TD, TG).
`ML, MR, KE, SN, TD, TG).
`
`Published
`Published
`With international search report.
`With international search report.
`
`(21) International Application Number: (cid:9)
`(21) International Application Number:
`
`PCT/GB97/02172
`PCT/GB97/02172
`
`(22) International Filing Date: (cid:9)
`(22) International Filing Date:
`
`12 August 1997 (12.08.97)
`12 August 1997 (12.08.97)
`
`(30) Priority Data:
`(30) Priority Data:
`9617181.4 (cid:9)
`9617181.4
`
`15 August 1996 (15.08.96) (cid:9)
`15 August 1996 (15.08.96)
`
`GB
`GB
`
`(71) Applicant (for all designated States except US): W.L. GORE &
`(71) Applicant (for all designated States except US): W.L. GORE &
`ASSOCIATES (UK) LTD. [GB/GB]; 1 Bell Yard, London
`1 Bell Yard, London
`ASSOCIATES (UK) LTD. [GB/GB];
`WC2A 2JP (GB).
`WC2A 2JP (GB).
`
`(72) Inventors; and
`(72) Inventors; and
`(75) Inventors/Applicants (for US only): HALLEY, David, George
`(75) Inventors/Applicants (for US only): HALLEY, David, George
`[GB/GB]; Wester Lie, Main Street, St. Bothwells TD6
`[GB/GB]; Wester Lie, Main Street, St. Bothwells TD6
`OAR (GB). CLARKSON, George [GB/GB]; 46 Sheriff Park,
`OAR (GB). CLARKSON, George [GB/GB]; 46 Sheriff Park,
`Linlithgow, W. Lothian EH49 7SS (GB). TROUBA, John,
`Linlithgow, W. Lothian EH49 7SS (GB). TROUBA, John,
`Edward [US/US]; 4 Sullivan Chase Drive, Avondale, PA
`Edward [US/US]; 4 Sullivan Chase Drive, Avondale, PA
`19311 (US).
`19311 (US).
`
`(74) Agents: McCALLUM, William, Potter et al.; Cruikshank &
`(74) Agents: McCALLUM, William, Potter et al.; Cruikshank &
`Fairweather, 19 Royal Exchange Square, Glasgow 01 3AE
`Fairweather, 19 Royal Exchange Square, Glasgow G1 3AE
`(GB).
`(GB).
`
`(54) Title: WATER-VAPOUR-PERMEABLE COMPOSITE MATERIAL
`(54) Title: WATER-VAPOUR-PERMEABLE COMPOSITE MATERIAL
`(57) Abstract (cid:9)
`(57) Abstract
`
`8
`
`12 (cid:9)
`
`10
`
`fl
`
`J.
`T
`
`The invention relates to a compos-
`The invention relates to a compos
`ite lining material for a garment or the (cid:9)
`ite lining material for a garment or the
`like comprising a water resistant water-
`like comprising a water resistant water-
`vapour-permeable flexible substrate (2)
`vapour-permeable flexible substrate (2)
`having a fabric (4) secured to a first side
`having a fabric (4) secured to a first side
`of the substrate (2). A second side of the
`of the substrate (2). A second side of the
`substrate (2) is provided with an abra-
`substrate (2) is provided with an abra
`sion resisting discontinuous layer (10)
`sion resisting discontinuous layer (10)
`made up of a plurality of discrete abra-
`made up of a plurality of discrete abra
`form a lining for the material.
`sion resisting polymeric dots (12). The dots (12) prevent abrasion of the flexible substrate (2) and, in use, form a lining for the material.
`sion resisting polymeric dots (12). The dots (12) prevent abrasion of the flexible substrate (2) and, in use,
`
`<¦ -K < <v\ <^<
`6
`v
`
`<\^'
`4
`
`2
`
`Petitioner - Owens Corning
`Ex. 1013, p. 1 of 36
`
`(cid:9)
`

`

`FOR THE PURPOSES OF INFORMATION ONLY
`FOR THE PURPOSES OF INFORMATION ONLY
`
`Codes used to identify States party to the PCT on the front pages of pamphlets publishing international applications under the PCT.
`Codes used to identify States party to the PCT on the front pages of pamphlets publishing international applications under the PCT.
`
`AL
`AL
`AM
`AM
`AT
`AT
`AU
`AU
`AZ
`AZ
`BA
`BA
`BB
`BB
`BE
`BE
`BF
`BF
`BG
`BG
`BJ
`BJ
`BR
`BR
`BY
`BY
`CA
`CA
`CF
`CF
`CG
`CG
`CH
`CH
`CI
`CI
`CM
`CM
`CN
`CN
`CU
`cu
`CZ
`cz
`DE
`DE
`DK
`DK
`EE
`EE
`
`Albania
`Albania
`Armenia
`Armenia
`Austria
`Austria
`Australia
`Australia
`Azerbaijan
`Azerbaijan
`Bosnia and Herzegovina
`Bosnia and Herzegovina
`Barbados
`Barbados
`Belgium
`Belgium
`Burkina Faso
`Burkina Faso
`Bulgaria
`Bulgaria
`Benin
`Benin
`Brazil
`Brazil
`Belarus
`Belarus
`Canada
`Canada
`Central African Republic
`Central African Republic
`Congo
`Congo
`Switzerland
`Switzerland
`Cede d'Ivoire
`C6te d'lvoire
`Cameroon
`Cameroon
`China
`China
`Cuba
`Cuba
`Czech Republic
`Czech Republic
`Germany
`Germany
`Denmark
`Denmark
`Estonia
`Estonia
`
`ES
`ES
`Ft
`FI
`FR
`FR
`GA
`GA
`GB
`GB
`GE
`GE
`GH
`GH
`GN
`GN
`GR
`GR
`HU
`HU
`IE
`IE
`IL
`IL
`IS
`IS
`IT
`IT
`JP
`JP
`KE
`KE
`KG
`KG
`KP
`KP
`
`KR
`KR
`KZ
`KZ
`LC
`LC
`LI
`U
`LK
`LK
`LR
`LR
`
`Spain
`Spain
`Finland
`Finland
`France
`France
`Gabon
`Gabon
`United Kingdom
`United Kingdom
`Georgia
`Georgia
`Ghana
`Ghana
`Guinea
`Guinea
`Greece
`Greece
`Hungary
`Hungary
`Ireland
`Ireland
`Israel
`Israel
`Iceland
`Iceland
`Italy
`Italy
`Japan
`Japan
`Kenya
`Kenya
`Kyrgyzstan
`Kyrgyzstan
`Democratic People's
`Democratic People's
`Republic of Korea
`Republic of Korea
`Republic of Korea
`Republic of Korea
`Kazakstan
`Kazakstan
`Saint Lucia
`Saint Lucia
`Liechtenstein
`Liechtenstein
`Sri Lanka
`Sri Lanka
`Liberia
`Liberia
`
`LS
`LS
`LT
`LT
`LU
`LU
`LV
`LV
`MC
`MC
`MD
`MD
`MG
`MG
`MK
`MK
`
`ML
`ML
`MN
`MN
`MR
`MR
`MW
`MW
`MX
`MX
`NE
`NE
`NL
`NL
`NO
`NO
`NZ
`NZ
`PL
`PL
`PT
`PT
`RO
`RO
`RU
`RU
`SD
`SD
`SE
`SE
`SG
`SG
`
`Lesotho
`Lesotho
`Lithuania
`Lithuania
`Luxembourg
`Luxembourg
`Latvia
`Latvia
`Monaco
`Monaco
`Republic of Moldova
`Republic of Moldova
`Madagascar
`Madagascar
`The former Yugoslav
`The former Yugoslav
`Republic of Macedonia
`Republic of Macedonia
`Mali
`Mali
`Mongolia
`Mongolia
`Mauritania
`Mauritania
`Malawi
`Malawi
`Mexico
`Mexico
`Niger
`Niger
`Netherlands
`Netherlands
`Norway
`Norway
`New Zealand
`New Zealand
`Poland
`Poland
`Portugal
`Portugal
`Romania
`Romania
`Russian Federation
`Russian Federation
`Sudan
`Sudan
`Sweden
`Sweden
`Singapore
`Singapore
`
`SI
`SI
`SK
`SK
`SN
`SN
`SZ
`sz
`TD
`TD
`TG
`TG
`Ti
`TJ
`TM
`TM
`TR
`TR
`TT
`TT
`UA
`UA
`UG
`UG
`US
`US
`UZ
`UZ
`VN
`VN
`YU
`YU
`ZW
`ZW
`
`Slovenia
`Slovenia
`Slovakia
`Slovakia
`Senegal
`Senegal
`Swaziland
`Swaziland
`Chad
`Chad
`Togo
`Togo
`Tajikistan
`Tajikistan
`Turkmenistan
`Turkmenistan
`Turkey
`Turkey
`Trinidad and Tobago
`Trinidad and Tobago
`Ukraine
`Ukraine
`Uganda
`Uganda
`United States of America
`United States of America
`Uzbekistan
`Uzbekistan
`Viet Nam
`Viet Nam
`Yugoslavia
`Yugoslavia
`Zimbabwe
`Zimbabwe
`
`Petitioner - Owens Corning
`Ex. 1013, p. 2 of 36
`
`

`

`WO 98/06891
`WO 98/06891
`
`PCT/GB97/02172
`PCT/GBOT,01,72
`
`1
`
`WATER-VAPOUR-PERMEABLE COMPOSITE MATERIAL
`WATER -VAPOUR -PERMEABLE COMPOSITE MATERIAL
`The present
`The present invention relates to a flexible water-
`invention relates to a flexible water-
`resistant water-vapour-permeable composite material,
`resistant water-vapour-permeable composite material,
`particularly for use in garments, which exhibits a
`particularly for use in garments, which exhibits a
`combination of good breathability (i.e. water vapour
`combination of good breathability (i.e. water vapour
`transmission) and good durability.
`transmission) and good durability.
`Water-vapour-permeable laminate materials which are
`Water-vapour-permeable laminate materials which are
`resistant to liquid water penetration are known from US
`resistant to liquid water penetration are known from US
`patents 3,953,566 and 4,194,041 (W. L. Gore & Associates
`patents 3,953,566 and 4,194,041 (W. L. Gore & Associates
`Inc.) (cid:9)
`Inc.)
`US Patent No. 3,953,566 refers to the production
`US Patent No. 3,953,566 refers to the production
`of an expanded porous polytetrafluoroethylene (PTFE)
`of an expanded porous polytetraf luoroethylene ( PTFE)
`membrane. (cid:9)
`membrane.
`Such membranes generally have intrinsically
`Such membranes generally have intrinsically
`poor abrasion resistance. (cid:9)
`poor abrasion resistance.
`US Patent No. 4,194,041
`US Patent No. 4,194,041
`discloses a material which comprises a porous membrane
`discloses a material which comprises a porous membrane
`(particularly expanded PTFE) provided on one surface
`(particularly expanded PTFE) provided on one surface
`thereof with a continuous layer of a hydrophilic
`thereof with a continuous layer of a hydrophilic
`material which is water-vapour-permeable, such as a
`material which is water-vapour-permeable , such as a
`hydrophilic polyurethane which has poor abrasion
`hydrophilic polyurethane which has poor abrasion
`resistance. (cid:9)
`resistance.
`Other water-resistant water-vapour-
`Other water-resistant water-vapour-
`permeable materials also having poor abrasion resistance
`permeable materials also having poor abrasion resistance
`are also commercially available and these include
`are also commercially available and these include
`polyurethane coatings applied to a fabric, polyurethane
`polyurethane coatings applied to a fabric, polyurethane
`membranes laminated to a fabric, and polyester membrane-
`membranes laminated to a fabric, and polyester membrane-
`fabric combinations.
`fabric combinations.
`Such materials often include an inner liner which
`Such materials often include an inner liner which
`protects against abrasion the polyurethane -coated face
`protects against abrasion the polyurethane-coated face
`of the material in use. (cid:9)
`of the material
`The preformed liner is
`in use.
`The preformed liner is
`generally laminated to the polyurethane-coated face by
`generally laminated to the polyurethane-coated face by
`means of a layer of adhesive. (cid:9)
`means of a layer of adhesive.
`However, the liner adds
`However,
`the liner adds
`to the cost, weight and bulk of the material. (cid:9)
`to the cost, weight and bulk of the material.
`In some
`In some
`applications,
`applications, it may be desirable to eliminate the
`it may be desirable to eliminate the
`liner. (cid:9)
`liner.
`However, this has the disadvantage of exposing
`However,
`this has the disadvantage of exposing
`the soft hydrophilic polyurethane directly to abrasive
`the soft hydrophilic polyurethane directly to abrasive
`forces.
`forces .
`
`US Patent No. 5,026,591 discloses coating a
`US Patent No. 5,026,591 discloses coating a
`
`Petitioner - Owens Corning
`Ex. 1013, p. 3 of 36
`
`(cid:9)
`

`

`WO 98/06891
`WO 98/06891
`
`2
`2
`
`PCT/GB97/02172
`PCT/GB97/02172
`
`.
`
`.
`
`scaffold material (expanded PTFE or microporous
`scaffold material
`(expanded PTFE or microporous
`polypropylene) with a continuous coating of a
`polypropylene) with a continuous coating of a
`hydrophilic material
`hydrophilic material (hot melt hydrophilic polyurethane
`(hot melt hydrophilic polyurethane
`or polyurethane acrylate) and pressing directly into the
`or polyurethane acrylate) and pressing directly into the
`coating a substrate (a polyamide non-woven, a polycotton
`coating a substrate (a polyamide non-woven, a polycotton
`woven blend etc.) and then allowing the coating to cure.
`woven blend etc.) and then allowing the coating to cure.
`The objective is to provide a continuous coating of
`The objective is to provide a continuous coating of
`hydrophilic material without any leaks therein,
`hydrophilic material without any leaks therein,
`sandwiched between the scaffold material and the
`sandwiched between the scaffold material' and the
`substrate.
`substrate .
`
`US Patent No. 4,925,732 discloses the production of
`US Patent No. 4,925,732 discloses the production of
`a laminate for making shoes composed of a pair of
`a laminate for making shoes composed of a pair of
`moisture permeable materials (e.g. leather and fabric)
`moisture permeable materials (e.g.
`leather and fabric)
`adhered together by means of a moisture permeable
`adhered together by means of a moisture permeable
`adhesive (e.g. a polyurethane adhesive).
`adhesive (e.g. a polyurethane adhesive) .
`European Patent No. 0465817 discloses a laminate
`European Patent No. 0465817 discloses a laminate
`for use as a protective material comprising an expanded
`for use as a protective material comprising an expanded
`PTFE liquid barrier layer, having a water-vapour
`PTFE liquid barrier layer, having a water-vapour
`permeable adhesive layer thereon, and active carbon
`permeable adhesive layer thereon, and active carbon
`beads and a net partially embedded in the adhesive
`beads and a net partially embedded in the adhesive
`layer. (cid:9)
`layer.
`The net however remains above the surface of
`The net however remains above the surface of
`the adhesive so as to protect the active carbon beads
`the adhesive so as to protect the active carbon beads
`from being mechanically dislodged. (cid:9)
`from being mechanically dislodged.
`The net thickness
`The net
`thickness
`is typically about 0.5 mm (500 microns).
`is typically about 0.5 mm (500 microns) .
`Water-resistant materials which resist liquid water
`Water-resistant materials which resist liquid water
`penetration are well known to persons skilled in the art
`penetration are well known to persons skilled in the art
`of making rainwear. (cid:9)
`of making rainwear.
`Clearly, the degree of water-
`Clearly,
`the degree of water-
`resistance required in a so-called waterproof garment
`resistance required in a so-called waterproof garment
`depends upon the severity of
`depends upon the severity of the climatic conditions to
`the climatic conditions to
`which it is subjected. (cid:9)
`which it is subjected.
`A suitable test of water-
`A suitable test of water-
`resistance (Suter test) is described herein. (cid:9)
`resistance (Suter test)
`An
`is described herein.
`An
`acceptable practical
`acceptable practical indication of water-resistance is
`indication of water-resistance is
`one in which there is no evidence of water being forced
`one in which there is no evidence of water being forced
`through a sample by a pressure of 1.4 pounds per square
`through a sample by a pressure of 1.4 pounds per square
`inch (0.1kg/cm2), or more typically 2.0 pounds per square
`inch (O.lkg/cm2), or more typically 2.0 pounds per square
`inch (0.14kg/cm2). (cid:9)
`inch (0 . 14kg/cm2) .
`This also gives a measure of
`This also gives a measure of
`hydrophobicity in respect of porous materials.
`hydrophobicity in respect of porous materials.
`
`Petitioner - Owens Corning
`Ex. 1013, p. 4 of 36
`
`(cid:9)
`

`

`WO 98/06891
`WO 98/06891
`
`PCT/GB97/02172
`PCT/GB97/02172
`
`3
`
`The benefit of a water-vapour-permeable material is
`The benefit of a water-vapour-permeable material
`is
`that perspiration from the wearer's body is allowed to
`that perspiration from the wearer's body is allowed to
`escape from within the garment by passage through the
`escape from within the garment by passage through the
`material, thus preventing build-up of liquid water
`material,
`thus preventing build-up of
`liquid water
`within the garment and consequent clammy feeling. In
`within the garment and consequent clammy feeling.
`In
`order to be considered as water-vapour-permeable, the
`order to be considered as water- vapour-permeable ,
`the
`flexible substrate should generally have a water-vapour-
`flexible substrate should generally have a water-vapour-
`permeability of at least 1,000, preferably greater than
`permeability of at
`least 1,000, preferably greater than
`1500 and more preferably greater than 3000 g/m2/day.
`1500 and more preferably greater than 3000 g/m2/day.
`However, values in excess of 100,000 g/m2/day are
`However, values in excess of 100,000 g/m2/day are
`possible with certain substrates. (cid:9)
`The overall water-
`possible with certain substrates.
`The overall water-
`vapour-permeability of the flexible composite material
`vapour-permeability of
`the flexible composite material
`of the present invention will usually be somewhat lower
`of
`the present
`invention will usually be somewhat
`lower
`than this (e.g. 5,000 to 12,000 g/m2/day or up to 30,000
`than this (e.g. 5,000 to 12,000 g/m2/day or up to 30,000
`g/m2 for certain substrates) but generally speaking its
`g/m2 for certain substrates) but generally speaking its
`water-vapour-permeability may also be within the ranges
`water-vapour-permeability may also be within the ranges
`outlined above.
`outlined above.
`A suitable water-resistant water-vapour-permeable
`A suitable water-resistant water-vapour-permeable
`flexible membrane is disclosed in US Patent No.
`flexible membrane is disclosed in US Patent No.
`3,953,566 which discloses a porous expanded
`3,953,566 which discloses a porous expanded
`polytetrafluoroethylene (PTFE) material. (cid:9)
`The expanded
`polytetraf luoroethylene (PTFE) material.
`The expanded
`porous PTFE has a micro-structure characterised by nodes
`porous PTFE has a micro-structure characterised by nodes
`interconnected by fibrils. (cid:9)
`If necessary, the water-
`interconnected by fibrils.
`If necessary,
`the water-
`resistance may be enhanced by impregnating the expanded
`resistance may be enhanced by impregnating the expanded
`PTFE with an hydrophobic impregnant (such as a low
`PTFE with an hydrophobic impregnant
`(such as a low
`molecular weight perfluoro compound, for example a
`molecular weight perfluoro compound,
`for example a
`perfluoroalkyl acrylate or methacrylate). (cid:9)
`Such
`perf luoroalkyl acrylate or methacrylate) .
`Such
`impregnants are also oleophobic. (cid:9)
`The impregnants can
`impregnants are also oleophobic.
`The impregnants can
`coat the nodes and fibrils of the porous PTFE.
`coat
`the nodes and fibrils of
`the porous PTFE.
`The water-resistant water-vapour-permeable membrane
`The water-resistant water- vapour-permeable membrane
`might also be a microporous material such as a high
`might also be a microporous material such as a high
`molecular weight microporous polyethylene or
`molecular weight microporous polyethylene or
`polypropylene, microporous polyurethanes or polyesters
`polypropylene, microporous polyurethanes or polyesters.
`In addition, the water-resistant water-vapour-
`In addition,
`the water-resistant water- vapour-
`permeable flexible membrane may include a coating of a
`permeable flexible membrane may include a coating of a
`water-resistant water-vapour-permeable hydrophilic film
`water-resistant water -vapour -permeable hydrophilic film
`of the type disclosed in US Patent No. 4,194,041, the
`of
`the type disclosed in US Patent No. 4,194,041,
`the
`
`Petitioner - Owens Corning
`Ex. 1013, p. 5 of 36
`
`(cid:9)
`

`

`WO 98/06891
`WO 98/06891
`
`PCT/GB97/02172
`PCT/GB97/02172
`
`4
`
`membrane and hydrophilic film together forming a
`membrane and hydrophilic film together forming a
`substrate. (cid:9)
`substrate.
`Such hydrophilic films are generally also
`Such hydrophilic films are generally also
`oleophobic. The flexible membrane may be formed of
`oleophobic.
`The flexible membrane may be formed of
`porous expanded PTFE as described in US Patent No.
`porous expanded PTFE as described in US Patent No.
`3,953,566.
`3,953,566.
`
`Such materials as described are essentially
`Such materials as described are essentially
`conventional.
`conventional .
`
`It is an object of the present invention to provide
`It is an object of the present
`invention to provide
`good abrasion resistance in water-resistant water-
`good abrasion resistance in water-resistant water-
`vapour-permeable composite materials, without
`vapour-permeable composite materials, without the need
`the need
`for a protective liner.
`for a protective liner.
`
`According to the present invention there is
`According to the present
`invention there is
`provided a composite lining material for a garment or
`provided a composite lining material for a garment or
`the like comprising
`the like comprising
`(a) a water-resistant, water-vapour-permeable, flexible
`(a)
`a water-resistant, water-vapour-permeable,
`flexible
`substrate having a first and second side;
`substrate having a first and second side;
`(b) a fabric secured to said first side of the
`(b)
`a fabric secured to said first side of the
`substrate; and
`substrate ;
`and
`(c) a plurality of discrete abrasion-resisting
`(c)
`a plurality of discrete abrasion-resisting
`polymeric dots forming a discontinuous lining- forming
`polymeric dots forming a discontinuous lining-forming
`pattern over the surface of said second side of the
`pattern over the surface of said second side of
`the
`substrate and which dots resist abrasion of the flexible
`substrate and which dots resist abrasion of the flexible
`substrate.
`substrate .
`
`According to a further aspect of the present
`According to a further aspect of the present
`invention the composite material
`invention the composite material is embodied in garments
`is embodied in garments
`such as hats, gloves or shoes.
`such as hats, gloves or shoes.
`According to a still further aspect of
`According to a still further aspect of the present
`the present
`invention there is provided a process of producing a
`invention there is provided a process of producing a
`composite lining material for a garment or the like
`composite lining material for a garment or the like
`comprising securing a fabric to a first side of a
`comprising securing a fabric to a first side of a
`flexible, water-resistant, water-vapour-permeable
`flexible, water-resistant, water- vapour-permeable
`substrate, and applying a plurality of abrasion-
`substrate, and applying a plurality of abrasion-
`resisting polymeric dots to a second side of said
`resisting polymeric dots to a second side of said
`substrate in order to form a discontinuous lining-
`substrate in order to form a discontinuous lining-
`forming pattern over the surface of said second side to
`forming pattern over the surface of said second side to
`resist abrasion of the flexible substrate.
`resist abrasion of
`the flexible substrate.
`The contribution made by the present invention is
`The contribution made by the present
`invention is
`
`Petitioner - Owens Corning
`Ex. 1013, p. 6 of 36
`
`(cid:9)
`

`

`WO 98/06891
`WO 98/06891
`
`PCT/GB97/02172
`PCT/GB97/02172
`
`5
`
`to provide a discontinuous abrasion-resisting lining-
`to provide a discontinuous abrasion-resisting lining-
`forming layer over the flexible substrate material so as
`forming layer over the flexible substrate material so as
`to provide a protective surface layer which protects the
`to provide a protective surface layer which protects the
`water-vapour-permeable flexible substrate from abrasion
`water-vapour-permeable flexible substrate from abrasion
`forces in a particularly lightweight, convenient and
`forces in a particularly lightweight, convenient and
`economical manner. (cid:9)
`Thus, it is surprisingly found
`economical manner.
`Thus,
`it is surprisingly found
`that the application of an abrasion resisting layer,
`that
`the application of an abrasion resisting layer,
`comprising a discontinuous pattern of abrasion-resisting
`comprising a discontinuous pattern of abrasion-resisting
`polymeric material is in itself sufficient to provide
`polymeric material
`is in itself sufficient to provide
`abrasion resistance and durability, without the need to
`abrasion resistance and durability, without
`the need to
`apply the conventional inner liner. The abrasion-
`apply the conventional
`inner liner.
`The abrasion-
`resisting polymeric material constitutes the surface
`resisting polymeric material constitutes the surface
`layer of the composite material and is the layer which
`layer of
`the composite material and is the layer which
`is innermost when the material is used to form a
`is innermost when the material
`is used to form a
`garment, that is to say it is the surface layer which is
`garment,
`that
`is to say it is the surface layer which is
`closest to the skin of the wearer. It has been
`closest
`to the skin of
`the wearer.
`It has been
`surprisingly found that the discontinuous pattern of
`surprisingly found that the discontinuous pattern of
`abrasion-resisting material, whilst providing the
`abrasion-resisting material, whilst providing the
`necessary moisture vapour permeability, is sufficient to
`necessary moisture vapour permeability,
`is sufficient to
`resist abrading of the material during flexing thereof,
`resist abrading of
`the material during flexing thereof,
`both against itself and against any other materials
`both against
`itself and against any other materials
`which may be present (for example other garments worn by
`which may be present
`(for example other garments worn by
`the wearer).
`the wearer) .
`
`For the purposes of the present invention, it is
`For the purposes of
`the present
`invention, it is
`preferable that, for a given polymer, the resistance to
`preferable that,
`for a given polymer,
`the resistance to
`abrasion is greater for a lining formed by polymeric
`abrasion is greater for a lining formed by polymeric
`dots which have a smooth, rounded, non-angular external
`dots which have a smooth,
`rounded, non-angular external
`surface. (cid:9)
`surface.
`Also, smooth rounded dots, when constituting
`Also, smooth rounded dots, when constituting
`the innermost lining surface of a garment, will present
`the innermost
`lining surface of a garment, will present
`a more comfortable feel to the wearer and avoid snagging
`a more comfortable feel
`to the wearer and avoid snagging
`of the skin or any inner clothing worn by the wearer.
`of
`the skin or any inner clothing worn by the wearer.
`Embodiments of the present invention will now be
`Embodiments of
`the present
`invention will now be
`described, by way of example, with reference to the
`described, by way of example, with reference to the
`accompanying drawings, in which:-
`accompanying drawings,
`in which: -
`Fig. 1 is a fragmentary plan view, to an enlarged
`Fig.
`1 is a fragmentary plan view,
`to an enlarged
`scale of a first embodiment of a composite lining
`scale of a first embodiment of a composite lining
`material in accordance with the invention;
`material
`in accordance with the invention;
`
`Petitioner - Owens Corning
`Ex. 1013, p. 7 of 36
`
`(cid:9)
`

`

`wo 98/06891
`WO 98/06891
`
`6
`6
`
`PCT/GB97/02172
`PCT/GB97/02172
`
`-
`
`-
`
`Fig.
`2 is a diagrammatic cross- sectional view on
`Fig. 2 is a diagrammatic cross-sectional view on
`the line A-A of Fig. 1;
`the line A-A of Fig. 1;
`Fig.
`Fig. 3 is a diagrammatic cross-sectional view
`3
`is a diagrammatic cross-sectional view
`similar to Fig.
`similar to Fig. 2 of a second embodiment of the present
`2 of a second embodiment of the present
`invention;
`invention;
`Fig. 4 is a perspective view from above of an image
`Fig. 4 is a perspective view from above of an image
`produced from a Scanning Electron Microscope (SEM) of a
`produced from a Scanning Electron Microscope (SEM) of a
`composite lining material
`composite lining material incorporating polymeric dots
`incorporating polymeric dots
`in accordance with the invention;
`in accordance with the invention;
`Fig.
`5 is a vertical sectional view of an image
`Fig. 5 is a vertical sectional view of an image
`produced from a Scanning Electron Microscope of a
`produced from a Scanning Electron Microscope of a
`polymeric dot on a composite lining material
`polymeric dot on a composite lining material in
`in
`accordance with the invention; and
`accordance with the invention;
`and
`Fig.
`6 is a schematic illustration of a coating
`Fig. 6 is a schematic illustration of a coating
`apparatus for applying,
`apparatus for applying, in accordance with the
`in accordance with the
`invention, an abrasion-resisting polymeric material onto
`invention, an abrasion-resisting polymeric material onto
`a substrate.
`a substrate.
`
`A
`A
`
`Referring to Figs.
`Referring to Figs. 1 and 2 of the drawings, a
`1 and 2 of
`the drawings, a
`composite lining material comprises a waterproof, water-
`composite lining material comprises a waterproof, water-
`vapour-permeable flexible substrate 2 having a face
`vapour-permeable flexible substrate 2 having a face
`fabric 4 adhered to one side 6 of the substrate 2 .
`fabric 4 adhered to one side 6 of the substrate 2. (cid:9)
`second side 8 of the substrate 2 has firmly adhered
`second side 8 of the substrate 2 has firmly adhered
`thereto an abrasion-resisting, discontinuous lining-
`thereto an abrasion-resisting, discontinuous lining-
`forming layer 10 made up of a plurality of discrete,
`forming layer 10 made up of a plurality of discrete,
`substantially smooth- surfaced non-angular dots 12 of an
`substantially smooth-surfaced non-angular dots 12 of an
`abrasion-resisting polymeric material such as an
`abrasion-resisting polymeric material such as an
`abrasion-resisting polyurethane and which dots project
`abrasion-resisting polyurethane and which dots project
`from the side 8 of the substrate 2. (cid:9)
`from the side 8 of
`the substrate 2.
`The polymer from
`The polymer from
`which the dots are made should have an elastic modulus
`which the dots are made should have an elastic modulus
`of greater than about 800 psi
`of greater than about 800 psi (5.5 Nmm-2) in order to
`(5.5 Nmm"2)
`in order to
`provide the desired abrasion resistance.
`provide the desired abrasion resistance.
`The flexible substrate 2 is composed of an expanded
`The flexible substrate 2 is composed of an expanded
`polytetraf luoroethylene (PTFE) membrane as disclosed in
`polytetrafluoroethylene (PTFE) membrane as disclosed in
`aforementioned US Patent No. 3,953,566 and which PTFE
`aforementioned US Patent No. 3,953,566 and which PTFE
`has a porous microstructure characterised by nodes
`has a porous microstructure characterised by nodes
`interconnected by fibrils. (cid:9)
`interconnected by fibrils.
`The membrane 2 is resistant
`The membrane 2 is resistant
`to passage of liquid water therethrough but
`to passage of liquid water therethrough but is water-
`is water-
`
`Petitioner - Owens Corning
`Ex. 1013, p. 8 of 36
`
`(cid:9)
`

`

`WO 98/06891
`WO 98/06891
`
`7
`7
`
`PCT/GB97/02172
`PCT/GB97/02172
`
`-
`
`-
`
`vapour-permeable. (cid:9)
`vapour -permeabl e .
`The membrane 2 has a weight of 15g/m2
`The membrane 2 has a weight of 15g/m2
`and a maximum pore size of 0.2 microns determined by
`and a maximum pore size of 0.2 microns determined by
`known bubble point measurement
`known bubble point measurement techniques such as that
`techniques such as that
`described in US Patent No. 5026591 (Henn).
`described in US Patent No. 5026591 (Henn) .
`The face fabric 4 is laminated to side 6 of
`The face fabric 4 is laminated to side 6 of
`substrate 2 by any conventional means and the face
`substrate 2 by any conventional means and the face
`fabric 4 can be one of a number of known face fabrics
`fabric 4 can be one of a number of known face fabrics
`such as a woven, non-woven or knitted fabric of a
`such as a woven, non-woven or knitted fabric of a
`material such as nylon or polyester. (cid:9)
`material such as nylon or polyester.
`In use, the face
`In use,
`the face
`fabric constitutes the outer surface of a garment
`fabric constitutes the outer surface of a garment formed
`formed
`from the composite material and provides the required
`from the composite material and provides the required
`visual or aesthetic appearance and the necessary
`visual or aesthetic appearance and the necessary
`mechanical properties.
`mechanical properties.
`
`Each of
`Each of the polyurethane dots 12 is substantially
`the polyurethane dots 12 is substantially
`circular in plan view as shown in Fig.
`circular in plan view as shown in Fig. 1 and part-
`1 and part-
`spherical
`spherical in cross-section as shown in Fig. 2 defined by
`in cross-section as shown in Fig.
`2 defined by
`an arc having a radius of the order of about 400
`an arc having a radius of the order of about 400
`microns. (cid:9)
`microns .
`In the present embodiment the dots 12 are
`In the present embodiment
`the dots 12 are
`arranged in repeat regular pattern of seven dot
`arranged in repeat regular pattern of seven dot
`rosettes,
`rosettes, i.e. six dots are arranged around a central
`i.e. six dots are arranged around a