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Gore-Tex


Gore-Tex is a proprietary waterproof and breathable membrane made from expanded (ePTFE), featuring a microporous structure with approximately nine billion pores per square inch that repel liquid water droplets—being 20,000 times smaller than water—while allowing sweat vapor molecules, which are 700 times smaller, to escape for enhanced comfort during activity. Developed in 1969 by , son of founder Wilbert L. Gore, through rapid stretching of to form the durable ePTFE , it marked a breakthrough in material science by combining impermeability to external moisture with internal moisture management. The technology, patented in 1976, propelled the company's expansion from industrial PTFE applications—initiated when Wilbert and Vieve Gore founded the firm in 1958—into consumer and performance products, fundamentally transforming outdoor gear like jackets, footwear, and gloves for sports such as , , and by providing reliable weather resistance without overheating. Beyond apparel, Gore-Tex's has enabled its use in medical implants, including vascular grafts that promote due to the membrane's inert .

History

Invention of Expanded PTFE

In 1969, Robert W. "Bob" Gore, son of founders Wilbert L. and Genevieve Gore, discovered expanded polytetrafluoroethylene (ePTFE) while attempting to develop a new stretching process for (PTFE), a originally invented by J. Plunkett in 1938. The family-owned company, established in , in 1958, focused on PTFE applications after Wilbert Gore identified untapped commercial potential in the material during his tenure at . Wilbert tasked his son, then a researcher with a recent Ph.D. in from the , with creating a thin, strong PTFE form for use as pipe thread tape sealant, as conventional slow stretching methods yielded brittle results. On the evening of October 28, 1969, working alone in the company laboratory, Bob Gore heated rods of extruded PTFE and, in frustration after repeated failures with gradual extension, rapidly stretched the material beyond its expected breaking point. Contrary to prior observations where PTFE snapped under tension, the rapid pull caused the polymer to expand into a soft, porous microstructure characterized by nodes connected by elongated fibrils, forming microscopic voids that imparted unique properties to the material. This serendipitous breakthrough, stemming from empirical trial-and-error rather than theoretical prediction, marked the invention of ePTFE, which W. L. Gore & Associates later trademarked as the basis for GORE-TEX products. Wilbert Gore recognized the discovery's significance immediately and pursued patent protection; the foundational U.S. Patent 3,953,566 for the process of producing porous PTFE products was issued on April 27, 1976, to and assigned to the company, detailing the rapid expansion technique under controlled temperature and stretch conditions. Earlier related filings, such as application Serial No. 863,446 on October 3, 1969, supported the development of the expanded form from unsintered PTFE shapes. The transformed PTFE from a dense, non-porous solid into a versatile expanded variant, enabling subsequent innovations in waterproof breathable fabrics and medical implants, though initial commercialization focused on industrial seals before apparel applications.

Early Commercialization and Adoption

Following the discovery of expanded polytetrafluoroethylene (ePTFE) in 1969, initially commercialized the material in medical applications, with the first GORE-TEX Vascular Graft introduced in 1975, marking the company's entry into the medical products sector. This graft leveraged ePTFE's and for , establishing early revenue streams before broader fabric applications. In 1976, Gore launched GORE-TEX Fabric for protective apparel, with its inaugural sale to Early Winters, Ltd., a Seattle-based outfitter, for use in outerwear. The fabric's waterproof yet breathable properties addressed longstanding challenges in rain gear, prompting initial adoption in outdoor equipment; the first commercial Gore-Tex product was a that year, followed by parkas. Early Winters produced the first Gore-Tex in 1977, marketed for its superior moisture management during activities like . Adoption accelerated modestly in the late 1970s among niche outdoor brands, as high production costs limited mass-market penetration; released its Golden Mantle jacket featuring Gore-Tex in 1978 after collaboration with Gore representatives. The outwear division achieved profitability by 1979, reflecting growing demand from consumers seeking durable, weather-resistant clothing amid rising interest in recreational hiking and climbing. Despite these advances, early faced hurdles from complexities and skepticism over the material's longevity, with Gore emphasizing rigorous testing to build trust among partners.

Patent Disputes and Legal Challenges

W.L. Gore & Associates, Inc. faced early challenges to its foundational patents on expanded polytetrafluoroethylene (ePTFE), the core material in Gore-Tex fabrics, through litigation with competitor Garlock, Inc. In 1974, Gore initiated suit against Garlock in the U.S. District Court for the District of Delaware, alleging infringement of U.S. Patent Nos. 3,953,566 (issued April 27, 1976) and 4,187,390 (issued February 5, 1980), which claimed processes for rapidly stretching heated, unsintered PTFE extrusions to achieve a porous, expanded microstructure with nodes interconnected by fibrils. Garlock counterclaimed invalidity under 35 U.S.C. § 102(b), arguing that Gore's pre-filing sales of ePTFE samples to customers in 1969 constituted a public use or commercial offer for sale that barred patentability. The district ruled in 1980 that Gore's activities were experimental to refine the , not commercial, and thus did not trigger the statutory bar; it held the patents valid, enforceable, and infringed by Garlock's similar methods for producing expanded PTFE and . The U.S. of Appeals for the Federal Circuit affirmed these findings in 1983, clarifying that even secret commercial use does not qualify as "public use" if the primary purpose remains experimental improvement of the under conditions of reasonable secrecy. Garlock's subsequent appeal on inequitable conduct—alleging Gore withheld during prosecution—was rejected in 1988, with the finding no clear error in the judge's determination of no or deceptive intent, and denying Garlock's fees request. A separate, decades-long dispute arose with C.R. Bard, Inc. (later Bard Peripheral Vascular, Inc.), centered on ePTFE applications in vascular grafts but implicating the same microstructure technology licensed for Gore-Tex. Bard filed suit in 1974, asserting rights stemming from its 1972 patent application (eventually issuing as continuations including U.S. Patent No. 6,436,135 in 2002), which claimed thin-walled ePTFE tubing with a specific fibril length-to-node ratio for improved patency in implantable grafts. After numerous trials, mistrials, and appeals, a 2010 jury verdict found Gore willfully infringed the '135 patent by manufacturing and selling ePTFE grafts incorporating the claimed microstructure, awarding Bard $371 million in damages based on reasonable royalty calculations from 2001 onward. The Federal Circuit upheld the infringement and willfulness findings in 2015, rejecting Gore's invalidity arguments over prior art (including Gore's own earlier ePTFE disclosures) and enablement, as substantial evidence supported the jury's view that the patent taught a person of ordinary skill how to achieve the claimed structure without undue experimentation. These cases underscored the robustness of Gore's ePTFE patents against invalidity challenges, despite competitors' efforts to exploit prior commercial activities or , enabling Gore to maintain exclusivity over the material's methods essential to Gore-Tex's waterproof-breathable properties; however, they also exposed vulnerabilities in derivative applications, resulting in significant liability for willful infringement in medical contexts.

Material Structure

Microscopic Composition

The Gore-Tex membrane consists of expanded (ePTFE), a synthetic processed through rapid unidirectional and biaxial stretching to induce a microporous . This expansion transforms the dense PTFE into a network of microscopic nodes interconnected by fine , forming a fibrillar microstructure with high . The nodes, aggregates of PTFE crystallites approximately 10 micrometers in diameter, act as junctions from which —elongated chains of polymer molecules—extend, creating an irregular lattice that traps air within interconnecting voids. Pore sizes in this ePTFE structure typically range from tens to hundreds of nanometers, engineered such that they are smaller than liquid water droplets (preventing penetration via ) but larger than molecules (approximately 0.4 nanometers), enabling . The material contains billions of these pores—estimated at 9 billion per —distributed throughout the membrane, contributing to its semi-permeable nature. , defined by the internodal distance between , can be controlled during manufacturing; shorter distances yield finer pores for enhanced , while longer ones increase permeability. Scanning electron microscopy reveals the membrane's spongy, fibrous appearance, with fibrils often 10-100 nanometers in diameter and nodes exhibiting a rough, crystalline . This microstructure imparts strength despite the material's thinness (typically 5-25 micrometers), as the network distributes stress and resists tearing. Variations in ratios during production allow tailoring of the node-fibril , affecting overall and characteristics.

Laminate Integration

The expanded polytetrafluoroethylene (ePTFE) membrane central to Gore-Tex is integrated into functional fabrics via a process that bonds it to outer textiles and, in some cases, inner linings, forming durable laminates suitable for apparel and equipment. This bonding protects the fragile microporous structure of the membrane, which would otherwise be prone to damage from abrasion or flexing, while preserving its waterproof and breathable properties. The process, developed by , typically involves applying controlled heat and pressure to fuse layers, often without relying on liquid adhesives to avoid compromising vapor transmission. Gore-Tex laminates are classified by layer count, with two-layer (2L) and three-layer (3L) constructions being predominant. In 2L configurations, the ePTFE is directly laminated to the outer face fabric—commonly or —creating a bonded to which a separate, non-adhered liner is added during garment assembly for wearer comfort and additional protection. This approach yields lighter, more flexible fabrics but requires careful handling to prevent at seams. 3L laminates, by contrast, encapsulate the membrane between the outer fabric and a bonded inner layer, such as a polyurethane film or , enhancing overall durability, reducing bulk, and improving packability for high-performance applications like gear. Post-lamination, seams in finished garments are sealed using proprietary Gore-Tex tapes, which are applied via heat-activated adhesives to ensure hydrostatic resistance exceeds 28,000 mm , as per industry standards. Variations like Gore-Tex Paclite employ minimalist 2.5L designs with a dotted inner coating for reduced weight, while Gore-Tex Pro uses reinforced 3L weaves for extreme resistance, achieving up to 100,000 abrasion cycles in lab tests. These integrations maintain the membrane's RET (retistance to evaporative transmission) below 13 for certified , verified through rigorous testing protocols.

Properties

Waterproofing and Breathability Mechanisms

The waterproofing mechanism of Gore-Tex relies on its expanded polytetrafluoroethylene (ePTFE) membrane, a microporous structure formed by rapidly stretching polytetrafluoroethylene resin to create nodes interconnected by fibrils, resulting in billions of microscopic pores per square centimeter. These pores, typically on the order of 0.1 to 1 micrometer in diameter, are sufficiently small—approximately 20,000 times smaller than the diameter of a liquid water droplet—that surface tension prevents water droplets from entering and penetrating the membrane under normal hydrostatic pressures encountered in apparel applications. The inherent hydrophobicity of PTFE, with its low surface energy, further inhibits wetting by liquid water, ensuring the membrane remains impermeable to rain or splashes while laminated between outer and inner fabric layers to maintain structural integrity. Breathability in Gore-Tex is achieved through the same porous structure, which permits the of molecules from sweat—generated by the body during activity—outward along a vapor pressure , as individual molecules (about 0.0003 micrometers) or small clusters can traverse the pores without the cohesive forces of liquid impeding passage. This vapor transmission occurs via rather than bulk airflow, with the membrane's design allowing over 9 billion pores per to facilitate equivalent to rates measured in grams per square meter per 24 hours under standardized testing conditions like those specified by ASTM standards. The process depends on environmental factors such as , , and activity level; in high- conditions, the diminishes, potentially leading to if vapor cannot escape efficiently, though the membrane's windproof properties aid in maintaining the by preventing stagnant air layers. Together, these mechanisms enable Gore-Tex to balance impermeability to external liquid with internal moisture management, though real-world performance varies with laminate construction, garment design, and external conditions; for instance, the membrane withstands hydrostatic heads exceeding 28,000 mm of in some configurations, far beyond typical rainfall pressures. Empirical testing confirms that the ePTFE pores selectively transport vapor while rejecting liquid due to size exclusion and interfacial energy barriers, distinguishing it from non-porous hydrophilic alternatives that rely on adsorption-desorption cycles.

Durability, Chemical Resistance, and Other Traits

Gore-Tex laminates demonstrate robust durability attributable to the expanded (ePTFE) membrane's inherent high tensile strength, typically ranging from 50 to 800 , and its resistance to and mechanical stress. The ePTFE structure, when combined with protective outer fabrics, withstands repeated flexing, tearing, and exposure to harsh environmental without significant of core performance metrics like . However, overall tear and puncture resistance in finished garments largely depends on the face fabric's denier and weave rather than the membrane alone, as evidenced by field testing where outer layers bear the brunt of wear. The material's chemical resistance derives from PTFE's fluoropolymer composition, rendering it inert to a broad spectrum of aggressive substances including acids, bases, solvents, and hydrocarbons at ambient to elevated s. Expanded PTFE maintains or enhances this , showing minimal in corrosive environments compared to denser PTFE forms, with applications in confirming resilience against chemical . Exceptions include to molten metals or certain fluorinated compounds under and , where swelling or can occur. Additional traits include a low coefficient of , facilitating smooth handling and reduced wear in dynamic uses, alongside operational across a wide range from approximately -200°C to +260°C for the base , though laminated fabrics are typically rated up to 135°C for prolonged exposure. Gore-Tex variants also exhibit UV resistance, blocking over 90% of rays, and retain properties under prolonged exposure to extreme conditions without notable aging or embrittlement. These characteristics collectively enable long-term reliability in demanding scenarios, though real-world longevity requires proper maintenance to prevent contaminant buildup that could compromise .

Manufacturing and Processing

Production Techniques

The production of the Gore-Tex membrane, composed of expanded (ePTFE), commences with blending fine powder resin with a liquid , such as an isoparaffinic , to create a paste-like consistency suitable for forming. This mixture, typically containing 15-30% by weight, is preformed under pressure to remove air voids and ensure uniformity. The paste undergoes ram through a die to produce a continuous sheet or of desired thickness, often on the order of 0.1 to 1 mm initially. Following , the is extracted via heating or volatilization at temperatures around 100-200°C, yielding a dried, unsintered PTFE structure that retains shape but lacks . The defining step involves rapid biaxial stretching—or expansion—of the dried extrudate at temperatures exceeding PTFE's crystalline transition (approximately 19°C) but below full (around 327°C), with stretch ratios often 10:1 to 100:1 in longitudinal and transverse directions. This process, detailed in U.S. Patent 3,953,566 granted to on April 27, 1976, induces fibrillations where crystalline regions form nodes interconnected by fine , creating a microporous with pore sizes of 0.1-10 micrometers and up to 9 billion pores per square inch. Post-expansion, the material is sintered briefly at 360-400°C to nodes and lock the microstructure, preventing collapse while maintaining strength and flexibility. For integration into fabrics, the ePTFE is laminated to textile layers—typically a durable outer fabric and optional inner liner—via dot adhesives, coatings, or direct bonding, ensuring waterproofness without compromising breathability. Variations in stretch rates, temperatures, and grades allow tailoring of properties like and tensile strength for specific applications.

Quality Control and Variations

W.L. Gore & Associates implements rigorous quality control through certification of manufacturing partners, who must adhere to proprietary standards for membrane lamination, seam sealing with GORE-SEAM tape, and overall processing to prevent defects in waterproofing and breathability. Products undergo multi-stage testing, including laboratory assessments for hydrostatic resistance exceeding 28,000 mm water column, moisture vapor permeability via RET values under ISO 11092, and field trials simulating extreme abrasion, flexing, and laundering cycles to verify durability over the garment's lifecycle. Third-party validations, such as OEKO-TEX STANDARD 100 for chemical safety and bluesign system for sustainable input materials, supplement internal protocols, with compliance enforced via ISO 9001 quality management and ISO 14001 environmental systems. Gore-Tex variations arise primarily from differences in laminate construction and membrane formulation to optimize for specific performance needs, such as two-layer (2L) designs in Paclite for minimal weight and packability versus three-layer (3L) in for superior abrasion resistance in rugged use. Traditional expanded polytetrafluoroethylene (ePTFE) membranes, with pore sizes around 20 nm for selective vapor transmission, have been adapted into (ePE) variants since 2018 to eliminate (PFAS) while maintaining comparable waterproofness and metrics. Manufacturing adjusts parameters like membrane thickness (e.g., under 100 nm per layer in stacks), face fabric denier, and bonding techniques to yield specialized types, including Surround for 360-degree or stretch-integrated laminates, all validated against uniform quality benchmarks.

Applications

Outdoor and Protective Apparel

GORE-TEX fabrics entered the outdoor apparel market with the launch of the first commercial jackets in 1976, sold to Early Winters, Ltd., a Seattle-based company, marking the initial application of expanded polytetrafluoroethylene (ePTFE) membrane in consumer garments for weather protection. These early products emphasized lightweight waterproofing combined with , enabling users to remain dry during activities like and while allowing vapor from to escape. In outdoor pursuits such as , , , and , GORE-TEX garments form the basis for shells and layered systems, providing total windproofing, durable rated to standards exceeding 28,000 mm hydrostatic head in many configurations, and metrics often above 15,000 g/m²/24h for vapor transmission. GORE-TEX PRO variants target extreme conditions, incorporating multi-layer constructions with enhanced resistance for prolonged exposure to rugged terrain, as seen in professional alpine gear that withstands repeated mechanical stress without . ![Sportful Gore-Tex Windstopper cycling gilet][float-right] For protective apparel, GORE-TEX technologies extend to specialized gear for firefighters and responders, where GORE-TEX CROSSTECH® fabrics integrate chemical-resistant barriers compliant with NFPA 1971 standards for structural , offering breathable defense against flames, convective heat up to specified thermal protective performance levels, water, and blood-borne pathogens. In defense and applications, variants like GORE-TEX PYRAD® provide flame-retardant, low-visibility for tactical operations, balancing mobility with barriers against environmental hazards and . These fabrics have been field-tested for over 35 years in high-risk scenarios, prioritizing durability through reinforced laminates that maintain integrity after multiple wash cycles and exposures.

Footwear and Accessories

Gore-Tex membranes are incorporated into the uppers, linings, and sometimes soles of to deliver waterproofing alongside , enabling moisture from sweat to escape while blocking external water ingress. This construction is prevalent in hiking boots, shoes, and safety footwear, where it maintains foot comfort during prolonged exposure to wet conditions. For example, GORE-TEX Extended Comfort technology in shoes maximizes heat and moisture transfer, supporting all-day wear in variable weather. Materials in Gore-Tex footwear achieve breathability values up to six times the minimum required by EN ISO 20345/47 standards for protective shoes, enhancing durability against and . Innovations like GORE-TEX SURROUND extend to 360 degrees by integrating the into the outsole, facilitating vapor escape through the bottom during high-activity pursuits in warm environments. Brands such as have adopted Gore-Tex in their footwear lines since at least 2019, citing its reliability for user trust in waterproof performance. Rugged variants, including GORE-TEX Pro introduced in 2006, target extreme outdoor demands in boots for and professional use. In accessories, Gore-Tex fabrics equip gloves and hats for windproof, waterproof protection with breathability, suitable for activities from daily commuting to . Gloves featuring Gore-Tex offer touchscreen compatibility, enhanced grip for , and dexterity for or , performing effectively in cold, wet conditions. Hats and gauntlets with Gore-Tex provide regulation and all-weather shielding, as seen in products for and climbing, where they exceed basic waterproof thresholds while preserving wearer comfort. These applications span everyday wear to specialized gear, prioritizing functionality over aesthetics in harsh environments.

Medical and Industrial Uses

Gore-Tex materials, utilizing expanded (ePTFE), are employed in various medical implants and devices due to their , flexibility, and resistance to ingrowth. Synthetic vascular grafts made from ePTFE facilitate blood flow in bypass surgeries and arterial reconstructions, with products like Gore's HEAC (high elasticity arterial covered) stents approved for clinical use. Cardiovascular patches, such as the GORE-TEX Cardiovascular Patch introduced in the , repair heart defects and prevent adhesions during surgeries. Surgical meshes constructed from ePTFE support repairs by providing a for integration while minimizing inflammatory responses. Sutures of expanded PTFE, cleared by the FDA under regulation 878.5010, offer nonabsorbable options for cardiovascular and , exhibiting low thrombogenicity. In medical device manufacturing, GORE Microfiltration Media, composed of ePTFE, protects components in hearing instruments, transducers, and infusion sets by allowing acoustic transmission or gas passage while blocking contaminants and moisture. Pericardial membranes like PRECLUDE, made from ePTFE, shield the heart during resternotomy procedures in congenital heart disease patients, reducing injury risk from adhesions. For industrial applications, ePTFE-based Gore-Tex products excel in sealing and filtration environments requiring chemical inertness and durability. GORE GR Sheet Gasketing, 100% expanded PTFE, forms reliable seals in steel piping and equipment exposed to aggressive media, resisting creep and cold flow across a wide range. Joint sealants, such as GORE-TEX expanded PTFE tapes, provide conformable, waterproof barriers in flanges and valves for industries like chemical , rated for temperatures up to 260°C and compatible with most solvents. Filtration solutions include GORE RASTEX Weaving Fiber for high-temperature industrial filters, maintaining dimensional stability in harsh conditions better than traditional synthetics, and media for particle, gas, and catalytic filtration to control emissions and ensure process purity in manufacturing. These applications leverage ePTFE's microporous structure for selective permeability, preventing leaks or contaminants in sectors like pharmaceuticals and energy production.

Innovations and Developments

Evolution of Product Generations

The original GORE-TEX fabric, based on expanded (ePTFE), was developed in 1969 by through rapid stretching of PTFE, creating a microporous membrane that repels liquid water while permitting vapor transmission for . Commercialization began in 1976 with the first sale of GORE-TEX Fabric to Early Winters, Ltd., for rainwear described as versatile protective gear. Early products faced challenges, including a 1978 recall of first-generation fabrics due to performance inconsistencies like wetting out under prolonged exposure, prompting refinements in lamination and sealing processes. By 1979, GORE-SEAM tape improved seam waterproofing, enhancing overall reliability. Subsequent generations introduced specialized product technologies to address trade-offs in , , and , evolving from basic two-layer (2L) constructions to three-layer (3L) laminates integrating face fabric, , and backer. In the late 1990s, GORE-TEX PACLITE emerged as a lightweight, packable 2L option with delaminated design for reduced bulk, publicly launched around 1998 to suit active pursuits. The 2006 debut of first-generation GORE-TEX PRO targeted extreme conditions with reinforced 3L structures for superior abrasion resistance and longevity in professional and applications. GORE-TEX Active followed in , optimizing next-to-skin comfort and via hydrophilic enhancements in lighter shells. Later innovations included GORE-TEX SHAKEDRY in the mid-2010s, a face-fabric-free for minimal weight and rapid drying, though it faced discontinuation by 2022 amid supply constraints and regulatory pressures on perfluorocarbons (PFCs). Recent generations shifted to (ePE) membranes starting in 2022, replacing ePTFE to eliminate intentional addition while preserving waterproofness (minimum 28,000 mm hydrostatic head) and breathability (RET < 13), with lower-mass designs reducing carbon footprints per lifecycle assessments. This ePE iteration applies across lines like next-gen , launched for fall/winter 2025, emphasizing durability without environmental trade-offs.

Recent Advancements and Partnerships

In 2023, introduced expanded polytethylene (ePE) membrane technology as a PFAS-free alternative to expanded (ePTFE) in GORE-TEX products, aiming to preserve waterproof, windproof, and breathable properties while reducing environmental persistence of fluorinated chemicals. This shift enabled the rollout of PFAS-free consumer garments by late 2023, with full phase-out targeted for all consumer-facing items by 2024, though industrial and legacy applications retained PTFE-based variants due to performance requirements like NFPA 1971 standards for gear. By fall 2025, Gore launched next-generation GORE-TEX products featuring an advanced ePE laminate, engineered for extreme conditions with enhanced durability—up to 20% lighter than prior iterations—superior abrasion resistance, and a 30% lower during production, as measured against ePTFE benchmarks. These advancements prioritize mechanical bonding techniques for laminate integrity, supporting applications in and professional outdoor pursuits without compromising ratings exceeding 20,000 g/m²/24h. Concurrently, in July 2025, Gore expanded its GORE-TEX CROSSTECH lineup with new moisture barriers for structural turnout gear, incorporating Innovate technology that achieves total levels below 100 per NFPA certification while improving liquid penetration resistance and flexibility. Strategic partnerships have accelerated ePE integration. In August 2025, Gore collaborated with Arc'teryx to co-develop the updated GORE-TEX Pro membrane, incorporating proprietary three-layer constructions for reduced weight and optimized stretch, debuting in Arc'teryx's high-alpine apparel lines. Fjällräven renewed its partnership with Gore—dormant since the 1990s—for an autumn/winter 2025 collection of hardshell jackets and pants, leveraging PFAS-free ePE and durable water repellent (DWR) finishes to align with Gore's sustainability metrics, including recyclability enhancements. Similarly, SOREL partnered with Gore in October 2025 to infuse GORE-TEX into its Callsigne Horizon boot series, adapting ePE for insulated, urban-rugged footwear with sub-zero thermal retention. These alliances emphasize co-engineering for sector-specific performance, such as Gore's contributions to U.S. military temperate-weather combat boots showcased at AUSA 2025, featuring ePE for all-weather systems.

Controversies and Criticisms

Environmental Impact and PFAS Allegations

Gore-Tex fabrics traditionally incorporate an expanded (ePTFE) membrane, a classified as a per- and polyfluoroalkyl substance (), a group of synthetic chemicals renowned for their environmental persistence due to strong carbon-fluorine bonds that resist natural degradation, in and humans, and potential links to adverse health effects such as certain cancers and disruption as identified by agencies like the U.S. Environmental Protection Agency (EPA). While the polymerized ePTFE in finished Gore-Tex products is chemically stable and exhibits low leaching potential under normal use, manufacturing processes involving PFAS precursors and processing aids have raised concerns about emissions into air, , and . W.L. Gore & Associates' production facilities, particularly in , have been implicated in and contamination with compounds, including (PFOA), detected at levels exceeding EPA health advisory limits in nearby private wells as early as the . In December 2024, the state of filed a against the company, alleging that operations at 13 of its 14 local facilities released over decades, contributing to elevated disease rates in affected communities, though Gore maintains it complied with regulations and phased out PFOA—a key processing aid—by 2015 following a 2006 EPA . A 2023 class-action suit by residents near the Cherry Hill plant similarly attributed detections in well water to plant emissions, prompting ongoing litigation and remediation efforts. Allegations of greenwashing emerged in a February 2025 federal class-action lawsuit, accusing Gore of misleading consumers by marketing certain products as or PFAS-free despite reliance on fluorinated durable water-repellent (DWR) treatments and ePTFE membranes that plaintiffs claim release trace during washing or wear, though independent verification of significant consumer-level shedding remains limited. In response, Gore has accelerated transitions to PFAS-free alternatives, introducing an (ePE) membrane in 2021—certified as free of intentionally added —and committing to its widespread adoption in consumer products by the end of 2025, alongside non-fluorinated DWR options, while asserting that legacy ePTFE poses minimal environmental risk post-polymerization. These developments reflect broader industry pressures amid regulatory scrutiny, including restrictions on , but critics argue historical legacies and incomplete phase-outs undermine sustainability claims.

Legal Actions and Regulatory Scrutiny

, the developer of Gore-Tex, has been involved in extensive patent litigation to enforce its rights over expanded (ePTFE) technology. A prominent example is the multi-decade dispute with C.R. Bard, Inc., originating from Bard's development of thin-walled ePTFE vascular grafts in the , which Gore alleged infringed its foundational patents, including U.S. No. 4,187,390 issued in 1980. initiated infringement claims in 1984, leading to a 1991 district court ruling that partially invalidated 's patents under the doctrine of obviousness, though subsequent appeals prolonged the case. The litigation spanned over 30 years, with a 2008 awarding $290 million later overturned; by 2010, Bard secured a $371 million judgment against after the Federal Circuit upheld findings of patent unenforceability due to 's alleged inequitable conduct in prosecution. The U.S. denied 's petition for in 2013, effectively concluding the matter in Bard's favor. Gore has pursued other infringement actions, such as against Garlock, Inc. in the 1980s over processes for producing similar fluoropolymer films, where the Federal Circuit in 1988 affirmed Gore's patent validity but remanded for further infringement analysis. These cases underscore Gore's aggressive defense of its ePTFE innovations, which underpin Gore-Tex's waterproof-breathable properties, though outcomes have varied, with some patents deemed obvious in light of prior art like stretched Teflon films. In recent years, Gore has faced litigation tied to (PFAS) used in Gore-Tex manufacturing. On December 18, 2024, Anthony G. Brown filed a lawsuit in U.S. District Court against Gore, alleging the company knowingly released PFAS from its facilities since the 1970s, contaminating and without adequate disclosure to regulators despite internal awareness of risks by 1990. The suit seeks remediation costs, civil penalties under state environmental laws, and abatement of ongoing pollution from Gore's use of PFAS in ePTFE production. Consumer class-action suits have also emerged. On February 11, 2025, plaintiffs filed in the U.S. District Court for the Northern District of , accusing of greenwashing by marketing Gore-Tex products as -free or environmentally superior while concealing persistent content that allegedly leaches into the environment and poses health risks. A separate filed February 19, 2025, in federal court similarly claims deceptive advertising of Gore-Tex apparel and gear, seeking damages for purchasers misled about chemical safety. denies the allegations, asserting compliance with regulations and ongoing phase-out efforts. Regulatory scrutiny has intensified amid broader PFAS restrictions, though not exclusively targeting Gore-Tex. The U.S. Agency's 2024 designation of PFOA and PFOS as hazardous under CERCLA has prompted investigations into legacy sites, including Gore facilities, potentially imposing liability for cleanup. State-level bans, such as California's 2025 prohibition on in apparel effective 2025 and New York's similar measures, challenge Gore-Tex formulations reliant on fluorinated polymers for performance, forcing reformulation or labeling adjustments without direct enforcement actions against Gore to date.

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