BR112020008659B1 - METHOD FOR IMPROVING FUNCTIONALITIES AND FABRIC ARTICLE - Google Patents

Abstract

method to improve the functionalities and fabric article. These are methods for improving the localized modeling and/or support, shape retention, comfort and/or support functionality of clothing items and other fabric articles by applying an aqueous dispersion of polyurethane at a selected intensity and/or or at one or more selected locations on the item of clothing or other fabric article. These are also clothing items and other fabric articles with enhanced functionalities of localized shaping and/or support, shape retention, comfort and/or support, prepared in accordance with these methods.

Description

FIELD OF INVENTION

[001] The present invention relates to methods for using aqueous polyurethane dispersions to improve the localized modeling and/or support, shape retention, support and/or comfort functionalities of clothing items and other fabric articles.

BACKGROUND OF THE INVENTION

[002] A shaping piece is designed to temporarily alter the shape of the user's body to obtain a more elegant figure. In recent years, fashion trends have tended to adopt clothing and accessory designs that increasingly accentuate the natural curves of the human body, and shapewear has been a growing trend in the market. The main application was in women's clothing such as underwear, lingerie, jeans and woven pants. Many female consumers look for a comfortable piece of clothing that enhances their shape and at the same time highlights their best features, for example, a shapewear pair of jeans that can slim the tummy, tighten the thigh and lift the buttocks. Such a piece of clothing improves the wearer's appearance and self-esteem.

[003] Current techniques for shaping mainly use different wire mesh structures with long floating point, higher denier or high elastic fiber spinning; or to apply a special silhouette pattern to strategically selected areas. Another common practice includes introducing second layers of fabric or cushions sewn with base fabric, or selecting fabrics with different elasticity and sewing them together in different positions. See, for example, the US 7,950,069, 7,341,500 and 7,945,970, WO2013/154445 A1, Patent Publications No. 2010/0064409a1 and 2011/0214216a1, GB247754A and EP 0519135B1. In one design, a rigid panel is added inside the denim in front of the belly to help slim the belly. In another, a piece of padding or sponge is inserted into the pants to lift and improve the visual profile of the wearer's buttocks. However, all of these designs and methods compromise users' comfort and are often visible on the surface of the garment.

[004] Polyurethanes (including polyurethanoureas) can be used as adhesives for various substrates, including fabrics. Typically, these polyurethanes are fully formed non-reactive polymers or isocyanate-terminated reactive prepolymers. These reactive polyurethane adhesives often require extended curing times to develop adequate bond strength, which can be a disadvantage in manufacturing processes. Furthermore, the isocyanate groups of polyurethanes are notoriously sensitive to humidity, which limits storage stability and reduces the shelf life of the product incorporating these polyurethanes. Typically, these polymers, when fully formed, are dissolved in a solvent (solvent-based), dispersed in water (water-based), or processed as solid thermoplastic materials (hot melt). Notably, solvent-based adhesives face increasingly stringent environmental and health legislation aimed at reducing emissions of volatile organic compounds (VOC) and hazardous air pollutants (HAP). Therefore, alternatives to conventional solvent-based products are needed.

[005] Hot melt adhesives, although environmentally safe and easy to apply as films, generally exhibit high solidification and low recovery when subjected to repeated stretching cycles. Therefore, improvements are needed.

[006] Many attempts have been made to develop water-based polyurethane adhesives to overcome these shortcomings.

[007] Patent No. US 5,270,433 discloses an "adhesive composition comprising a substantially transparent, solvent-free, one-component polyurethane aqueous dispersion containing the reaction products of (a) a polyol mixture comprising polypropylene glycol , (b) a mixture of polyfunctional isocyanates comprising ααα1α1-tetramethyl xylene diisocyanate (TMXDI), (c) a functional component capable of forming salt in aqueous solution and (d) optionally, a chain extension agent". Adhesive films of this composition have low recovery power and low heat resistance in view of the asymmetric structure and steric hindrance of the isocyanate groups in TMXDI, preventing the formation of strong interchain urea hydrogen bonds in the rigid segments of the polymer.

[008] Patent Application Publication No. US 2004/0014880 A1 discloses an aqueous polyurethane dispersion for adhesive bonding in wet and dry laminates, declared to have high coating capacity, adhesive strength and heat resistance. This dispersion contains a substantial amount of organic solvent - methyl ethyl ketone (MEK).

[009] Patent Application Publication No. US 2003/0220463 A1 discloses a method for making a polyurethane dispersion that is free of organic solvent, such as N-methylpyrrolidone (NMP). However, the composition is limited to a prepolymer with low free diisocyanate species such as methylene bis(4-phenylisocyanate) (4,4'-MDI). The process for producing such a low-free diisocyanate prepolymer is complicated (as disclosed in US Patent No. 5,703,193). This processing also requires short path distillation of the free diisocyanate and is therefore not economical to produce a prepolymer for making a polyurethane dispersion.

[010] Patent No. US 4,387,181 describes a stable aqueous dispersion of polyurethane containing solvent N-methylpyrrolidone (NMP) prepared by reacting prepolymer and polyamine terminated with isocyanate and blocked with oxime containing carboxylic group. The prepolymer is produced by reacting aromatic diisocyanates such as 4,4'-diphenylmethanediisocyanate (MDI) or toluene diisocyanate (TDI) with polyether or polyester polyols and a dihydroxy alkanoic acid. Oxime-blocked isocyanate groups are capable of reacting with polyamine at 60 to 80 °C within 6 to 18 hours. The dispersion is stable in storage, and the film formed from the dispersion has good tensile properties. However, this dispersion still has organic solvent present and the longer curing time required is inadequate for tissue bonding and lamination in practice.

[011] Patent No. US 5,563,208 describes an acetone process for preparing an essentially solvent-free aqueous polyurethane dispersion comprising urethane prepolymers with blocked isocyanate groups and polyamines in the molecular weight range of 60 to 400 in a molar ratio of blocked isocyanate groups to primary and/or secondary amino groups of 1:0.9 to 1:1.5. This dispersion is stable in storage at room temperature and provides a heat-resistant binder in the coating. It requires a long curing time (up to 30 minutes), which is still not suitable for tissue bonding and adhesion. Additionally, the acetone process requires an additional distillation step to remove the acetone from the dispersion, which makes this process less economical.

[012] Patent No. US 6,586,523 describes an acetone process for the preparation of a self-crosslinking polyurethane dispersion for sizing agents comprising a prepolymer with partially blocked and partially extended isocyanate groups and excess polyfunctional compounds with molecular weights from 32 to 500 with primary or secondary amino and/or hydroxyl groups. This dispersion composition reduces curing time to some degree, but still has shortcomings because an additional distillation step is required to remove the acetone.

[013] Patent No. US 6,555,613 describes a solvent-free aqueous dispersion of a reactive polyurethane with a number average molecular weight (Mn) of 800 to 14,000, a degree of branching of 0.0 to 3.0 mol/kg and an isocyanate functionality of 2.0 to 6.0 per mol. Polyurethane is manufactured from a polyester polyol, a polyisocyanate and polyisocyanate adduct, with low molecular weight polyol and anion-forming units after neutralization incorporated into the polymer chains and with blocked isocyanate groups capable of additional cross-linking reactions. The result of this dispersion is a hard, shiny, elastic coating material, but this coating material does not have the elastomeric characteristics and stretch/rebound properties necessary for an adhesive to be used with elastic fabrics.

[014] Polymer compositions such as polyurethaneurea films and tapes comprising fully formed polyurethaneurea with blocked isocyanate end groups are disclosed in US Patent No. 7,240,371. These compositions are prepared from solvent-free prepolymer systems comprising at least one polyether or polyoyl polyester, a mixture of MDI isomers and a diol.

[015] Patent No. US 9,346,932 describes aqueous polyurethane dispersions provided in solvent-free systems of a prepolymer comprising at least one polyether, polyester or polycarbonate polyol, a mixture of MDI isomers and a diol, and molded three-dimensional articles from them.

[016] Carmen, C. et al. discloses a method of adding polymer composition to the edge of garments to form edge bands of garments and adding film to garments, such as bras, to form laminated fabrics in EP Patent 2280619B1 and Publication Patent Application No. US 2009/0181599A1 discloses fabric laminates or fabric bands having various layered structures, including at least one fabric layer and at least one polymer layer that have been attached or bonded together.

[017] Other examples of polymeric compositions are polyurethane tapes, such as those commercially available from Bemis, and polyolefin resins that can be formed into films, such as those commercially available from ExxonMobil, under the trade name VISTAMAXX. These films can be bonded to fabric by applying heat.

DESCRIPTION OF THE INVENTION

[018] The inventors of the present application have found that the application of an aqueous polyurethane dispersion comprising a prepolymer comprising a glycol, an isocyanate and a diol compound and, optionally, 1-hexonal and further comprising water, a neutralizer, a surfactant, a defoamer, an antioxidant and/or a thickener may be applied at a selected intensity and/or to a selected location or locations of a fabric article to improve localized shaping functionalities and/or support, shape retention. , support and/or comfort of the fabric item.

[019] Therefore, one aspect of the present invention relates to a method for improving the localized modeling and/or support functionalities of clothing and other fabric articles. The method comprises applying the aqueous polyurethane dispersion at a selected intensity and/or to one or more selected locations of clothing or other fabric articles. The method further comprises curing the polyurethane aqueous dispersion on the item of clothing or other fabric articles after applying the polyurethane aqueous dispersion at the selected intensity and/or in one or more selected locations so that the shaping and/or support is improved.

[020] Another aspect of the present invention relates to a method for improving the support of clothing items and other fabric articles. The method comprises applying the aqueous polyurethane dispersion at a selected intensity and/or to one or more selected locations on the item of clothing or other fabric articles where it is desirable to support the clothing or other fabric articles. The method further comprises curing the clothing item or other fabric articles after applying the aqueous polyurethane dispersion at the selected intensity and/or in one or more locations, so as to improve the strut of the clothing or other fabric articles. .

[021] Another aspect of the present invention relates to a method for improving the comfort of clothing items and other fabric articles. The method comprises applying the aqueous polyurethane dispersion at a selected intensity and/or to one or more selected locations on the clothing item or other fabric articles, where greater comfort of the clothing item or other fabric articles is desired. The method further comprises curing the clothing item or other fabric articles after applying the aqueous polyurethane dispersion at the selected intensity and/or in one or more locations so as to improve the comfort of the clothing item or other articles. of fabric.

[022] Another aspect of the present invention relates to a method for improving the shape retention of clothing items and other fabric articles. The method comprises applying the aqueous polyurethane dispersion at a selected intensity and/or to one or more selected locations on the item of clothing or other fabric articles, wherein better shape retention of the item of clothing or other articles is desired. of fabric. The method further comprises curing the clothing item or other fabric articles after applying the aqueous polyurethane dispersion at the selected intensity and/or in one or more locations so as to improve the shape retention of the clothing item or other fabric articles. fabric items.

[023] Still another aspect of the present invention relates to the item of clothing and other fabric articles with an aqueous dispersion of polyurethane applied and cured at a selected intensity and/or one or more selected locations that exhibit improved shaping functionalities and/or or localized support, shape retention, support and/or comfort.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[024] Provided by this disclosure are methods for improving localized modeling and/or support, shape retention, support and/or comfort functionality of the item of clothing and other fabric articles through the application of an aqueous dispersion of polyurethane at intensities selected and/or in one or more selected locations on the clothing item or other fabric article.

[025] By “improved”, “improving” or “improvement”, as used herein, means any improvement detectable visually, physically or by quantifying localized modeling and/or support, shape retention, bracing and/or comfort of the item of clothing and other fabric articles with the polyurethane aqueous dispersion applied compared to the item of clothing and other fabric articles without the polyurethane aqueous dispersion.

[026] By "intensity", as used herein, is meant to include both the weight of the application and the design of the application pattern of the aqueous polymeric dispersion.

[027] The aqueous polyurethane dispersions that fall within the disclosure are provided from specific urethane prepolymers, which are also disclosed herein. Aqueous polyurethane dispersions and prepolymers do not contain an organic solvent or co-solvent, alkyl ethoxylates or organotin catalyst.

[028] As used herein, the term "dispersion" refers to a system in which the dispersed phase consists of finely divided particles and the continuous phase can be a liquid, solid or gas.

[029] As used herein, the term "aqueous polyurethane dispersion" refers to a composition containing at least one polyurethane or urea polyurethane polymer or prepolymer (such as the polyurethane prepolymer described herein) that has been dispersed in an aqueous medium such as water, including deionized water.

[030] A dry aqueous polyurethane dispersion, as used herein, is an aqueous polyurethane dispersion that has been subjected to curing or drying by any suitable method. The dried aqueous polyurethane dispersion may be in the form of a molded article, for example, a film.

[031] As used herein, the term "solvent", unless otherwise indicated, refers to a non-aqueous medium, wherein the non-aqueous medium includes organic solvents, including volatile organic solvents (such as acetone) and solvents slightly less volatile organics (such as MEK or NMP).

[032] As used herein, the term "essentially solvent-free" or "essentially solvent-free system" refers to a composition or dispersion in which the majority of the dispersed composition or components have not been dissolved or dispersed in a solvent.

[033] The prepolymers for use in the aqueous polyurethane dispersions used in the present invention comprise a glycol, an aliphatic diisocyanate and a diol.

[034] Glycol components suitable as starting material for the preparation of prepolymers used in the present invention include polycarbonates and polyesters, polycarbonate glycols, polyether glycols and polyester glycols.

[035] Examples of polyether glycols that can be used include, but are not limited to, those glycols with two or more hydroxy groups, from the ring-opening polymerization and/or copolymerization of ethylene oxide, propylene oxide, oxide of trimethylene, tetahydrofuran and 3-methyltetrahydrofuran or from the condensation polymerization of a polyhydric alcohol, preferably a diol or diol mixtures, with less than 12 carbon atoms in each molecule, such as ethylene glycol, 1 ,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 1,7-heptanediol, 1,8-octanediol, 1,9 -nonanediol, 1,10-decanediol and 1,12-dodecanediol. A linear bifunctional polyether polyol is preferred, and apol(tetramethylene ether) glycol of molecular weight of about 1,700 to 2,100, such as Terathane® 1800 (Invista) with a functionality of 2, is particularly preferred for use in the prepolymers used herein. invention.

[036] Examples of polyester glycols that can be used include those ester glycols with two or more hydroxy groups, produced by condensation polymerization of aliphatic polycarboxylic acids and polyols, or mixtures thereof, of low molecular weights with no more than 12 atoms of carbon in each molecule. Examples of suitable polycarboxylic acids are malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, undecanedicarboxylic acid and dodecanedicarboxylic acid. Examples of polyols suitable for the preparation of polyester polyols are ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol and 1,12-dodecanediol. A linear bifunctional polyester polyol with a melting temperature of about 5°C to about 50°C is preferred.

[037] Examples of polycarbonate glycols that can be used include carbonate glycols with two or more hydroxy groups, produced by condensation polymerization of phosgene, chloroformic acid ester, dialkyl carbonate or diallyl carbonate and aliphatic polyols or mixtures thereof. same, low molecular weight with no more than 12 carbon atoms in each molecule. Examples of polyols suitable for the preparation of polycarbonate polyols are diethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, 3-methyl-1,5- pentanediol, 1,7-heptanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol and 1,12-dodecanediol. A bifunctional linear polycarbonate polyol with a melting temperature of about 5°C to about 50°C is preferred.

[038] In a non-limiting embodiment, the prepolymer contains at least 65% or at least 71% or at least 72% of glycol, based on the total weight of the prepolymer.

[039] The isocyanate component suitable as another stall material to make the prepolymers useful in the present invention is a dicyclohexylmethane diisocyanate, such as Vestanate® H12MDl (Evonik).

[040] In a non-limiting embodiment, the prepolymer contains at least 10% or at least 22% or at least 24% of the isocyanate, based on the total weight of the prepolymer.

[041] Diols suitable as additional starting materials for the preparation of prepolymers disclosed herein include at least one diol with two hydroxy groups capable of reacting with the isocyanate and at least one carboxylic acid group capable of forming salt upon neutralization and unable to react with isocyanate. Examples of diols with a carboxylic acid group include, but are not limited to, 2,2-dimethylopropionic acid (DMPA), such as Bis-MPA (GEO), 2,2-dimethylobutanoic acid, 2,2-dimethylovaleric acid, and initiated caprolactones. with DMPA, such as CAPA™ HC 1060 (Solvay). DMPA is preferred.

[042] In a non-limiting embodiment, the prepolymer may contain at least 1% or at least 2.2% or at least 2.4% of the diol, based on the total weight of the prepolymer.

[043] In a non-limiting embodiment, the prepolymer further comprises a monofunctional alcohol including methanols, ethanols, propanols, butanols and 1-hexanol. In this non-limiting embodiment, the prepolymer contains less than 1% or less than 0.5% 1-hexaonol, based on the total weight of the prepolymer.

[044] The prepolymer can be prepared by mixing the glycol, isocyanate and diol in one step and reacting them at temperatures of about 50 °C to about 100 °C for a suitable time until all hydroxy groups are removed. essentially consumed and a desired % NCO of the isocyanate group is achieved. Alternatively, this prepolymer can be produced by charging molten glycol into a reactor at about 55°C, followed by adding a solid DMPA powder with stirring and circulation until the solid diol particles are dispersed and dissolved in the glycol. . The molten isocyanate is then charged into the reactor with continuous stirring and the capture reaction is allowed to occur at around 90 °C for around 240 minutes, still with continuous stirring. The viscous prepolymer formed is then sampled to determine the extent of the reaction by measuring the weight percentage of isocyanate groups (%NCO) of the prepolymer via a titration method. The theoretical value of % NCO after the reaction is complete is 2.97, assuming the MW of glycol is 1,800. If the determined % NCO value is greater than the theoretical value, the reaction must continue until the theoretical value is reached or the % NCO number becomes constant. Once the reaction is determined to be complete, the temperature of the prepolymer is maintained between 85°C and 90°C. Significantly, the prepolymers are essentially solvent-free and do not contain alkyl ethoxylates or organotin catalysts. It is preferred that the reaction to prepare the prepolymer is carried out in a moisture-free atmosphere covered by nitrogen to avoid side reactions.

[045] The prepolymer of the present invention is then used to produce an aqueous polyurethane dispersion comprising the prepolymer and water, as well as a neutralizer, a surfactant, an antifoam, an antioxidant and/or a thickener.

[046] In a non-limiting embodiment, the prepolymer is added in an amount such that the final aqueous polyurethane dispersion contains at least 30% glycol, at least 10% isocyanate and at least about 1% diol, based on the total weight of the aqueous polyurethane dispersion.

[047] In a non-limiting embodiment, the aqueous polyurethane dispersion further contains at least 50% water, at least 1% surfactant and/or thickener and/or less than 1% neutralizer, antioxidant or antifoam.

[048] The neutralizers used in these dispersions must be capable of converting acidic groups into saline groups. Examples include, but are not limited to, tertiary amines (such as triethylamine, N,N-diemylmeylamine, N-memylmorpholine, N,N-diisopropylethylamine and triethanolamine) and alkali metal hydroxides (such as lithium, sodium and potassium hydroxides). Primary and/or secondary amines can also be used as neutralizers for acid groups. The degrees of neutralization are generally between about 60% to about 140%, for example, in the range of about 80% to about 120% of the acid groups.

[049] Examples of surfactants include, but are not limited to, anionic, cationic or nonionic dispersants or surfactants, such as alkyldiphenyloxide disulfonate, sodium dodecyl sulfate, sodium dodecylbenzenesulfonate, ethoxylated nanophenols and pyridinium lauryl bromide.

[050] Examples of suitable defoamers include, among others, mineral oils and/or silicone oils, such as BYK 012 and Additive 65 (a silicone additive from Dow Corning), and Surfynol™ DF 110L (a non-ionic acetylene glycol surfactant of high molecular weight from Air Products & Chemicals).

[051] Examples of suitable thickeners include, but are not limited to, polyurethanes such as Munzing's Tafigel PUR 61, hydrophobically modified ethoxylate urethanes (HEUR), hydrophobically modified alkali swellable emulsions (HASE) and hydrophobically modified hydroxyethyl cellulose ( HMHEC).

[052] Examples of antioxidants include, among others, hindered phenols, such as Irganox 245 (BASF) or Cyanox 1790 (Cytec). Furthermore, diamines, including ethylene diamine and similar materials, can be used as a diamine chain extender in place of water.

[053] In a non-limiting embodiment, the dispersion is prepared by adding the prepolymer using a high-speed rotor/stator disperser. The prepolymer, produced as above, is transferred directly to the disperser head and dispersed under high shear forces in deionized water, preferably containing at least one surfactant, a neutralizer, an antioxidant and/or a foam control agent. A little more prepolymer than required by the dispersion recipe is needed to compensate for loss in the transfer line and reactor. When the prepolymer addition is complete, a thickener can be added.

[054] Aqueous polyurethane dispersions for use in the present invention should have a solids content of about 10% to about 50% by weight, for example, from about 30% to about 45% by weight. The viscosity of aqueous polyurethane dispersions for use in the present invention can vary over a wide range from about 0.01 Pa.s (10 centipoise) to about 100 Pa.s (100,000 centipoise), depending on processing and application requirements. . For example, in a non-limiting embodiment, the viscosity is in the range of about 0.5 Pa.s (500 centipoise) to about 30 Pa.s (30,000 centipoise). The viscosity can be varied using an appropriate amount of thickening agent, such as from about 0 to about 5.0% by weight, based on the total weight of the aqueous polyurethane dispersion.

[055] Aqueous polyurethane dispersion can be applied to selected locations of clothing items or other fabric articles and/or at selected intensities by methods such as, without limitation, filling, coating, printing, bonding, laminating, spraying and other methods application/treatment and then cured (or dried) with a residence time of about 1 to about 5 minutes.

[056] The aqueous polyurethane dispersion can be diluted to a desired solid content before application to the clothing item or other fabric article.

[057] These aqueous polyurethane dispersions, when applied at selective intensities and/or selected locations of clothing items and other fabric articles, have been found useful for improving localized modeling and/or support, shape retention, support and /or comfort of the item of clothing and other fabric articles.

[058] Examples of clothing that can be improved using the dispersions and methods according to the present invention include, among others: disposable underwear, bras, panties, lingerie, swimwear, girdles, nightgowns, socks, leggings , sleepwear, aprons, wetsuits, ties, lab coats, space suits, uniforms, hats, garters, sweatbands, belts, clothing for physical activity, outerwear, rainwear, cold jackets, pants, shirts, dresses , blouses, men's and women's t-shirts, outerwear, corsets, vests, panties, stockings, high socks, dresses, blouses, tuxedos, bisht, abaya, hijab, jilbab, thoub, burka, cape, costumes, wetsuit, kilt, kimono , dry-fit, dresses, protective clothing, sari, sarongs, skills, leg warmers, stole, suits, straitjacket, toga, tights, towel, uniform, veils, neoprene suit, compression clothing for medical use, bandages , inner lining of suits, waistbands and all their components.

[059] Examples of other fabric articles that can be improved using the dispersions and methods according to the present invention include, among others, seats and benches, cushions, fillings, footwear, shoe inserts, bedding, materials protection of packaging and car interiors.

[060] In a non-limiting embodiment, the inventors of the present application have found that selectively localizing an aqueous polymeric dispersion in, for example, a garment improves fit and modeling in unexpected ways. More specifically, it was found that the application of the aqueous polymer dispersion in one location on a garment can influence, trigger and/or guide the fit and modeling in other locations on the garment. Furthermore, these garments are more comfortable. Use of the polymeric aqueous dispersion in this manner provides symmetrical correction of different breast size/shape by selective application of the dispersion to locations in a bra or other supportive undergarment. In particular, the scatter print on the bottom cup of a bra resulting in less visual discernibility and less measurable, as determined by a three-dimensional body scanner, the difference between the two breasts/cups is a model with a different breast size/shape. Additionally, for a bralette for an open blouse or tube dress, as available from Tommy Hilfiger, the scatter print on the bra cup has resulted in smoothing leakage and eliminating inverted back leakage, a common problem with this design. . Additionally, the scatter print on a bra on the bottom and side of the breast area provides suspension shaping and compression on the chest. Dispersion printing on the belly section of a legging resulted in better back waist grip. Consequently, this use of aqueous polymer dispersions provides an invisible treatment that retains the garment's elegant, simplistic design while avoiding the appearance of functional elements, provides designers and apparel manufacturers with a means to create new, distinctive garments with enhanced functionality, and enables customization. bulk of garments.

[061] In another non-limiting embodiment, the inventors of the present application have found that the selective localization application of the aqueous polymeric dispersion, together with the selected application weight and application pattern design, creates a localized modeling and support functionality for garments. . Additionally, these garments have increased comfort. Various patterns selected for scattering application include, but are not limited to, dots, shapes such as triangles, circles and rectangles, zigzags and/or lines, depending on what modeling and support functionality is desired. This application of aqueous polymeric dispersion as a dispersion provides flexibility in designing graduated modulus of elasticity in garments and enables seamless garment technology with enhanced functional benefits while eliminating the steps of cutting and sewing, layering, splicing and/or or use of elastic bands. Consequently, using aqueous polymer dispersion in this manner provides designers with flexibility, reduces steps, and saves time and money in production. Furthermore, clothing produced using this method can be thinner and lighter. Apparel produced using this method exhibits a smoother appearance, especially on any module interface. Furthermore, printing the aqueous polymer dispersion, for example, on the thigh/calf/leg on leggings should increase the garment's power for training and activities.

[062] In another non-limiting embodiment, the inventors of the present application have found that selective application of the aqueous polymeric dispersion to strategic areas of clothing can result in clothing that remains in place during movement, exercise and use. For example, scatter printing in the tummy area of, for example, leggings or yoga pants can result in support and shaping of the tummy, better fit at the rear waistband and better positioning of the clothing item during activity, all at the same time. Similarly, it was found that selective printing of dispersion at different locations such as the waistband, leg of leggings, cup and strap of bra, seamless blouse/sports tank cup and straps results in better support at the location , while still providing the necessary extension and/or recovery. Application to select bra strap locations can eliminate the need for uncomfortable plastic strap adjusters, improving function and comfort. This use thus provides an invisible, seamless, simplified and more flexible design while reducing manufacturing time. Additionally, selective application of dispersion to the edges, bands and hems of a garment reduces curling of those bands, hems and edges of the garment without making the garment more complex, thicker, heavier, more expensive and uncomfortable.

[063] Furthermore, the inventors of the present application have found that the ability of the aqueous polymeric dispersion to improve shape retention, support and comfort when applied at selected locations and/or intensity in accordance with the methods of the present invention has many useful applications beyond clothing. For example, applying the aqueous polymer dispersion at selected locations and/or intensity improves the comfort of seats, cushions and padding. Unexpectedly, it was found that when modifying the foam by applying dispersion and then subjecting the foam to static weight/pressure, greater resistance to compressive collapse, lower collapse rate, lower extent of collapse, higher recovery rate were observed. after weight removal and greater extent of recovery. This improved compressive strength improves the lifespan of these fillings and cushions. Additionally, applying aqueous polymer dispersion to these fabric articles can reduce vibration/shock effects and reduce packaging volume, creating thinner and better protective material.

[064] The methods of the present invention can also be used to improve shape retention, for example, of footwear, padding and seats.

[065] Furthermore, the methods of the present invention can be used to assist items such as, among others, shoe pads, automobile fabrics and bedding materials that remain in place.

[066] As shown here, the application of aqueous polymeric dispersion in accordance with the methods of the present invention allows highly selective and precisely controlled amounts of improvement in the modulus of elasticity of the item of clothing and other fabric articles and provides advantages to existing techniques , such as PU dispersions, PU foam, fiberfill, spring cushions, generally wider and indiscriminate cut/sewn fabric panels.

[067] All patents, patent applications, test procedures, priority documents, articles, publications, manuals and other documents cited herein are incorporated in their entirety by reference to the extent that such disclosure is not inconsistent with this invention and for all jurisdictions in which such incorporation is permitted.

TEST METHODS AND EXAMPLES

[068] The following test methods and examples demonstrate the present invention and its usability. The invention is capable of other and different embodiments, and its various details are subject to modification in various apparent aspects without departing from the scope of the present invention. Therefore, the test methods and examples should be considered illustrative in nature and not limiting.

TEST METHODS FOR CLOTHING ITEMS WEAR STRENGTH TEST:

[069] Force sensors were used to capture and record the force on the body during bending. The sensors were positioned between the garment and the fit model and detected force in various locations such as waist, back, shoulder, front, chest, under bust, side of bust, ankle, knee, buttock and belly. Garments with and without polyurethane water dispersion treatment were compared. During the measurement, the model stood still or acted by repeating movements to imitate wear movements that the consumer would make on clothes. The change in force during movement was used to analyze comfort, support, shaping and support.

3D BODY SCANNING:

[070] A 3D body scanner was used to capture the silhouette of a live model with or without a piece of clothing. The change in silhouette showed the modeling effect of clothing treated with aqueous polyurethane dispersion in various regions of the body.

FIT MODEL REVIEW:

[071] The professional fit model with experience in garment fitting provided reviews of the garments after use. Feedback includes garment fit, comfort, support, appearance, support, shape retention, and other expectations regarding the wearing experience.

TEST METHODS FOR FABRICS TRACTION TEST:

[072] A mobile device was used to fix fabrics at two ends and stretch the fabric to a certain extent. The force, modulus and hysteresis during stretching and recovery were used to analyze the elastic and recovery power of the fabric, essential for the modeling, support and comfort of the garment.

WASHING DURABILITY:

[073] Fabrics treated with aqueous polyurethane dispersion were exposed to several washing and drying cycles (up to 50 washes) to imitate the life cycles of clothing. The washed and dried fabrics underwent other tests, as mentioned. The change before and after washing and drying was used to analyze the durability of the fabric's shape and functions.

TOUCH TEST ON FABRIC:

[074] Testers were asked to blindly touch and feel the fabrics to examine the softness, regularity, and cooling expectations of the fabric.

TEST METHODS USED ON FIBER FILLING SHAPES AND MATERIALS: COMPRESSION AND RECOVERY TESTING:

[075] Thickness changes in the material are measured while changing the compression level by loading and unloading a series of static weights. The material was placed between flat plate supports. The weight was loaded onto the top plate and held in place for a few minutes before adding more weight. After adding weight for the highest requirement, the weight was gradually unloaded to the same levels as the loading. Thickness was measured to determine compressive strength and percentage recovery.

EXAMPLES

[076] The following examples describe non-limiting embodiments of compositions used in the present invention. The invention is capable of other and different embodiments, and its various details are subject to modification in various apparent aspects without departing from the scope of the present invention. Therefore, the Examples should be considered illustrative in nature and not limiting.

[077] In these examples, the following raw materials were used: TABLE 1

EXAMPLE 1: PREPARATION OF PRE-POLYMER WITHOUT 1-HEXANOL

[078] A polyurethane prepolymer was manufactured using polytetramethylene glycol ether, an aliphatic diisocyanate such as PICM (4,4'- methylene bis(cyclohexyl isocyanate), a hydrogenated version of 4,4'- MDI) and a diol containing a sterically hindered carboxylic acid group. More specifically, the following ingredients and unit quantities were used to make the prepolymer: TABLE 2

[079] The reaction to prepare the prepolymer was carried out in a moisture-free atmosphere and covered with nitrogen to avoid side reactions.

[080] In this example, a 113.56 l (30 gallon) reactor lined with a hot water jacket and equipped with an agitator was used. This reactor was heated to a temperature of about 55 °C. A predetermined weight of molten Terathane® 1800 glycol was charged into the reactor. Then, the solid DMPA powder was added to the reactor with stirring and circulation under a nitrogen blanket, until the solid DMPA particles were dispersed and dissolved in glycol.

[081] The molten PICM was then loaded into the reactor with continuous stirring and the capping reaction was allowed to occur at 90 °C for 240 minutes, still with continuous stirring. The viscous prepolymer formed was then sampled to determine the extent of the reaction by measuring the weight percentage of isocyanate groups (% NCO) of the prepolymer through a titration method. The theoretical value of % NCO after the reaction is complete is 2.97, assuming the MW of glycol is 1,800. If the determined % NCO value is greater than the theoretical value, the reaction must continue until the theoretical value is reached or the % NCO number becomes constant. Once the reaction was determined to be complete, the temperature of the prepolymer was maintained between 85 and 90 °C.

EXAMPLE 2: PREPARATION OF AQUEOUS POLYMER DISPERSION WITH PRE-POLYMER FROM EXAMPLE 1

[082] The dispersion was prepared by adding the prepolymer from Example 1, using a high-speed rotor/stator disperser. The prepolymer, as done in Example 1, was transferred directly to the disperser head and dispersed under high shear forces in deionized water containing a surfactant, a neutralizer, an antioxidant and a foam control agent. A little more prepolymer was required than required by the dispersion recipe to compensate for the loss in the transfer line and reactor.

[083] The ingredients for making the dispersion and the composition of the dispersion are shown below, in Table 3. TABLE 3

[084] In the production of a typical 100 kg batch of the aqueous polymer dispersion, the surfactant Dowfax 2A1 (1.2652 kg), an antioxidant Irganox 245 (0.6051 kg) and foam control agent BYK-012 (0 .1265 kg) were mixed and dissolved in deionized water (54.8093 kg). Triethylamine neutralizer (0.783 kg) was added to the above water mixture 5 minutes before adding the prepolymer. The prepolymer (41.4109 kg) maintained at a temperature between 85 and 90 °C was added to the water mixture with high speed dispersion. The rate of addition (typically about 1.5 kg/min or about 30 minutes) of the prepolymer must be controlled to allow uniform dispersion to form, and the temperature of the dispersion must be maintained between 40 and 45 °C . After the addition of the prepolymer was completed, mixing was continued for 60 minutes. Then, a thickener Tafigel PUR 61 (1.00 kg) was added and allowed to mix for another 60 minutes. The produced dispersion was stirred continuously at low speed for 8 hours (or overnight) in the vessel to eliminate foam and ensure the reaction reached completion. The finished dispersion typically contains about 42% solids, with a viscosity of 4 Pa.s (4,000 centipoise) and a pH in the range of 7.0 to 8.5. Breaking toughness (T) is the maximum or breaking strength of a filament expressed as force per unit cross-sectional area. Toughness can be measured on an Instron model 1130 available from Instron of Canton, Massachusetts, and is reported as grams per denier (grams per dtex). Filament toughness at break (and elongation at break) can be measured according to ASTM D 885.

[085] The dispersion was then filtered through 100 micron bag filters to remove large particles before packaging for transport. It is recommended to use 208.20 L (55 gallon) metal drums with polyethylene inner lining to contain the dispersion for transportation.

[086] Final product specifications were determined as shown in Table 4. TABLE 4 *Sampled 20 to 30 minutes before the polymer is dispersed **Sampled and measured 24 hours after the dispersion is thickened.

EXAMPLE 3: PREPARATION OF THE PRE-POLYMER WITH 1-HEXANOL

[087] The polyurethane prepolymer was manufactured using polytetramethylene glycol ether, 1-hexanol, an aliphatic diisocyanate such as PICM (4,4'-methylene (cyclohexyl isocyanate), a hydrogenated version of 4, 4'-MDI) and a diol containing a sterically hindered carboxylic acid group. Table 5 lists the ingredients and unit quantities used to make the prepolymer. TABLE 5

[088] The reaction to prepare the prepolymer was carried out in a moisture-free atmosphere and covered with nitrogen to avoid side reactions.

[089] In this example, a 113.56 l (30 gallon) reactor lined with a hot water jacket and equipped with an agitator was used. This reactor was heated to a temperature of about 55 °C. A predetermined weight of molten Terathane® 1800 glycol was charged into the reactor. 1-hexanol was added second. Then, the solid DMPA powder was added to the reactor with stirring and circulation under a nitrogen blanket, until the solid DMPA particles were dispersed and dissolved in glycol.

[090] The molten PICM was then loaded into the reactor with continuous stirring and the capping reaction was allowed to occur at 90 °C for 240 minutes, still with continuous stirring. The viscous prepolymer formed was then sampled to determine the extent of the reaction by measuring the weight percentage of isocyanate groups (% NCO) of the prepolymer through a titration method. The theoretical value of % NCO after the reaction is complete is 2.80, assuming the MW of glycol is 1,800. If the determined % NCO value is greater than the theoretical value, the reaction must continue until the theoretical value is reached or the % NCO number becomes constant. Once determined that the reaction is complete, maintain the prepolymer temperature between 85 and 90 °C.

EXAMPLE 4: PREPARATION OF AQUEOUS POLYMER DISPERSION WITH PRE-POLYMER FROM EXAMPLE 3

[091] The dispersion was prepared by adding the prepolymer from Example 3, using a high-speed rotor/stator disperser. The prepolymer, as made in Example 3, was transferred directly to the disperser head and dispersed under high shear forces in deionized water, containing a surfactant, a neutralizer, an antioxidant and a foam control agent. A little more prepolymer than required by the dispersion recipe is needed to compensate for loss in the transfer line and reactor.

[092] Table 6 lists the ingredients used to make the dispersion and the composition of the dispersion. TABLE 6

[093] When making a typical batch of this 100 kg (1.2652 kg) dispersion Dowfax 2A1 surfactant, an Irganox 245 antioxidant (0.6051 kg) and BYK-012 foam control agent (0.1265 kg) were mixed and dissolved in deionized water (54.8083 kg). Triethylamine neutralizer (0.7866 kg) was added to the above water mixture 5 minutes before adding the prepolymer. The prepolymer (41.4083 kg) maintained at a temperature between 85 and 90 °C was added to the water mixture with high speed dispersion. The rate of addition (typically about 1.5 kg/min or about 30 minutes) of the prepolymer must be controlled to allow uniform dispersion to form, and the temperature of the dispersion must be maintained between 40 and 45° W. After the addition of the prepolymer was completed, mixing was continued for 60 minutes. Then, a thickener Tafigel PUR 61 (1.00 kg) was added and allowed to mix for another 60 minutes. The produced dispersion was stirred continuously at low speed for 8 hours (or overnight) in the vessel to eliminate foam and ensure the reaction reached completion. The finished dispersion typically contains about 42% solids, with a viscosity of 4 Pa.s (4,000 centipoise) and a pH in the range of 7.0 to 8.5.

[094] The dispersion is then filtered through 100 micron bag filters to remove large particles before packaging for transport. It is recommended to use 208.20 L (55 gallon) metal drums with vented lids and an inner polyethylene liner to contain dispersion for transportation.

[095] Final product specifications were determined as shown in Table 7. TABLE 7 *Sampled 20 to 30 minutes before polymer is dispersed **Sampled and measured 24 hours after dispersion is thickened.

Claims (10)

1. METHOD FOR IMPROVING THE LOCAL FUNCTIONALITIES of modeling and/or support, shape retention, comfort and/or support of clothing and other fabric articles, the method being characterized by comprising: applying an aqueous dispersion of polyurethane at an intensity selected and/or in one or more selected locations of an item of clothing or other article of fabric; and curing the polyurethane aqueous dispersion on the item of clothing or other fabric article after applying the polyurethane aqueous dispersion at the selected intensity and/or at the one or more selected locations, such that shaping and/or support, shape retention , comfort and/or support of clothing and other fabric articles are improved. 2. METHOD according to claim 1, characterized in that the aqueous polyurethane dispersion comprises: a prepolymer comprising a glycol compound, an isocyanate and a diol compound; and water, a neutralizer, a surfactant, an antifoam, an antioxidant or a thickener. 3. METHOD, according to claim 2, characterized in that the prepolymer further comprises 1-hexanol. 4. METHOD, according to claim 2, characterized in that the isocyanate is dicyclohexylmethane diisocyanate. 5. METHOD, according to claim 2, characterized in that the prepolymer contains at least 70% glycol, at least 20% isocyanate and at least 2% diol. 6. METHOD, according to claim 3, characterized in that the prepolymer contains less than 1% 1-hexanol. 7. METHOD, according to claim 2, characterized in that the aqueous polyurethane dispersion comprises: the pre-polymer; and water, the neutralizer, the surfactant, the defoamer, the antioxidant and a thickening water. 8. METHOD, according to claim 2, characterized in that the aqueous polyurethane dispersion contains at least 30% glycol, 10% isocyanate and at least 1% diol. 9. METHOD, according to claim 8, characterized in that the aqueous polyurethane dispersion further contains at least 50% water, at least 1% surfactant and/or thickener and/or less than 1% neutralizer, antioxidant or antifoam. 10. FABRIC ARTICLE, characterized by exhibiting enhanced functionalities of localized modeling and/or support, shape retention, comfort and/or support produced in accordance with the method, as defined in any one of claims 1 to 9.