CN100406236C - 柔软材料 - Google Patents

柔软材料 Download PDF

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CN100406236C
CN100406236C CNB008098581A CN00809858A CN100406236C CN 100406236 C CN100406236 C CN 100406236C CN B008098581 A CNB008098581 A CN B008098581A CN 00809858 A CN00809858 A CN 00809858A CN 100406236 C CN100406236 C CN 100406236C
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interval
separation assembly
base material
softness
tensile elasticity
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CN1359267A (zh
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D·S·泰勒
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Sterling Molding 2016 Co Ltd
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Stirling Moulding Co ltd
Stirling Moulded Composites Ltd
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    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/28—Shock absorbing
    • A41D31/285—Shock absorbing using layered materials
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/015—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches with shock-absorbing means
    • A41D13/0156—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches with shock-absorbing means having projecting patterns
    • A—HUMAN NECESSITIES
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    • A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63C—LAUNCHING, HAULING-OUT, OR DRY-DOCKING OF VESSELS; LIFE-SAVING IN WATER; EQUIPMENT FOR DWELLING OR WORKING UNDER WATER; MEANS FOR SALVAGING OR SEARCHING FOR UNDERWATER OBJECTS
    • B63C9/00—Life-saving in water
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    • B63C9/093—Body suits, i.e. substantially covering the user's body ; Immersion suits, i.e. substantially completely covering the user using solid buoyant material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61G—TRANSPORT, PERSONAL CONVEYANCES, OR ACCOMMODATION SPECIALLY ADAPTED FOR PATIENTS OR DISABLED PERSONS; OPERATING TABLES OR CHAIRS; CHAIRS FOR DENTISTRY; FUNERAL DEVICES
    • A61G7/00—Beds specially adapted for nursing; Devices for lifting patients or disabled persons
    • A61G7/05—Parts, details or accessories of beds
    • A61G7/057—Arrangements for preventing bed-sores or for supporting patients with burns, e.g. mattresses specially adapted therefor
    • A61G7/05707—Arrangements for preventing bed-sores or for supporting patients with burns, e.g. mattresses specially adapted therefor with integral, body-bearing projections or protuberances
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    • B32B2266/02—Organic
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    • B32B2266/025—Polyolefin
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    • B32B2437/00—Clothing
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment
    • B32B2571/02—Protective equipment defensive, e.g. armour plates, anti-ballistic clothing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Mechanical Engineering (AREA)
  • Ocean & Marine Engineering (AREA)
  • Laminated Bodies (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)
  • Materials For Medical Uses (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Details Of Garments (AREA)

Abstract

一种柔软材料，它包含许多与可拉伸的弹性柔软基材(2)连接的分离的弹性组件(1)。这样的材料适合为人体和动物体提供防护物。所述组件优选含有泡沫材料例如聚乙烯泡沫材料封闭单元，所述基材包含针织织物。在一个有利的实施方式中，将第二个柔软基材粘合到组件(1)上面，将组件夹在两层基材(2)之间。

Description

柔软材料
本发明涉及一种柔软材料的制备方法，该柔软材料主要适用作保护人体和动物体的柔软的防护材料。
目前，防护材料和防护物用于保护人体免受碰撞、摩擦和其他伤害。防护物用于运动中例如橄榄球、骑马运动和人体会受到伤害的其他活动中，例如建筑和其他行业。
常规防护物可以构成衣服的一个部位例如肩垫，或与衣服分离例如胫骨垫。
目前的一种款式包含模塑泡沫制品，其形状适于身体的一个具体部位。但是，这有许多问题，该制品必须制成不同的尺寸以适合不同的人体。而提供不同尺寸则很昂贵或不方便。而且，非常贴合身体的制品又会限制穿戴者的运动，尤其穿在关节上或在关节附近时。模塑泡沫制品用于一个部位时仅能适合于一个关节。当关节运动时，该制品就不再适合。这就降低了它能提供的保护性。
在DE4341722中，揭示了一种用于治疗淋巴静压纤维状组织的衬垫材料，其中并排放置许多底部增大的泡沫材料组件，组件的底部与要结合的底层相接触。组件侧壁之间的构槽使材料能够弯曲，形成压力绷带。但是，绷带的泡沫材料组件在它们的底部彼此接触，这就限制了材料的整体可拉伸性，设计的组件在穿戴时会接触皮肤，这也会限制活动。
在一个部位上，模塑泡沫制品仅适合于一个关节。当关节运动时，该制品就不再适合了。这就降低了它能提供的保护性。
美国专利№3285768揭示了一种覆有表面可变形泡沫的织物。通过在泡沫片材上开槽沟或切削至一定深度，然后将它叠压到织物上，或将泡沫片材叠压到织物上，然后在泡沫材料层上开槽沟或切削制得变形的泡沫。但是，这些方法都不能将泡沫材料切成许多间隔的分离组件。如果织物用于运动员的防护物，穿戴者除了舒适性外还要求相当大的运动自由度时，间隔的分离组件就更好了。
目前的另一种款式是一种棉被状材料，将很多长条状泡沫材料缝在两层织物之间。这种材料的制备很耗时。而且这种材料仅能在垂直于泡沫材料条的方向上自由弯曲。根据所用的泡沫材料类型要在泡沫材料条长度方向上弯曲材料涉及到使条自身弯曲，是很难的。美国专利№5551082揭示了一种相似类型的外衣。这是一种运动服，其中战略性地放置的条状的凝胶、包封的空气或泡沫垫，它们分别结合到弹性织物外层上。
本发明的一个目的是克服或至少减少与常规防护材料的制备和由其制成的防护物的缺点。
根据本发明的第一方面，提供柔软材料的制备方法，它包括下述步骤：提供回弹性材料片；将切割器压入并切透片材，将片材切成许多间隔的分离组件；使间隔组件的一面凸出于用来将组件固定在原位的夹具的表面；通过加热基材，或活化施加在分离组件所述面与基材之间的粘合剂，或将组件焊接到基材上，使可拉伸的弹性柔软基材结合到分离组件的一面上。
分离组件优选用热熔粘合剂粘合到基材上，尽管它们也可以采用加热的方式，将组件熔化焊接到基材上。
根据本发明的第二方面，提供的柔软材料包含一层结合到可拉伸的弹性柔软基材上的弹性分离组件，这种组件是根据本发明第一方面所述的方法制成的。
这种柔软材料能够比常规材料更容易适应人体，因为它可在三维方向上弯曲。因此，穿戴更舒适，并能够比常规材料更好地适于运动。当用作防护材料或制成一种尺寸、或只要几种尺寸的防护物时，就可以适用于许多不同尺寸的身体。
因为组件是分离并间隔的，这有利于使基材弯曲成曲面，并能够使材料在所有方向上都弯曲，而不会“锁住”或阻止在一个具体方向上的运动。相对于现有技术不能在所有方向上弯曲的款式，这是本发明柔软材料的一个尤其有利的方面。
组件优选含有弹性泡沫材料，例如聚乙烯封闭单元，也能含有多种不同类型的泡沫材料或其他材料，例如不同密度的泡沫材料层，以形成所要求的性能。
组件可以是完全相同，也可以是不同的尺寸和形状，以舒适地适于穿戴者身体的部位，或一些其他制品。
组件优选是块状物。它们的形状可以规则或不规则的，例如剖面为六边形或八边形。组件优选均匀地分布在基材上，密度为100-8000个/米2，更优选为250-8000个/米2，再优选为4000-6000个/米2。在一个实施方式中，组件为立方块，边长12mm，间距2mm。这样形成的密度约为5000个/米2。这就使材料容易沿所有方向弯曲，比已知的棉被状防护材料好。另外，一种类型材料可切成许多不同尺寸，例如形成不同尺寸的防护物，而不会显著影响其弯曲能力。而现有棉被状防护材料中的每条泡沫条的尺寸都必须改变以形成尺寸不同的制品，以不降低柔软性。
基材是可拉伸的回弹性材料或弹性材料，尽管也可使用可拉伸的弹性膜或片，但优选织物。使材料能适应较大的结构范围。合适的织物包括针织尼龙和聚酯织物，更具体是含弹性体的材料。
优选将第二层柔软基材材料粘合到组件上面，使组件夹在两层之间。这时，因为第一层基材是可拉伸回弹性层或弹性层，所以当它弯曲时，它有助于防止材料一面皱褶。最好两层基材都是可拉伸回弹性的。但是，在仅有单层可拉伸基材，而且材料用于弯曲结构的情形下，材料优选排置成使可拉伸层位于曲面外表面上。
所述材料可以包含于织物或其他穿戴物内。它尤其适于加入防护服和防护物，例如肩垫、膝垫、胫骨垫、臂带、头罩、人体和动物的背心和长手套。要明白，在这些衣服所需求的部位有块状物，而在某些部位就没有。例如，在头罩内耳罩上就不需有块状物。
所述材料也可以用于家具或室内装潢材料内，而且尤其适用于轮椅和病床。间隔的组件有助于减少褥疮。由于材料是弹性的，它可用作衬垫物，例如用于鞍座。当材料含有泡沫层时，它就具有良好的热绝缘性能，它可用来加入或用于形成水中服。泡沫材料能使材料浮在水中，所以它非常适用于或用来形成浮力背心、救生衣和助泳物。例如，当将该材料加入泳衣内用作助泳物时，可帮助穿戴者浮起来。这时，泡沫块可设置成当游泳训练者的信心和技术提高时，可依次从泳衣内拆下来。
该材料也可以用于包装和覆层。
如上所述，组件可以不是分布在基材的整个表面上。尤其是在基材的一个边缘区域内没有组件。所述边缘区域可以包括一个扣件装置，例如VELCRO(注册商标)，使它自身固定，或固定到另一个制品如一件服装上。
在一个实施方式中，组件可以包含一系列间隔条。这样的材料在不同方向上弯曲时会有不同性能。
优选的是，在切成分离的组件之前，用热熔粘合剂涂敷至少组件的所述面。或者或另外，用热熔粘合剂涂敷基材与组件所述面邻接的面。也可以将一片热熔膜插入组件所述面与基材之间，形成所述粘合层。
有利的是，使用切割器将弹性片材切成许多分离组件。切割器在切透所述弹性材料后用作夹具，在施加基材层时将组件固定在原位。优选能使每个被切割的组件的所述面都能够凸起于切割器栅格表面的切割器。切割完毕后，片材会略微回弹。或者，提供一种装置例如顶出器，以实现该作用。
在该方法的一个实施方式中，提供一片弹性材料，用热熔粘合剂涂敷该片的至少一面。使粘合剂面朝上，将该片放到切割器栅格上，用切割器栅格将片材切成许多例如正方形的组件。将该片材向下压到切割器上，切透所述片材。然后从组件间去掉多余材料。将一个可拉伸的弹性基材放到被切割的片材上，并加热至活化粘合剂使组件连接到基材上。然后，从切割器上取下基材，基材上带有组件。
要明白，在该实施方式中，切割器栅格用作夹具，在施加基材层时，使组件固定在原位。如果柔软材料要切成大片，尤其是大张不规则形状片，那么这些片可以放入一个特殊结构的夹具内，以将它们在施加基材前固定在原位。如前所述，方便的做法是在弹性材料片切割前，其一面或两面上施加粘合剂层。
或者，使用一组滚动切割器，沿第一方向将弹性材料片切成条状。然后，沿与第一方向呈一定角度的第二方向，切成分离的组件。滚动切割器每次切割后优选横向移动，以便在两个方向上切出窄材料条，使组件分开。去掉窄材料条后留下的就是彼此间隔的分离组件。
下面用实施例并参照附图说明本发明各方面的实施方式，其中：
图1是本发明柔软材料片的一部分的放大视图；
图2显示了用图1所示材料制成的护臂带；
图3是切割器栅格的平面图；
图4-6是在图1所示材料的制造过程中的使用的设备的垂直剖面图；
图7是本发明柔软材料的另一个实施方式的剖面图。
参照图1，一种柔软材料包含许多的弹性封闭单元聚乙烯泡沫材料立方块1，其边长约为12mm，角的圆弧半径约为2.5mm，用热熔粘合剂将其连接到织物基材2上。立方块1分布均匀，每个立方块彼此间隔约2mm。织物2是可拉伸的弹性针织织物，优选含有聚酯或弹性纤维。
立方块1周边有织物2边缘。沿织物相反的二端边缘上，有VELCRO条3(注册商标)，仅示出了一种。
参照图2，显示了戴在手臂5上的防护臂带4。臂带4用图1所示类型材料的长方形片制成。但在织物基材6的二面上粘有许多泡沫材料立方块7，立方块7夹在二层织物基材之间。基材6相对的两端都有边缘，VELCRO8的条固定在该边缘上，使材料相对的两端以重叠方式固定起来，形成圆筒。改变末端的重叠程度，就可以将圆筒紧紧包住不同尺寸的手臂。在立方块7两面上设置基材层6，可防止立方块7在材料弯曲围起来形成圆筒时分得太开。臂带外面的基材6受到拉伸，而臂带里面的立方块7的边缘受到挤压。由此，在材料两面上设置的基材层就能够持续地提供良好的防护性，即使是弯曲很厉害时也是这样。
图3显示了用于制造图1所示材料的切割器的平面图。该切割器包括形成许多立方块的刀刃，所述立方块的边长为12mm，角的圆弧半径为2.5mm。
图4-6是在图1所示材料的制造过程中的设备的垂直剖面图。参照这些图，用热熔粘合剂11涂敷在12mm厚的聚乙烯泡沫材料10封闭单元的一面上。将泡沫材料10放到图3所示类型切割器12上。用压机13下压，使切割器12切透泡沫材料10，形成许多分离的立方块。然后去掉压力，由于泡沫材料的回弹性，它会轻微回弹，使每个立方块露出的表面凸出，位于切割器表面的上方。然后，从组件之间去掉多余材料。
接着，如图5所示，将一层织物放到泡沫材料上，将切割器12和热压板15与织物14接触。热量透过织物14传到泡沫材料上，并活化粘合剂，将织物14粘合到泡沫材料10上。在该实施方式中，切割器栅格用作夹具，在施加织物基材14保持泡沫材料立方块固定原位。
然后，如图6所示，从切割器上取下织物，织物上带有泡沫立方块10。
在另一种方法中，切割器栅格内设置有顶出器以顶出组件，使所有废料都留在切割器内。
如果泡沫10要切成大片，尤其是不规则形状的大片时，例如适用于骑手夹克衣的材料片，那么在施加织物基材14之前将这些片材放入特殊结构的夹具内定位。如上所述，弹性泡沫片材在切割出组件之前，在其一面或两面上要施加热熔粘合剂。
在又一种变化中，使用一组滚动切割器，沿第一方向将弹性材料片切成条。沿垂直于第一方向的第二方向切割片材，形成立方块。然后，切割器横向移动，在两个方向上切割出泡沫材料窄条，使立方块分隔开，剥下泡沫材料窄条，留下立方块。
图7显示了另一种柔软材料的实施方式，除了将一层织物16粘合到组件17的二个相对面上外与图1所示的相似，。该实施方式可用与图1所示相似的方式制成，只是在泡沫层相对的两面上涂敷粘合剂，而且从切割器上取下粘合到第一层织物上的泡沫立方块后，将第二层织物放到组件的露出表面上，并用热压板压，进行粘合。
在上述方法的其他变化中，将热熔粘合剂施加到表面上，而不是将热熔粘合剂施加到柔软材料表面上。或者或另外，也可以将热熔膜插入组件与基材之间。
尤其是当基材粘合到组件的两面上，即组件夹在它们之间时，也可以使用加热的展平辊以代替热压板，将组件粘合到基材上。这有助于在活化粘合剂前，使材料通过辊子之间。
本发明的柔软材料比已知防护材料的制备更方便，而且更柔软，用途更多。它们也可以用于多种用途包括防护物和衣服。

Claims (13)

1.一种制备柔软材料的方法，它包括下述步骤：
提供弹性材料的片材(10)；
将切割器(12)压入并切透所述片材(10)，将所述片材切成许多间隔的分离组件(17)；
使间隔的分离组件(17)的一面凸出于切割器(12)的表面，该切割器(12)在切透所述片材后用作夹具，用来将间隔的分离组件(17)固定在原位；
提供一个第一柔软的可拉伸弹性基材(14)；
在所述间隔的分离组件(17)的一面与所述第一柔软的可拉伸弹性基材(14)的一面之间施加粘合剂，并加热所述第一柔软的可拉伸弹性基材(14)以活化该粘合剂，或加热所述第一柔软的可拉伸弹性基材(14)，使间隔的分离组件(17)焊接到所述第一柔软的可拉伸弹性基材(14)的一面上，从而将所述第一柔软的可拉伸弹性基材(14)的一面粘结到间隔的分离组件(17)的一面上。
2.如权利要求1所述的方法，其中所述切割器(12)在切透片材(10)后，被调整成使每个间隔的分离组件(17)的所述面凸起于切割器(12)的表面。
3.如权利要求2所述的方法，其中位于间隔的分离组件(17)之间的多余弹性材料留在切割器(12)内。
4.如权利要求2所述的方法，其中在间隔的分离组件(17)粘结到所述第一柔软的可拉伸弹性基材(14)上之前，从间隔的分离组件(17)之间取下所述多余弹性材料。
5.如权利要求1-4中任一项所述的方法，其中所述的间隔的分离组件(17)含有泡沫材料。
6.如权利要求1-4中任一项所述的方法，它还包括附加步骤，即，将第二柔软的基材(16)粘结到间隔的分离组件(17)所述面的相反面上。
7.如权利要求1-4中任一项所述的方法，其中在切成间隔的分离组件(17)之前，用热熔粘合剂涂敷所述片材(10)的至少一个所述面。
8.如权利要求1-4中任一项所述的方法，其中用热熔粘合剂涂敷所述第一柔软的可拉伸弹性基材(14)的与间隔的分离组件(17)的所述面相邻的一面。
9.如权利要求1-4中任一项所述的方法，其中将一片热熔膜插入间隔的分离组件(17)的所述面与所述第一柔软的可拉伸弹性基材(14)的所述面之间，形成所述粘合剂。
10.如权利要求1所述的方法，其中使用一组滚动切割器，沿第一方向将片材(10)切成条状，然后沿垂直于第一方向的第二方向，切割成间隔的分离组件(17)。
11.如权利要求10所述的方法，其中滚动切割器每次切割后都横向移动，以便在两个方向上切出窄材料条，使间隔的分离组件分开，去掉窄材料条后留下的就是彼此间隔的分离组件(17)。
12.如权利要求1-4中任一项所述的方法，其中用热压板加热所述第一柔软的可拉伸弹性基材(14)。
13.如权利要求9中任一项所述的方法，其中使所述第一柔软的可拉伸弹性基材(14)和相邻的间隔的分离组件(17)在加热的展平辊之间通过，从而加热所述第一柔软的可拉伸弹性基材(14)。
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ATE258018T1 (de) 2004-02-15
USRE43994E1 (en) 2013-02-12
USRE44851E1 (en) 2014-04-22
DE60007869T2 (de) 2004-11-18
CA2375515C (en) 2008-01-29
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CA2375515A1 (en) 2001-01-18

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Co-patentee before: Stryn moulding Co Ltd

Patentee before: Stirling Moulded Composites Ltd.

CX01 Expiry of patent term
CX01 Expiry of patent term

Granted publication date: 20080730