EP2864536B1 - Stretchable sheets comprising a variety of layers and zones and methods to produce such products - Google Patents

Stretchable sheets comprising a variety of layers and zones and methods to produce such products Download PDF

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Publication number
EP2864536B1
EP2864536B1 EP13762221.3A EP13762221A EP2864536B1 EP 2864536 B1 EP2864536 B1 EP 2864536B1 EP 13762221 A EP13762221 A EP 13762221A EP 2864536 B1 EP2864536 B1 EP 2864536B1
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EP
European Patent Office
Prior art keywords
zones
different
workpiece
fibers
materials
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP13762221.3A
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German (de)
English (en)
French (fr)
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EP2864536A2 (en
Inventor
Reuven Melamed
Giloh EHUD
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tamicare Ltd
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Tamicare Ltd
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Publication date
Priority claimed from US13/531,024 external-priority patent/US9731319B2/en
Application filed by Tamicare Ltd filed Critical Tamicare Ltd
Publication of EP2864536A2 publication Critical patent/EP2864536A2/en
Application granted granted Critical
Publication of EP2864536B1 publication Critical patent/EP2864536B1/en
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/061—Load-responsive characteristics elastic

Definitions

  • the present invention relates to a method for producing a non-woven and stretchable workpiece that can be used to produce products and sheets such as two-dimensional and three-dimensional products and sheets, composed of flexible, stretchable and/or elastic materials such as natural elastomers and other synthetic polymers.
  • the method of the invention can be used for layering additional material such as fibers, in order to make 2D and 3D stretchable and/elastic products.
  • the present invention is related to methods for producing a non-woven and stretchable workpiece as set out in the claims.
  • Methods of the invention may be used to produce a variable layered sheet of stretchable, elastic or shape-retaining products, composed principally of materials such as resilient elastomers including, but not limited to, natural latex rubber or polyurethane.
  • the methods of the invention use controlled spraying for spraying the principal material or materials onto a surface of a wall such as a workpiece former.
  • the resulting product is a sheet having at least two different zones unified within the sheet.
  • the methods of the invention are improved methods for preparing products having a single or double-sided surface coating of same or different types of loose fibers, and a method for generating same or different microporosity regions in such products.
  • the method of the present invention can be used to form a sheet with different thicknesses, composites and structures in different areas.
  • the creation of such sheet or fabric is very similar to "3D printing.”
  • Creating nonwoven disposable fabric, by using the disclosed technology, is in fact 3D printing of fabric.
  • the methods of the invention can be used to form sheets comprising two or more zones, wherein at least one zone is characterized by a different composite and features than one of the remaining zones; and the sheet is stretchable and non-woven.
  • Methods of the invention for producing a stretchable workpiece can comprise applying one or more materials on a conveyor or a mold using different machines or compartment or different materials in different layouts so to produce a workpiece having two or more zones, wherein at least one zone comprises a different material feature than one of the remaining zones.
  • the present invention is generally related to methods for producing stretchable, elastic or shape-retaining products composed of principal materials comprising resilient elastomers such as natural latex rubber, polyurethane or other synthetic materials, in a sprayable liquid state, and methods for producing such products, using a controlled spraying of the liquid material onto a surface of a wall such as a workpiece former.
  • the resulting product is a sheet having at least two different zones as desired.
  • the methods of the present invention can be used to form products having a single or double-sided fiber flocked surface, and form products such as non-woven sheets having a desired level of porosity at each different zone, in order to gain breathability or permeability at the different zones of such products.
  • the product produced by the invention has improved specifications and feeling on both sides of the product.
  • the unified sheet allows the creation of a product with different performances at different areas, without the need to attach together different sheets of different materials.
  • the phrase 'unified within the sheet' means the composites of two zones adjacent one to the other, are blended at their connection lines, creating a continuous seamless sheet.
  • lock or “flocking” refers to the process of applying, attaching, or adhering loose fibers onto a surface.
  • a former or mould is an object made of any desired shape or size and serves as shape former for the making of products.
  • a former or mould may be constructed in a way that displays the shape and size of desired face mask.
  • the former may be flat and two-dimensional such as a flat belt conveyor.
  • the former may be three-dimensional and have a complex shape to which a workpiece substantially conforms.
  • the former may be made of any suitable material such as metal (e.g., aluminium), porcelain, ceramic, plastics, or composite (e.g., metal and plastic).
  • Stretchable, elastic products have a variety of uses including, without limitation, industrial use such as pipes, seals, membranes, sheets, filtering membranes; food industry such as breathable stretchable wrappers or coverings for objects including perishables such as food; medical industry for medical products such as dressings and bandages; sanitation, athletic, and personal hygiene industries such as garments including protective garments and undergarments like brassieres, undershorts, socks, or gloves and any other garment, undergarment or dressing for veterinary or outdoor use. Other examples of garments are described in USSN 10/723,244, filed November 26, 2003 , and in USSN 09/744,779, filed August 5, 1999 , both of which are incorporated by reference in their entirety.
  • loose fibers refers to any suitable loose flocking fiber material including natural or synthetic materials and may be hydrophilic, hydrophobic, or a combination of the two.
  • Hydrophilic fibers include wettable fibers, i.e., hydrophobic fibers that have been treated to render them hydrophilic, absorbent fibers, and superabsorbent polymer fibers.
  • wettable fibers include bicomponent fibers, polypropylene fibers, and polyester fibers that have been treated, for example with surfactants.
  • Example of wettable fibers are polyester fibers, such as DuPont-Akra Polyester Type 11A Bright commercially available from DuPont Company treated with a surfactant such as Tween 20 commercially available from ICI Americas Inc.
  • Absorbent fibers are hydrophilic fibers.
  • Absorbent fibers may comprise rayon fibers, acrylic fibers, nylon fibers, polyvinyl alcohol fibers, and fibers of natural or regenerated cellulosics.
  • Example of absorbent fiber is rayon fibers.
  • Superabsorbent polymer fibers are hydrophilic fibers that are swellable and capable of absorbing greater than about 5 grams per gram (of fiber weight) of 1% saline solution. Examples of superabsorbent polymer fibers are polyacrylate fibers, fibers of grafted cellulose, and fibers of maleic acid.
  • superabsorbent polymer fibers examples include OASIS Type 101, commercially available from Technical Absorbents Limited and CAMELOT, commercially available from Camelot, Alberta, Canada.
  • a preferred fiber for use in the invention is cotton fibers. Any suitable method for delivering the loose fibers so that they may be applied to the surface can be used. For instance, the loose fibers can be sprayed or blown onto the surface of the wall as well as electrostatically and or pneumatically flocked.
  • product material comprises suitable stretchable material such as natural or synthetic polymers.
  • a natural polymer includes, without limitation, latex rubber.
  • a synthetic polymer includes, without limitation, polyurethane.
  • emulsions, suspensions, or solutions of the product material e.g., liquid latex rubber, are generally used.
  • the product material is preferably allowed to dry before it is removed from a surface.
  • the drying process may include curing or setting processes, depending on the choice of product material. For example, when latex rubber is used as the product material, the latex rubber would cure as it dries.
  • the preferred product material is natural latex rubber, which forms durable, flexible, stretchable, elastic shape-retaining products.
  • the term "wall” may refer to a flat or two-dimensional work piece former such as a flat conveyor belt or any suitable shaped flat surface to which a product substantially conforms.
  • the wall may be a three-dimensional workpiece former having a complex shape to which a workpiece substantially conforms.
  • the wall may be non-flat, embossed or complex shaped conveyor belt, perforated conveyor belt, or combination thereof.
  • the wall may be made of any suitable materials such as plastic, rubber, composite (e.g., of metal and plastic or ceramic), ceramics, metal such as aluminum or stainless steel.
  • the present invention provides a surprising and significant improvement over technologies known in the art by reducing the number of process steps and entailed costs. Moreover, the present invention provides a surprisingly effective and economical way to produce thin products, sheets and non-woven fabrics that combine different zones, which performs differently in the same unified sheet and may be flocked with fibers at least on one surface.
  • a method of the invention, for producing a non-woven and stretchable workpiece may comprise the steps of: (a) applying at least one type of wetting agent onto a surface of a wall; (b) applying a first layer of at least one type of loose fibers onto at least a portion of the surface of the wall to produce a partially fiber-coated surface.
  • the loose fibers are flocked electrostatically or by any other suitable way so that they hit the wall substantially perpendicular to its surface; and the method can include the further step (c) spraying a liquid product material of at least one type onto the upright standing fibers to form a product material layer of predetermined thickness on the fiber-coated surface and produce a stretchable workpiece, wherein the product material layer has an inner and outer surface and fibers are attached to the inner surface of the product material layer.
  • Another embodiment further comprises the step of applying a second layer of loose fibers onto at least a part of the outer surface of the product material layer, wherein the product material layer is uncured or partially uncured.
  • the method further comprises the steps of: allowing the product material layer to dry; and removing the stretchable workpiece from the surface.
  • the preceding methods may further comprise using different machine components or different materials in different configurations to produce zones of different qualities in the product.
  • the method for producing a stretchable workpiece can comprise applying one or more materials on a conveyor or a mold at the same time using different machines or compartment or different materials in different layouts so to produce a workpiece having two or more zones, wherein at least one zone features a different material characteristics than one of the remaining zones.
  • Each material applied may be a liquid material as defined above.
  • At least two different spraying nozzles are used side by side in conveyor cross direction to spray material (e.g., liquid material) in parallel, so that one zone of the product will comprise lower density then the other part.
  • material e.g., liquid material
  • Each nozzle may spray the same material or different materials.
  • the nozzles may be arranged in a row.
  • a first nozzle can spray at wider angle than a second nozzle to thicken a section of the product by providing thicker elastomeric layer.
  • the nozzles are configured to apply at the same time the same or different materials in different rates so to control amount of material sprayed in the different areas.
  • the nozzles are configured to apply at the same time the same or different materials in different rates so to control amount of material sprayed in the different areas and to create areas of different porosity.
  • Such nozzle arrays may be used, for example, in step (c) as described above to spray different product materials.
  • two different materials may be sprayed in two or more zones at the same time.
  • different materials may be layered by applying a first material layer and then applying a second material layer over the first.
  • the polymers may differ in: polymer type, formulation or any property or feature, such as, but not limited to any mechanical property, viscosity, color, scents or any other desired feature.
  • the different polymers can be selected independently from natural rubber, high modulus natural rubber, low modulus natural rubber, polyurethane, silicones, and the like.
  • the polymer applied to one of the zones of the product has a higher modulus than the polymer applied to at least one other zone.
  • the polymer applied to a first zone of the product has a higher modulus than the polymer applied to a second zone.
  • At least two flocking machines are used to apply different types of fibers.
  • Such flocking machines may be used, for example, in step (b), as described above, to apply different types of loose fibers, to the different zones of the product.
  • different types of fibers may be applied to the wetting agent in adjacent zones or one type of fibers may be applied to the wetting agent (one surface of the product material layer), and a second type of flock applied over the second surface of the product material layer.
  • At least two flocking machines are used to apply different fibers, the fibers may differ in type, material, length, diameter, color, odor, compostability, water retention, hydrophobicity or any other desired feature.
  • the flock may be sprayed on top of the same product material or different product material.
  • different flocks are applied to at least two different zones and the flocks are sprayed onto the same product material.
  • different flocks are applied to at least two different zones and each type of flock is sprayed onto a different product material.
  • the wetting agent is coated with a first flock, the first flock is sprayed onto one or more product materials in one or more zones, and a second flock is applied to the outer surface of the product material.
  • the preceding methods may be used to form unified stretchable non-woven sheets having two or more zones, wherein at least one zone has a different feature than one of the remaining zones.
  • the stretchable non-woven sheets may comprise three or more zones; or four or more zones; or five or more zones. In other embodiments, the stretchable non-woven sheets may comprise two to ten zones; or two to five zones; or two to four zones; or two or three zones. In yet other embodiments, the stretchable non-woven sheets can have two zones; or three zones; or four zones; or five zones; or as many zones as necessary for a given purpose. All zones are produced as a unified sheet.
  • Each of the zones of the stretchable non-woven sheets can be, for example, but not limited to (1) the upper surface and the bottom surface; (2) the right side and the left side; (3) a longitudinal, middle portion and the remaining side parts; (4) cross direction stripes; or any other desired zone definition or combination thereof.
  • the product zones each comprise different elastomeric materials, such as, but not limited to, natural latex rubber, polyurethane or other synthetic materials.
  • each of the zones may differ in any property, such as, but not limited to, polymer type, formulation, compostability, basis weight, thickness, porosity, water or any other liquid permeability, breathability, tear strength, elongation at break, retractive force after extension, tensile strength, any other mechanical property, color, odor, tactile, or feel.
  • the stretchable non-woven sheet comprises different loose fibers, at different zones, the fibers may differ in type, material, length, diameter, color, odor, compostability, water retention, hydrophobicity or any other desired feature.
  • the product zones comprise different porosity levels.
  • the sheet may comprise a first zone having a first material and first flock and a second zone, adjacent to the first zone, having the first material and a second flock.
  • the sheet may comprise a first zone having a first material and first flock; a second zone, adjacent to the first zone, having the first material and a second flock; and a third zone, adjacent to the first or second zone, having a second material and the first flock.
  • layers may be sprayed one on top of the other, such that a sheet may comprise adjacent zones where the stacks of applied layers are different in each zone. That may get different sandwiches side by side unified on the same sheet.
  • At least one of the zones of the sheet may comprise a polymer having a different modulus from the polymer of the remaining zones.
  • Such sheets can be useful for medical usage to provide a bandage having different local pressure requirements.
  • different materials may be using in different zones to create a "breathable" area in the sheet; or an improved leak proof area.
  • different fibers may be applied to the inner and outer surfaces of a sheet, such as providing cotton fibers to the inner surface and artificial fibers to the outer surface.
  • a sheet such as providing cotton fibers to the inner surface and artificial fibers to the outer surface.
  • Such sheets may be useful, for example, in manufacturing pants or other garments.
  • different zones may be provided with different colored flock.
  • Such different colors may be applied in adjacent zones on one surface of the sheet to produce a desired design effect; or one color flock may be provided to an inner surface of the sheet and another color flock to the outer surface of the sheet.
  • the methods and products provided herein can be used in the non-woven industry, as a sheet of stretchable non-woven fabric to be used as is, or in combination with other materials such as, but not limited to, woven and non-woven fabrics, to create finished ready to use products such as, but not limited to, diapers, sanitary napkins, bandages, packaging means, beddings upholsteries, curtains, apparels, outdoor and military accessories and the like.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
EP13762221.3A 2012-06-22 2013-06-20 Stretchable sheets comprising a variety of layers and zones and methods to produce such products Active EP2864536B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/531,024 US9731319B2 (en) 2004-11-05 2012-06-22 Stretchable sheets comprising a variety of layers and zones and methods to produce such products
PCT/IB2013/001807 WO2013190385A2 (en) 2012-06-22 2013-06-20 Stretchable sheets comprising a variety of layers and zones and methods to produce such products

Publications (2)

Publication Number Publication Date
EP2864536A2 EP2864536A2 (en) 2015-04-29
EP2864536B1 true EP2864536B1 (en) 2018-03-21

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP13762221.3A Active EP2864536B1 (en) 2012-06-22 2013-06-20 Stretchable sheets comprising a variety of layers and zones and methods to produce such products

Country Status (9)

Country Link
EP (1) EP2864536B1 (zh)
JP (1) JP6302898B2 (zh)
KR (1) KR102282010B1 (zh)
CN (1) CN104471131B (zh)
BR (1) BR112014032317B1 (zh)
CA (1) CA2877494C (zh)
IL (1) IL236344B (zh)
MX (1) MX359589B (zh)
WO (1) WO2013190385A2 (zh)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017001325A1 (de) * 2015-06-29 2017-01-05 Covestro Deutschland Ag Verfahren zur herstellung von 3d objekten
EP3356588B1 (en) * 2015-09-29 2019-07-03 PrimaLoft, Inc. Blowable floccule insulaton and method of making same
WO2018021292A1 (ja) * 2016-07-28 2018-02-01 株式会社エアウィーヴ 寝具および寝具用カバーシート
CN112740400A (zh) * 2018-12-28 2021-04-30 深圳市柔宇科技股份有限公司 可拉伸基材及其制造方法
CN110450414B (zh) * 2019-08-21 2021-09-14 华育昌(肇庆)智能科技研究有限公司 一种绒毛制品3d打印组件

Family Cites Families (16)

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Publication number Priority date Publication date Assignee Title
US2592602A (en) * 1950-09-20 1952-04-15 Walter R Saks Process of producing flocked articles
JPS5111131B1 (zh) * 1970-09-11 1976-04-09
JPS55147171A (en) * 1979-05-08 1980-11-15 Duskin Franchise Co Ltd Manufacture of multicolored flocked sheet
JPS57160608A (en) * 1981-03-31 1982-10-04 Toppan Printing Co Ltd Manufacture of facing sheet
JP2963314B2 (ja) * 1993-09-24 1999-10-18 三菱電線工業株式会社 電波吸収体の製造方法
US5873963A (en) * 1997-06-02 1999-02-23 The Procter & Gamble Company Process for making an absorbent composite web
EP1054092A1 (en) * 1999-05-17 2000-11-22 Nippon Petrochemicals Company, Limited Composite sheet having elasticity, elastic web made from thermoplastic elastomer, and method and apparatus of manufacturing the same
JP3658303B2 (ja) * 2000-09-01 2005-06-08 ユニ・チャーム株式会社 弾性伸縮性複合シートおよびその製造方法
JP2002144461A (ja) * 2000-08-28 2002-05-21 Uni Charm Corp 複合シート
FR2838936B1 (fr) * 2002-04-30 2004-12-24 Oreal Dispositif d'application d'un produit, notamment cosmetique, recouvert d'un floquage de differents types de fibres
US20050119631A1 (en) * 2003-10-22 2005-06-02 Tamicare Ltd. Method of producing absorptive areas for protective products
US20050142339A1 (en) * 2003-12-30 2005-06-30 Price Cindy L. Reinforced elastic laminate
US7901740B2 (en) * 2004-11-05 2011-03-08 Tamicare Ltd. Methods to produce stretchable products
US20060143767A1 (en) * 2004-12-14 2006-07-06 Kaiyuan Yang Breathable protective articles
US7709405B2 (en) * 2005-05-17 2010-05-04 Milliken & Company Non-woven composite
US8021735B2 (en) * 2007-01-08 2011-09-20 Xymid, Llc Stitchbonded fabric with a substrate having diverse regional properties

Also Published As

Publication number Publication date
BR112014032317B1 (pt) 2021-07-06
KR102282010B1 (ko) 2021-07-27
CA2877494C (en) 2020-08-04
CA2877494A1 (en) 2013-12-27
BR112014032317A8 (pt) 2021-04-06
MX359589B (es) 2018-10-03
CN104471131B (zh) 2017-06-13
JP2015521695A (ja) 2015-07-30
IL236344B (en) 2018-04-30
CN104471131A (zh) 2015-03-25
WO2013190385A2 (en) 2013-12-27
JP6302898B2 (ja) 2018-03-28
IL236344A0 (en) 2015-02-26
BR112014032317A2 (pt) 2017-06-27
KR20150023763A (ko) 2015-03-05
EP2864536A2 (en) 2015-04-29
MX2014016116A (es) 2015-11-30
WO2013190385A3 (en) 2014-02-20

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