GB2433465A

GB2433465A - Manufacture of an article form non woven sheets

Info

Publication number: GB2433465A
Application number: GB0525798A
Authority: GB
Inventors: Gregory James Murray; Lelsie Miles Blustin
Original assignee: BM Polyco Ltd
Current assignee: BM Polyco Ltd
Priority date: 2005-12-20
Filing date: 2005-12-20
Publication date: 2007-06-27
Anticipated expiration: 2025-12-20
Also published as: GB2433465B; GB0525798D0

Abstract

An apparatus for use in the manufacture of an article from first and second non woven sheets comprises (a) a sealing station for producing a seal of a defined pattern (392) between the first and second sheets and (b) a cutting station for producing a cut of a defined cutting pattern to the first and second non woven sheets, the seal being produced by produced by ultrasonic sealing (393) and the seal pattern is defined by a cylindrical sealing die (390). The cutting station may be provided by a cylinder (394) provided with a raised cutting die pattern (375), which generally follows the outline of the ultrasonic seal (370) and an interacting second cylinder (395) provided with a second relief pattern (398). The article may be a glove liner comprising a first skin contacting layer comprising a non-woven material and a second layer comprising a waterproof material. The non woven material may comprise spun-bonded, melt blown or chemically bonded polypropylene, polyester or other thermoplastic fibres or blends. The waterproof material such as polypropylene or polyester may be breathable.

Description

APPARATUS FOR MANUFACTURE OF AN ARTICLE FROM NON WOVEN SHEETS

There is provided apparatus for use in the manufacture of an article (e.g. a glove liner) from first and second non woven laminate sheets.

Traditional leather and cotton gloves, for example Canadian Rigger style and Drivers style are well-known and popular amongst users. Such gloves typically comprise a leather/cotton composite outer shell made by sewing pieces of leather and cotton fabric together. Such gloves are not fully waterproof. An inner lining comprising a woven or knitted textile is often also provided to the glove, but this of itself does little to enhance the waterproofing of the overall glove.

When such traditional gloves are used as hand protection during the chilly and damp late autumn and winter months the user's hands can tend to get cold and wet as a result of their inherently poor waterproofing properties. Similarly, if such traditional gloves are used for handling damp and oily objects the user's hands get wet and potentially contaminated and again are subject to the cold. Applicant has therefore identified the problem of providing a glove that has better waterproofing and hence, offers better protection from the cold and/or any liquid-borne contaminants.

There is described herein an enhanced liner for a glove and apparatus suitable for making such a liner which comprising non woven laminate sheets One suitable liner herein is made from a durable non woven material which laminates to a breathable waterproof material. The two layers are brought together with the non woven sides facing inwards (i.e. towards the skin of the user's hand). As the non woven material faces the hand, it suitably provides a comfortable, durable, absorbent layer. The waterproof material desirably helps insulate the user's hand from the cold and damp. In a preferred variation herein, a third layer comprising a non woven material is also provided such that the overall liner comprises a breathable waterproof layer sandwiched between two non woven layers.

In manufacture of the above described glove liner (or a similar article) opposing non woven faces may be brought together and sealed using a sealing pattern that defines the shape of the article (i.e. for the glove liner the sealing pattern would be glove-shaped).

The Applicant has now appreciated that problems can arise in the choice of a suitable sealing method. For example, heat based sealing techniques have been found to give inconsistent sealing and potentially give rise to problems relating to heat degradation of the non woven materials themselves. Furthermore, heat seals tend to be rough in nature and can be uncomfortable when used to seal an article such as a glove liner that is worn close to the skin of a user The Applicant has also realized that it can be advantageous to use a die to define the sealing pattern (i.e. a surface with a raised die outline that defines the sealing pattern) but that problems can arise when a flat die is used in a flat sealing process.

In more detail, undesirable variations and broken welds' can arise in the finished seal due to variations in flat die clamping pressures and the need for the face of the die profile to remain critically parallel to the material (that is being sealed) to retain the full contact needed for sealing In solution to these problems Applicant has devised apparatus for use in the manufacture of an article from first and second non woven laminate sheets that employs ultrasonic sealing to produce a seal between the sheets and defines a seal pattern by means of a cylindrical sealing die. Such apparatus has been found to be particularly suitable for use in a continuous manufacturing process as is preferred for volume manufacture.

It is an object of the present invention to provide apparatus for use in the industrial scale manufacture of an article from first and second non woven laminate sheets.

According to one aspect of the present invention there is provided apparatus for use in the manufacture of an article from first and second non woven laminate sheets, the apparatus comprising (a) a sealing station for producing a seal of a defined seal pattern between said first and second non woven laminates; and (b) a cutting station for producing a cut of a defined cutting pattern to the first and second non woven laminate sheets, wherein said seal is produced by ultrasonic sealing and said seal pattern is defined by a cylindrical sealing die.

The manufacturing apparatus herein are suitable for use in the manufacture of an article (e.g. a glove liner) from first and second non woven laminate sheets.

Suitable non woven laminate sheets include any of those described hereinafter, particularly a liner material comprising a first layer of a non woven material and laminating to said first layer, a second layer comprising a waterproof material.

The apparatus comprises a sealing station for producing a seal of a defined seal pattern between said first and second non woven laminates.

The seal is produced by ultrasonic sealing, wherein typically ultrasonic energy is provided by an ultrasonic horn of defined sealing energy. Suitably, the ultrasonic horn is adjustably mounted and the cylinder with the sealing die rotates relative to it such as to deliver material for ultrasonic sealing.

The seal pattern (e.g. in the form of a glove) is defined by a cylindrical sealing die.

That is to say, the seal pattern is provided as a die (i.e. raised outline) to a cylinder In a typical operation, the material is wound onto the cylinder and brought into contact with the sealing die. Supply of ultrasonic energy then results in the formation of a seal between the opposing first non woven layer faces of the two non woven laminate sheets that corresponds in profile to the sealing pattern defined by the sealing die.

The apparatus further comprises a cutting station for producing a cut of a defined cutting pattern within the first and second non woven laminate sheets, Suitably, said cut is produced by the interaction of a cylindrical cutting die (i.e. a first cylinder having a cutting pattern provided in cutting die relief) with a second cylinder that meshes with the first cylinder. Thus, in a typical operation, the already sealed together sheets are wound between the cylinder with culling die and the second cylinder. The meshing pressure between the cylinders then results in the formation of a cut in the already sealed non woven laminate sheets that corresponds in profile to the cutting pattern defined by the cutting die.

Suitably, the profile of the cutting pattern relates to that of the sealing pattern.

Preferably, the profile of the cutting pattern is arranged such as to provide a margin of a cut around the sealing pattern such that in use, the seal between the non woven laminate sheets is not disturbed by the cutting process. A margin of about 1 to 5mm is typical. Suitably, the profile of the cutting pattern may be arranged to give greater margins and/or tab profiles at defined positions relative to the seal pattern, but again not such as to disturb the integrity of the seal.

A full manufacturing line incorporating the apparatus herein suitably also incorporates one or more other stations, such as.

(c) first and second feeding stations for respectively feeding said first and second non woven laminate sheets; and for (d) a positioning station for positioning the sheets relative to each other (e.g using edge guidance control); and/or (e) a tensioning station for providing tension to the sheets along the line; and/or (f) a waste separation station for separating out waste sheet material that has been cut-away; and/or (g) a finished article collecting station.

The apparatus herein is particularly suitable for use in the manufacture of a liner for use with a glove outer comprising a first inner skin-contacting layer comprising a non woven material; and laminating to said first layer, a second layer comprising a waterproof material.

The liner is suitable for use with a glove outer. In alternatives, the liner may either be sewn into the glove when the glove is being manufactured (integral liner), or be introduced into it as a separable liner The liner and hence, outer glove herein suitably has a conventional form and is shaped for receipt by the hand of a user. In typical fashion therefore, the liner and outer glove defines four finger-receiving portions, a thumb-receiving portion and a body of hand-receiving portion The liner and/or outer glove may also extend somewhat along the wrist of a user The glove liner herein comprises a first inner skin-contacting layer comprising a non woven material. The first inner layer is skin contacting when the glove is worn. That is to say, the first layer typically contacts the skin of the hand, fingers and thumb of the user during normal use of the liner.

The first layer comprises a non woven material. Suitable non woven materials include spun-bonded, melt-blown or chemically-bonded polypropylene, polyester, polyamide or other thermoplastic fibres or blends.

In laminating contact with said first layer, there is provided a second layer.

The second layer comprises a waterproof material. Suitably, the waterproof material is also breathable in nature. The waterproof material is preferably formed as a film or membrane. Suitably, the waterproof material comprises an organic polymeric material, preferably a thermoplastic such as a polypropylene or polyester material.

Preferably, the waterproof material comprises a breathable polypropylene or polyester film. Generally, it has been found that polypropylene and polyester bonds well to the non woven. The film provides a waterproof lining for the glove and helps insulate the hand from cold and damp. As it is breathable it helps keep the hand cool and dry in hot weather.

In one aspect, there is further provided in laminating contact with (the other side of) the second layer, a third layer, that preferably comprises a non woven material.

Preferably, the first and third layers comprise the same non woven material.

Preferably, the means of laminating the second and third layers together corresponds to the means employed for laminating the first and second layers together.

There is provided a glove comprising a glove outer; and provided to said glove outer, a liner as described herein The liner may either be sewn to the glove outer (integral liner), or be provided as a separable liner to it Suitably, the glove outer comprises leather and/or cotton material or preferably layers of both of these materials that are sewn together.

There is further provided a method of making a liner herein comprising the steps of selecting a liner material comprising a first layer of a non woven material and laminating to said first layer, a second layer comprising a waterproof material; folding the liner material such as to bring opposing first layer sections into contact with each other; and sealing the opposing first layer sections with a seal defining a glove-like shape.

In the method aspect herein, a liner material is selected. The liner material comprises a first layer of a non woven material and laminating to said first layer, a second layer comprising a waterproof material.

The liner material is then folded such as to bring opposing first layer sections into contact with each other. Thus, the liner is typically folded over on itself in such a way as to bring opposing first layer sections into contact with each other. Folding in half such that opposing first layer halves are brought together is generally preferred.

In an alternative method, two separate pieces of liner material are brought together in such a way as to bring opposing first layer sections into contact with each other.

Thus, alternatively there is provided a method of making a liner herein comprising the steps of selecting first and second liner materials, each comprising a first layer of a non woven material and laminating to said first layer, a second layer comprising a waterproof material; bringing together the liner materials such as to bring opposing first layer sections into contact with each other; and sealing the opposing first layer sections with a seal defining a glove-like shape.

In both alternative methods, the opposing first layer sections are then sealed with a seal defining a glove-like shape (i.e. using a glove-like sealing pattern). That is to say seals are provided between the opposing first layer sections such as to provide a glove-like seal between them, which typically defines a thumb and four fingers per glove (exact dimensions will change to suit the shape, style and size of the glove outer).

Suitably, the seal is provided by ultrasonic welding, which Applicant has found to be more flexible from a manufacturing standpoint than the alternative heat welding. Heat welded seals have also been found to be less comfortable for the user.

Suitably, the glove-like sealing pattern is provided by feeding the liner material through a cylinder which is arranged to produce an ultra sonic seal in the material in the desired shape of a glove.

After sealing, the glove-like sealed together liner is subjected to a cutting process to provide a cut outside of the seal such as to produce a cut-out sealed glove liner.

Desirably, when cutting, a margin is left outside of the seal such, particularly at the tips of the fingers such as to provide marginal region (or finger tabs) that may be employed as stitch target areas when the liner is stitched to the glove outer.

The cutting is one aspect provided by feeding the sealed together liner through a second cylinder which cuts out the shape and produces the glove liner. Desirably, the machine is fully automatic and feeds, seals, cuts, counts and stacks the glove liners ready for packing.

There is also provided a method for assembling a glove herein by stitching a glove outer to the margin and/or finger tabs area provided to the glove liner.

In one aspect, the method comprises placing the glove liner (in its as formed condition) on top of a glove outer (turned inside out), inter-engaging the two portions (e.g. by stitching through the margin/finger tabs) and turning the assembly inside out through the cuff of the liner. The cuff of the liner is then sewn to the cuff of the outer glove. Finishing may then be applied (e.g. by applying edging and/or other embellishments) Whilst the liner herein is specifically designed for use as a liner for a full glove it may be appreciated that the liner itself has the shape of and can therefore function as a sort of glove. Uses of the liner might include as a dusting mitten with the outer non woven layer acting as the duster part.

Embodiments of the present invention will now be described with reference to the accompanying drawings in which.

Figurel shows a sectional view through an embodiment of leather glove having a first glove liner that may be manufactured using the apparatus herein; Figure 2 shows a sectional view through an alternative embodiment of leather glove having a first glove liner that may be manufactured using the apparatus herein; Figures 3a to 3b show perspective views and Figures 3c to 3d top views of steps in a representative method for making a glove liner; Figure 4 shows in perspective view an ultrasonic welding station for use in apparatus of manufacture of a glove liner herein; Figure 5 shows in side sectional view an ultrasonic welding station for use in apparatus of manufacture of a glove liner herein; Figure 6 shows in perspective view a cutting station for use in apparatus of manufacture of a glove liner herein; Figure 7 shows in side schematic view a manufacturing apparatus line for use in a method of manufacture of a glove liner herein; Figure 8 shows in top view a manufacturing apparatus line for use in a method of manufacture of a glove liner herein, and Figure 9 shows in top view a glove liner herein.

Referring now to the drawings, Figure 1 shows the upper and lower layers of a glove comprising an outer 10 of leather that joins through sewn contact points 20, 22 to glove liner 11 comprising a first (inner) layer 30 comprising a non woven material and in laminating contact therewith, a second (outer) layer 40 comprising a waterproof polyester film material. It will therefore be appreciated that in use, the first non woven layer 30 is in contact with the skin of the hand of the user.

Figure 2 shows a variation of the glove of Figure 1 in which, glove outer 110 joins through sewn contact points 120, 122 to glove liner 12 comprising a first (inner) layer 130 comprising a non woven material and in laminating contact therewith, a second (outer) layer 140 comprising a waterproof polyester film material, which in turn is in laminating contact with a third layer 132 also comprising a non woven material.

Again, in use, the first non woven layer 130 is in contact with the skin of the hand of the user.

A better understanding of the form of the glove liner 11 of Figure 1 may be gained by reference to Figures 3a to 3d, which steps in a representative method for making a glove liner herein. The description is equally applicable to the glove liner 12 of Figure 2.

Referring to Figure 3a, two webs 201a, 201b of liner material for respectively forming the upper and lower portions of the liner 11 are brought into face to face contact from respective rolls. The two webs of liner material 201 a, 201 b are orientated, such that their respective non woven layers 130 are face-to-face.

As shown at Figure 3b, a seal 270 is applied to the opposing webs of liner material 201a, 201b, with the seal 270 defining a glove- like shape.

Then, as shown at Figure 3c, a line of cut 275 is defined, which generally follows the outline of the seal 270 but leaves a small outer margin and additionally provides cuff tabs 279a, 279b; side tabs 280a, 280b; thumb end tab 282 and finger end tabs 284a to 284d. Each of these tabs can function as points for stitching the glove liner 11 to the leather glove outer 10 at the points 20, 22.

Figure 3d shows the final glove liner as cut away from the base liner material 201 and again defining cuff tabs 279a, 279b; side tabs 280a, 280b; thumb end tab 282 and finger end tabs 284a to 284d.

Whilst Figures 3a to 3d illustrate a representative method of making a glove liner herein, Applicant has found that certain improvements assist efficient manufacturing.

In one improvement, as shown at Figures 4 and 5 the step of ultrasonic welding of the glove liner is accomplished by means of an ultrasonic welding station including a cylindrical die.

In more detail, at Figures 4 and 5 there is shown cylinder 390, which is mounted for rotation on axle 391. The surface of the cylinder 390 is provided with a raised die pattern 392 in the shape of a glove. Mounted above the cylinder 390, there is provided an ultrasonic horn generator 393. The raised die pattern 392 has a height of approximately 3mm and a width of approximately 3mm all the way along its length.

In an ultrasonic welding operation it will be appreciated that the two webs 201a, 201b of liner material are fed onto the cylinder 390. The webs 201a, 201b are brought into contact with the glove-shaped die profile 392 and as the cylinder 390 rotates ultrasonic welding energy (typically of frequency about 30 KHz) is directed down from the oscillator horn 393 to the webs on the raised die 392 such as to cause a glove- shaped ultrasonic weld to be formed between the (non woven opposing faces) of the webs as they travel under the oscillator horn 393.

Whilst the cylinder 390 of Figures 4 and 5 is shown to have only a single glove-shaped die pattern it will be appreciated that variations are possible in which spaced repeat die patterns may be employed. Typically, a glove repeat spacing of about 20mm will be employed.

It will be appreciated that one advantage of the sealing operation described above is that the webs 201 a, 201 b move within the rotational speed of the sealing cylinder 390 such that the sealing takes place over a small area where the 201a, 201b are lined up between the horn 393 and the die profile 392 thereby reducing distortion and wear and tear of the apparatus.

In another improvement, as shown at Figure 6 the step of cutting the glove liner is accomplished by means of a cutting station including a cylindrical cutting die.

In more detail, at Figure 6 there is shown cylinder 394, which is mounted for rotation on axle 395. The surface of the cylinder 394 is provided with a raised cutting die pattern 375 in the general shape of a glove. The cutting pattern 375 generally follows the outline of the ultrasonic seal 370 of a glove liner 330 shape defined in already ultrasonically sealed non woven laminate webs 201a, 201b. As shown in Figure 3c however, the cutting pattern 375 leaves a small outer margin (e.g. about 3.5mm) and additionally defines cuff tabs 279a,279b; side tabs 380a, 380b; thumb end tab 382 and finger end tabs 384a to 384d. Since the cut is arranged to be outside of the seal 370, the integrity of that seal 370 is unaffected by the cutting operation.

The cutting function is achieved by the interaction of the cutting die 375 with second cylinder 396, which mounts on axle 397. The cylinders 375, 396 are of identical diameter and are linked for synchronous rotation with each other and the webs 375, 396. The second cylinder 396 is provided with a recessed relief pattern 398 on the surface thereof, which corresponds in shape to the shape of the raised cutting die 375, such that as the cylinders 375, 396 rotate synchronously, the die 375 meshes with the recess 398, thereby cutting the webs 375, 396.

Figure 9 shows the final glove liner 330 as cut away from its base liner material 301, the liner having ultrasonic seal 370 and again defining cuff tabs 279a, 279b; side tabs 380a, 380b; thumb end tab 382 and finger end tabs 384a to 384d.

Figures 7 and 8 show views of a manufacturing line for use in the industrial scale continuous manufacture of glove liners herein.

Referring to Figures 7 and 8, there are shown first and second unwinding stations Al and A2 for the unwinding respective rolls of non woven laminate webs 401a, 401b. It will be appreciated that the unwinding of the webs 401a, 401b is oriented such that opposing first non woven layer faces contact each other At positioning station B the respective webs 401a, 401b are brought together and correctly positioned relative to each other (e.g using edge guidance control and a turner bar to orientate the film) At ultrasonic sealing station C the respective webs 401a, 401b are ultrasonically sealed (e.g. to form a glove liner shaped seal as described in relation to Figures 4 and 5) by the action of ultrasonic welding horn D. At tensioning section E the already sealed together webs are correctly tensioned by means of a take up arrangement.

At cutting station F the respective webs 401a, 401b are cut into by the action of cylinder with cutting pattern die and the synchronised cylinder with the relief pattern (e.g. to form a glove shaped cut-away form as described in relation to Figure 6).

At waste separation station G all waste material (i.e. that waste that has been cut-away) is separated out. The waste wind up unit G2 (as shown in Figure 7 only) acts to wind up the waste sheet material 401 a, 401 b.

At finished article collecting station H the finished articles (e.g. glove liners) are collated together. Finished articles are generally stacked in bunches for ease of packing.

In the apparatus set up as described above the tension of the sheets within the line can be controlled by motorized inward rollers of the unwinding stations Al, A2 and the outward rollers of the separation station G, thus ensuring both sealing station C and cutting station F are in close sequence for accuracy.

One advantage of the apparatus set up described above is that the cutting cylinders 394, 396 of the cutting station F are driven and run in sequence with the cylinder 390 of the ultrasonic sealing station C. Accuracy of cut definition is therefore provided.

For flexibility, the apparatus set up may be arranged such that the sealing cylinders and/or cutting cylinders are interchangeable within the parameters of the overall manufacturing line.

Claims

CLAIMS

1. Apparatus for use in the manufacture of an article from first and second non woven laminate material, the apparatus comprising (a) a sealing station for producing a seal of a defined seal pattern between said first and second non woven laminates; and (b) a cutting station for producing a cut of a defined cutting pattern to the first and second non woven laminate sheets, wherein said seal is produced by ultrasonic sealing and said seal pattern is defined by a cylindrical sealing die.

2. Apparatus according to claim 1, wherein said ultrasonic sealing is by means of an ultrasonic horn of defined variable energy 3. Apparatus according to either of claims 1 or 2, wherein said cut is produced by the interaction of a cylindrical cutting die with a second cylinder that meshes therewith.

4. Apparatus according to claim 3, wherein said second cylinder also comprises a cutting die arranged to mesh with said cylindrical cutting die.

5. Apparatus according to any of claims 1 to 4, wherein the profile of the cutting pattern relates to that of the sealing pattern.

6. Apparatus according to claim 5, wherein said profile of the cutting pattern provides a margin of a cut around the sealing pattern.

7. Apparatus according to claim 6, wherein the profile of the cutting pattern provides enhanced margins and/or tab profiles at defined positions relative to the seal pattern.

8. Apparatus according to any of claims 1 to 7, wherein the sealing pattern has the profile of a glove liner.

9. Apparatus according to either of claims 8 or 9, wherein the cutting pattern defines one or tab profiles selected from the group consisting of cuff tab profiles; side tab profiles; thumb end tab profiles; finger end tab profiles; and any combinations thereof.

10. Apparatus according to any of claims 1 to 9, further comprising one or more additional stations selected from the group consisting of: (C) first and second feeding stations for respectively feeding said first and second non woven laminate sheets; (d) a positioning station for positioning the sheets relative to each other (e.g. using edge guidance control); (e) a tensioning station for providing tension to the sheets along the line; (f) a waste separation station for separating out waste sheet material that has been cut-away; (g) a finished article collecting station; and any combinations thereof.