MXPA05011973A - Molded composite fabrics and methods of making - Google Patents

Abstract

A molded composite fabric and methods of making are provided. The molded composite fabric has a polyethylene foam layer and a first fabric layer adhered to a first side of the polyethylene foam layer to define a composite fabric. The molded composite fabric also includes a feature molded in the composite fabric. The first fabric layer has a non-woven fabric with a web of randomly disbursed fibers. The method includes selecting a non-woven fabric having a web of randomly disbursed fibers, exposing the non-woven fabric to mechanical agitation, laminating the non-woven fabric to a first side of a polyethylene foam layer to a composite fabric, compressing the composite fabric between a top mold and a bottom mold, and maintaining the composite fabric between the top and bottom molds for a predetermined dwell time.

Description

COMPOSITE MOLDED FABRICS AND DEVELOPMENT METHODS Field of the Invention The present invention relates to composite molded fabrics and methods of processing. More particularly, the present invention relates to composite fabrics having a nonwoven fabric layer and a foam layer, wherein the composite fabrics include one or more configurations molded therein. BACKGROUND OF THE INVENTION A variety of clothing items or items include one or more molded shapes or configurations. For example, bras include molded bra cups in a composite fabric having a layer of fabric and a layer of foam. Similarly, protective products such as, for example, but not limited to, knee pads or knee pads, elbow pads or elbow pads, and the like, include configurations molded into a fabric composed of fabric and foam. In addition, a variety of non-clothing products such as, for example, but not limited to, automotive interiors, home furnishings and others, may include these composite molded fabrics. Typically, composite molded fabrics include a layer of urethane thermoplastic foam (TPU) adhered to REF. 168115 a fabric or knitted fabric. Unfortunately, TPU foam can be expensive and therefore, its use can be prohibitively expensive in many consumer product applications. Also, TPU foams are sensitive to ultraviolet radiation present in ambient light. Specifically, ultraviolet radiation tends to cause TPU foams to have a yellowish color. In many applications, the yellowing of the TPU foam is unacceptable. Therefore, many TPU foams are laminated or coated on both sides with a cloth layer to mask this yellowing. These additional coating layers can add cost and weight to the product that originates. The selection of the TPU foam and the fabric or knitted fabric are particularly suitable for use with each other in a composite molded fabric, since both the TPU foam and the knitted fabric normally require high molding temperatures and long times molding (for example, 204.44 ° C (400 ° F) approximately for 60 seconds)). Unfortunately, high molding temperatures and long molding times can also make the use of these composite fabrics prohibitively expensive in many consumer product applications. Accordingly, there is a continuing need for composite molded fabrics and molding methods that overcome and / or mitigate one or more of the aforementioned drawbacks and other drawbacks and deficiencies of the prior art. SUMMARY OF THE INVENTION An object of the present invention is to provide a composite molded fabric having a nonwoven fabric layer and a foam layer. Another object of the present invention is to provide a composite molded fabric having a nonwoven fabric layer laminated on both sides of a foam layer. Another object of the present invention is to provide a method of molding a composite fabric having a nonwoven fabric layer and a foam layer. Still another object of the present invention is to provide a method of manufacturing a composite fabric from a non-woven fabric and a foam layer. The aforementioned objects and other objects of the present invention are provided through a composite molded fabric. The composite molded fabric has a layer of polyethylene foam and a first layer of fabric adhered on the first side of the polyethylene foam layer to define a composite fabric. The composite molded fabric also includes a molded configuration in the composite fabric. The first layer of fabric has a non-woven fabric with a core of fibers randomly distributed. A fastener or bra is provided which includes a garment body and a pair of molded bra cups having a first layer of fabric adhered to a first side of the polyethylene foam layer. The first layer of fabric has a non-woven fabric with a core of fibers randomly distributed. A method of forming a molded non-woven fabric is also provided. The method includes the selection of a non-woven fabric that has a fiber core randomly distributed, the exposure of the non-woven fabric to a mechanical stirring process, the lamination of the non-woven fabric on a first side of a layer of polyethylene foam into a composite fabric, the compression of the composite fabric between a top mold and a lower mold, and the maintenance of the composite fabric between the upper and lower molds during a predetermined stop time. The features and advantages described above and others additional to the present invention will be appreciated and understood by those skilled in the art from the following detailed description and the figures. Brief Description of the Figures Figure 1 is a cross-sectional view of an exemplary embodiment of a composite molded fabric according to the present invention; Figure 2 illustrates a molding step for the composite fabric of Figure 1 during a heating portion; Figure 3 illustrates the step of molding the Figure 2 during a molding portion; Figure 4 illustrates a manufacturing process for composite molded fabrics according to the present invention; Figure 5 illustrates a first example embodiment of a garment having a molded fabric composed in an unassembled condition; and Figure 6 illustrates a second example embodiment of a garment having a molded fabric composed in an unassembled condition. Detailed Description of the Invention With reference to the figures and in particular to Figure 1, a molded fabric composed in accordance with the present invention is illustrated, generally, with the reference number 10. The composite fabric 10 includes one or more fabric layers 12 adhered with a foam layer 14, wherein the fabric and foam layers have been molded to define a molded configuration 16. The shape or configuration 16 can be any desired configuration as required through the end use of the fabric. composite fabric 10. For example, composite fabric 10 may find use in a garment, such as a bra requiring bra cups. In this example, configuration 16 can define the cups of the bra. In another example, the composite fabric 10 may find use in an item of protective clothing, such as a knee pad that requires the configuration to approximate the shape of the protected part of the body. In still another example, the composite fabric 10 can find use in a garment of insulating clothing, such as a coat, a jacket, a sweatshirt. In this example, the configuration 16 may be a plurality of expanded sections. In still another example, the composite fabric 10 can find use in a decorative garment, wherein the shape or configuration 16 is provided to add a pattern or design to the garment. It should be recognized that the composite fabric 10 is described above by way of example in use as a garment. Obviously, it is contemplated through the present disclosure that the composite fabric 10 finds use in other applications than garments. The fabric layer 12 can be adhered to the foam layer 14 by any known method. Preferably, the fabric layer 12 is adhered with the foam layer 14 through a solvent-based adhesive 18, such as, but not limited to, a soul adhesive, a film adhesive, a knit adhesive. of ligature and others. Obviously, it is contemplated through the present disclosure that the fabric layer 12 and the foam layer 14 are adhered to each other through other methods such as, but not limited to, sonic welding. Furthermore, it is contemplated through the present description that the fabric layer 12 and the foam layer 14 are adhered to each other continuously or discontinuously through their mating surfaces. For purposes of clarity, the composite fabric 10 is described herein having the fabric layer 12 adhered to one side of the foam layer 14. However, it is also contemplated through the present disclosure that the composite fabric 10 has a second layer of fabric (not shown) adhered to the opposite side of the foam layer 14, so that the composite fabric defines a three-layer structure having an intermediate layer of foam. The configuration 16 is molded into a composite fabric 10 after the fabric layer 12 and the foam layer 14 are bonded together. Advantageously, the materials of the fabric layer 12 and the foam layer 14 are configured for use with each other in the composite fabric 10 since both can be molded at low molding temperatures and short molding periods. Preferably, the fabric layer 12 is made of materials that can be molded at temperatures less than about 148.89 ° C (300 ° F) about 20 seconds. Similarly, the foam layer 14 is made of a material that can withstand the molding temperatures that the composite fabric 10 is exposed during the molding process. In an example mode, the fabric layer 12 is a non-woven fabric having a randomly distributed fiber web or filaments (hereinafter, they will be referred to as "fibers"), wherein it is preferred that the web has a uniform fiber orientation in the web. all directions. It is also preferred that the fibers be bonded and / or entangled with each other. The individual fibers may be one component, multiple component or any combination thereof. The fabric layer 12 may be substantially rigid or inextensible (hereinafter, "rigid") or may be substantially elastic depending on the final use of the composite fabric 10. In an exemplary embodiment, the fabric layer 12 provides the touch or manual perception acceptable for soft cloth applications. The manual perception, as well as other physical characteristics (eg, elasticity) of the fabric layer 12 can be affected by the structure of the individual fibers, the composition of the fiber materials, the size of the individual fibers or any of the combinations of them. For example, the fabric layer 12 may include about 100% of a polymer such as, for example, but not limited to, nylon, polypropylene, polyester and other polymers. Also contemplated by the present invention is at least one portion of the fibers in the fabric layer 12 that are natural fibers (e.g., cotton, wool, hemp). In another example, the fabric layer 12 includes multi-component fibers having a blend of polymers such as fibers having a mixture of a low melting temperature polymer and a high melting temperature polymer. The low melting temperature polymer allows the non-woven fabric to be molded, while the high melting temperature polymer introduces a structural stability to the fabric. By way of example, the low melting temperature polymer allows the non-woven fabric to be molded at lower temperatures of approximately 148.89 ° C (300 ° F.) In another embodiment, the fabric layer 12 may include at least two different fibers of a component. One of the fibers of a component has a polymer of low melting temperature, while the other of the fibers of a component has a polymer of high melting temperature. In yet another example, the fabric layer 12 can include fibers having two or more different diameters.

Accordingly, it is contemplated through the present disclosure that the fabric layer 12 has individual fibers sized, positioned, shaped, and that the composition of materials is sufficient to provide the desired physical characteristics for the composite fabric 10. The fabric layer 12 can be made using a non-woven process such as for example, but not limited to, the meltblowing process, the spinning process, the hydro-entangling process, the carding process, or any of the combinations thereof. An exemplary nonwoven fabric which is suitable for the fabric layer 12 used in soft fabric applications includes the EVOLON fabric, which is commercially available from Freudenberg Nonwovens of Durham, North Carolina. The EVOLON fabric is made using the spinning and hydro-entangling processes. Spunbond fibers are multi-component fibers having 70% PET and 30% NYLON. During the hydroentanglement portion of the process, the fibers are divided into segments. It has been found that the low molding temperatures provided through the use of the nonwoven fabric layer 12 advantageously allow the foam layer 14 to be made of foams which also have a low molding temperature such as for example , polyethylene foam. Preferably, the foam layer 14 is a low density polyethylene foam. Polyethylene foam is cheaper than TPU foams used in the prior art. In addition, the polyethylene foam does not yellowish or discolour when exposed to ultraviolet radiation present in the ambient light and therefore, the composite fabric 10 eliminates the need to coat the foam layer 14 with additional protective layers. As such, the composite fabric 10 can be made lighter and less expensive than the coated foams of the prior art. The thickness, smoothness and stretch level of the foam layer 14 and / or the fabric layer 12 can be selected to be combined with the desired end use of the composite fabric 10. Next, with reference to Figures 2 and 3, a molding step according to the present invention for the configuration 16 is illustrated, generally, through the reference number 20. The composite fabric 10 is illustrated in Figure 2 prior to molding of the configuration 16 and is illustrated in FIG. Figure 3 during the molding of the configuration. The molding step 20 includes a heating station 22 and a molding station 24. The heating station 22 can include, for example, one or more heating radiant plates for the temperature rise of the composite fabric 10 as it is moved through the heating station in the machine direction 26 to the molding station 24. The heating station 22 raises the temperature of the composite fabric 10, so that the composite fabric is heated to a predetermined temperature. For example, the heating station 22 raises the temperature of the composite fabric 10 to a lower temperature of approximately 190.56 ° C (375 ° F). In a preferred embodiment, the heating station 22 raises the temperature of the composite fabric 10 to approximately 148.89 ° C (300 ° F). Next, the molding step 20 moves the composite hot fabric 10 towards the molding station 24. The molding station 24 includes a molding cavity 28 having a desired shape. In the embodiment illustrated, the molding cavity 28 has a shape for configuring a cup of a holder. Preferably, the molding station 24 is a vacuum molding station which extracts the composite hot fabric 10 towards the cavity 28 in the molding direction 30. The molding station 24 keeps the composite fabric 10 in the cavity 28 for a predetermined time of unemployment. For example, the molding station 24 keeps the composite fabric 10 in the cavity 28 for less than 30 seconds. In a preferred embodiment, the molding station 24 holds the composite fabric 10 in the cavity 28 for about 20 seconds.

In an advantageous form, the predetermined temperature and dwell time of the molding step 20 (eg, 148.89 ° C (300 ° F) for about 20 seconds) are less than those currently used in the manufacture of compounds that have TPU foam and cloth or knitted fabric (eg, 204.44 ° C (400 ° F) for about 120 seconds). In this way, the molding step 20 can form the composite fabric 10 in the desired configuration in a faster and more economical way than the previous processes. Next, with reference to Figure 4, a manufacturing process according to the present invention for the manufacture of the composite fabric 10 is illustrated, generally, through the reference numeral 40. In addition to the molding step 20 described above, the manufacturing process 40 includes a washing or stirring step 42 and a rolling step 44. During the process 40, the fabric layer 12 is first exposed to the stirring step 42, then the fabric layer and the foam layer 14 are adhered to each other during the lamination step 44 to define the composite fabric 10, and finally, the composite fabric is molded during the molding step 20. Preferably, the stirring step 42 exposes the desired non-woven fabric 12 to a mechanical stirring process, more preferably, in the presence of a blowing agent. wetting such as, for example, but not limited to, water and / or fabric softener. For example, it is contemplated that the stirring step 42 is carried out in a common domestic washing machine or a common industrial jet coloring machine (processed with or without colorants). In this way, the stirring step 42 subjects the fabric layer 12 to the stirring process in the presence of a wetting agent in order to allow the individual fibers to reach a desired position with respect to each other as discussed immediately below. While not wishing to unite through a particular theory, it is believed that the stirring step 42 introduces an element of freedom into the individual fibers of the non-woven fabric 12. It is believed that this freedom allows the fibers to move and / or slide together to mitigate tearing of the fabric during subsequent lamination and molding steps. For example, it is believed that the agitation of the stirring step 42 weakens and / or breaks at least some of the joints and / or tangles between the individual fibers of the non-woven fabric 12. In a preferred embodiment of the stirring step 42 , the stirring step includes the use of a fabric softener as the wetting agent. While not wishing to be bound by a particular theory, it is believed that the fabric softener provides a degree of lubrication to the individual fibers of the non-woven fabric. It is believed that the lubrication of the individual fibers allows the fibers to slide together.

After the stirring step 42, the fabric layer 12 and the foam layer 14 are adhered to each other in the laminating step 44. During the laminating step 44, the fabric layer 12 is adhered to the foam layer 14. , for example, by applying an adhesive to the fabric and / or foam layers and compressing the layers together to define the composite fabric 10. In some embodiments of the present invention, the manufacturing process 40 may include a step of punch 46 prior to lamination step 44. Many of the low temperature molding foams available for use as the foam layer 14 (e.g., low density polyethylene foam) are closed cell foams. Thus, it is contemplated through the present invention that the manufacturing process 40 includes the piercing step 40 to induce a predetermined level of permeability and / or degree of respiration to the foam layer 14. In a preferred embodiment, the piercing step 46 removes the material from the foam layer 14 in order to provide the desired permeability. For example, the piercing stage 46 can punch a plurality of holes through the foam layer 14. After defining the composite fabric 10 in the lamination step 40, the manufacturing process 40 exposes the composite fabric to the molding process 20 for defining one or more molded configurations 16 in the composite fabric. It should be recognized that the process 40 that is described above has a laminating step 44 prior to the molding step 20. However, it is also contemplated through the present disclosure that the laminating and molding steps occur simultaneously with each other. . Advantageously, the composite fabric of the present invention outweighs the cost and weight associated with the composite fabrics of the prior art. For example, the composite molded fabric 10 can be used in the formation of a bra 50 as illustrated in Figure 5. The bra 50 includes a garment body 52 and a pair of bra cups 54. The body of the garment 52 garment 52 includes only the non-woven fabric layer 12, while the bra cups 54 include both the non-woven fabric layer and the foam layer 14. Therefore, the bra 50 includes only the composite fabric 10. in the areas of the support cups, which are molded to a desired depth of support cup. The holder 50 can be configured, so that the foam layer 14 of the support cups 54 is in contact with the wearer when worn as shown. Alternatively, the holder 50 can be configured so that the fabric layer 12 of the support cups 54 is in contact with the wearer when worn.

An alternative exemplary embodiment of a bra 60 having the composite molded fabric 10 is illustrated in Figure 6. The bra 60 includes a garment body 62 and a pair of molded inserts of bra cups 64. The garment body of clothing 62 may be one or more layers of woven and / or non-woven fabrics. The inserts 64 are formed from the composite fabric 10 and, thus, include both the nonwoven fabric layer 12 and the foam layer 14. The inserts 64 can be secured to the body of the garment 62 using any known method, such as, for example, but not limited to sewn seams, adhesives, welds, and others. Preferably, the inserts 64 are secured in the garment body 62, so that the foam layer 14 is in contact with the body of the garment and the fabric layer 12 is in contact with the garment body. user when worn as shown in Figure 6. Alternatively, the inserts 64 can be secured in the garment body 62, so that the fabric layer 12 is in contact with the body of the garment. of clothing and the foam layer 14 is in contact with the wearer when worn. It should also be noted that the terms "first", "second", "third", "superior", "inferior", and the like, could be used in this document to modify various elements. These modifiers do not imply a spatial, sequential or hierarchical order to the modified elements unless specifically indicated. While the present description has been explained with reference to one or more example modalities, it will be understood by those skilled in the art that various changes may be made and the equivalents may be replaced by the elements thereof without departing from the scope of the invention. present description. In addition, many modifications could be made to adapt a particular situation or material to the teachings of the description without departing from the scope of the description. Therefore, it is intended that the present description is not limited to the particular mode (s) that is described as the best mode contemplated, but that the description will include all modalities that fall within the scope of the appended claims. It is noted that in relation to this date the best method known by the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims (28)

1. CLAIMS Having described the invention as above, the content of the following claims is claimed as property: 1. A composite molded fabric, characterized in that it comprises: a layer of polyethylene foam; a first layer of fabric adhered to a first side of the polyethylene foam layer to define a composite fabric, the first layer of fabric includes a nonwoven fabric having a randomly distributed core of fibers; and a configuration molded into the composite fabric.
2. 2. The composite molded fabric according to claim 1, characterized in that the core of randomly distributed fibers comprises a uniform orientation of fiber in all directions.
3. 3. The composite molded fabric according to claim 1, characterized in that the core of randomly distributed fibers comprises fibers that are bonded and / or entangled with each other.
4. The composite molded fabric according to claim 1, characterized in that the core of randomly distributed fibers comprises fibers selected from the group consisting of fibers of a component, fibers of multiple components and any combination thereof.
5. The composite molded fabric according to claim 1, characterized in that the core of randomly distributed fibers comprises fibers selected from the group consisting of nylon fibers, polypropylene fibers, polyester fibers, cotton fibers, fibers of wool, hemp fibers and any of the combinations thereof.
6. 6. The composite molded fabric according to claim 1, characterized in that the core of randomly distributed fibers comprises fibers having two or more different diameters.
7. The composite molded fabric according to claim 1, characterized in that the first fabric layer comprises multi-component fibers having a mixture of a low melting temperature polymer and a high melting temperature polymer.
8. The composite molded fabric according to claim 1, characterized in that the first layer of fabric comprises at least two fibers of a component, at least one of the two fibers of a component has a polymer of low melting temperature and at least another of the two fibers of a component has a polymer of high melting temperature.
9. The composite molded fabric according to claim 1, characterized in that the first fabric layer is substantially rigid.
10. 10. The composite molded fabric according to claim 1, characterized in that the first fabric layer is elastic.
11. The composite molded fabric according to claim 1, further characterized in that it comprises a second layer of fabric adhered on a second side of the polyethylene foam layer.
12. The composite molded fabric according to claim 1, further characterized in that it comprises a plurality of holes defined through the polyethylene foam layer.
13. The composite molded fabric according to claim 1, characterized in that the configuration is selected from the group consisting of a cup, a knee pad, a plurality of expanded sections, a pattern, a design and any of the combinations from the same .
14. The composite molded fabric according to claim 1, characterized in that the first layer of fabric is adhered to the polyethylene foam layer through a material selected from the group consisting of a solvent-based adhesive, an adhesive of soul, a film adhesive, a tie-bonding adhesive, a sonic welding and any combination thereof.
15. 15. The composite molded fabric according to claim 1, characterized in that the first layer of fabric is adhered to the polyethylene foam layer continuously or discontinuously.
16. 16. A bra, characterized in that it comprises: a garment body; and a pair of molded bra cups having a first layer of fabric adhered to a first side of a layer of polyethylene foam, the first layer of fabric comprising a nonwoven fabric having a core of fibers randomly distributed.
17. The support according to claim 16, characterized in that the garment body comprises one or more layers of a woven fabric and / or a non-woven fabric.
18. The bra according to claim 17, characterized in that the pair of molded bra cups comprises a pair of inserts secured to the body of the garment.
19. 19. The bra according to claim 16, characterized in that the body of the garment comprises the first layer of fabric.
20. The bra according to claim 16, further characterized in that it comprises a second layer of fabric adhered on a second side of the polyethylene foam layer.
21. The bra according to claim 16, further characterized in that it comprises a plurality of holes defined through the polyethylene foam layer.
22. 22. A method of forming a non-woven molded fabric, characterized in that it comprises: selecting a non-woven fabric having a fiber core randomly distributed; exposing the non-woven fabric to a mechanical stirring process; laminating the non-woven fabric on a first side of a layer of polyethylene foam with a composite fabric; compress the composite fabric between the upper mold and the lower mold; and maintaining the composite fabric between the upper and lower molds during a predetermined stop time.
23. 23. The method according to the claim 22, characterized in that the exposure of the non-woven fabric to a mechanical stirring process comprises stirring the non-woven fabric in the presence of a wetting agent.
24. 24. The method according to claim 23, characterized in that the wetting agent comprises water and / or a fabric softener.
25. The method according to claim 22, further characterized by comprising punching a plurality of holes through the polyethylene foam layer before laminating the non-woven fabric on the first side of the polyethylene foam layer.
26. 26. The method according to claim 22, further characterized by comprising heating the composite fabric to a molding temperature less than about 190.56 ° C (375 ° F).
27. 27. The method according to claim 26, characterized in that the predetermined stop time is less than about 30 seconds.
28. 28. The method of compliance with the claim 22, further characterized in that it comprises heating the composite fabric to a molding temperature of approximately 148.89 ° C (300 ° F), and wherein the predetermined stop time is approximately 20 seconds.