US20060189238A1 - Molded composite fabrics and methods of making - Google Patents

Molded composite fabrics and methods of making Download PDF

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Publication number
US20060189238A1
US20060189238A1 US11/267,358 US26735805A US2006189238A1 US 20060189238 A1 US20060189238 A1 US 20060189238A1 US 26735805 A US26735805 A US 26735805A US 2006189238 A1 US2006189238 A1 US 2006189238A1
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United States
Prior art keywords
fabric
fibers
layer
composite fabric
molded
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US11/267,358
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English (en)
Inventor
Roger Warren
Rick Kelley
Asli Begenir
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HBI Branded Apparel Enterprises LLC
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Individual
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Priority to US11/267,358 priority Critical patent/US20060189238A1/en
Assigned to SARA LEE CORPORATION reassignment SARA LEE CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEGENIR, ASLI, KELLEY, RICK, WARREN, ROGER D.
Publication of US20060189238A1 publication Critical patent/US20060189238A1/en
Assigned to HBI BRANDED APPAREL ENTERPRISES, LLC reassignment HBI BRANDED APPAREL ENTERPRISES, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SARA LEE CORPORATION
Assigned to CITIBANK, N.A., AS THE COLLATERAL AGENT reassignment CITIBANK, N.A., AS THE COLLATERAL AGENT PATENT SECURITY AGREEMENT (SECOND LIEN) Assignors: HBI BRANDED APPAREL ENTERPRISES, LLC
Assigned to CITIBANK, N.A., AS THE COLLATERAL AGENT reassignment CITIBANK, N.A., AS THE COLLATERAL AGENT PATENT SECURITY AGREEMENT (FIRST LIEN) Assignors: HBI BRANDED APPAREL ENTERPRISES, LLC
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41C—CORSETS; BRASSIERES
    • A41C3/00—Brassieres
    • A41C3/0014—Brassieres made from one piece with one or several layers
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41C—CORSETS; BRASSIERES
    • A41C3/00—Brassieres
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41C—CORSETS; BRASSIERES
    • A41C5/00—Machines, appliances, or methods for manufacturing corsets or brassieres
    • A41C5/005—Machines, appliances, or methods for manufacturing corsets or brassieres by moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4871—Underwear
    • B29L2031/4885—Brassieres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3008—Woven fabric has an elastic quality
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3325—Including a foamed layer or component
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/601—Nonwoven fabric has an elastic quality
    • 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
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/647—Including a foamed layer or component

Definitions

  • the present invention is related to molded composite fabrics and methods of making. More particularly, the present invention relates to composite fabrics having a layer of non-woven fabric and a layer of foam, where the composite fabrics include one or more features molded therein.
  • a variety of apparel garments or items include one or more molded features.
  • brassieres include breast cups molded in a composite fabric that has a fabric layer and a foam layer.
  • protective products such as, but not limited to, kneepads, elbow pads, and the like include features molded in a composite fabric of fabric and foam.
  • non-apparel products such as, but not limited to, automotive interiors, home furnishings, and others can include such molded composite fabrics.
  • molded composite fabrics typically include a layer of thermoplastic urethane (TPU) foam adhered to a knit fabric.
  • TPU foam can be expensive and, thus, its use can be cost prohibitive in many consumer product applications.
  • TPU foams are sensitive to ultraviolet radiation present in ambient light. Specifically, ultraviolet radiation tends to cause TPU foams to yellow. In many applications, the yellowing of TPU foam is unacceptable. Therefore, many TPU foams are laminated or faced on both sides with a fabric layer to mask this yellowing. These additional facing layers can add cost and weight to the resultant product.
  • TPU foam and knit fabric are particularly suited for use with one another in a molded composite fabric as both the TPU foam and the knit fabric typically require high molding temperatures and lengthy molding times (e.g., 400 degrees Fahrenheit for about 60 seconds). Unfortunately, the high molding temperatures and lengthy molding times can also make the use of these composite fabrics cost prohibitive in many consumer product applications.
  • the aforementioned and other objects of the present invention are provided by a molded composite fabric.
  • 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.
  • a brassiere includes a garment body and a pair of molded breast cups having a first fabric layer adhered to a first side of a polyethylene foam layer.
  • the first fabric layer has a non-woven fabric with a web of randomly disbursed fibers.
  • a method of forming a molded non-woven fabric 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.
  • FIG. 1 is a cross sectional view of an exemplary embodiment of a molded composite fabric according to the present invention
  • FIG. 2 illustrates a molding step for the composite fabric of FIG. 1 during a heating portion
  • FIG. 3 illustrates the molding step of FIG. 2 during a molding portion
  • FIG. 4 illustrates a manufacturing process for molded composite fabrics according to the present invention
  • FIG. 5 illustrates a first exemplary embodiment of a garment having a molded composite fabric in an unassembled state
  • FIG. 6 illustrates a second exemplary embodiment of a garment having a molded composite fabric in an unassembled state.
  • Composite fabric 10 includes one or more fabric layers 12 adhered to a foam layer 14 , where the fabric and foam layers have been molded to define a molded feature 16 .
  • Feature 16 can be any desired feature as required by the end use of composite fabric 10 .
  • composite fabric 10 can find use in a garment, such as a brassiere that requires breast cups.
  • feature 16 can define the breast cups of the brassiere.
  • composite fabric 10 can find use in a protective apparel item, such as a kneepad that requires shaping to approximate the shape of the protected body part.
  • composite fabric 10 can find use in an insulating apparel garment, such as a coat, jacket, or sweatshirt.
  • feature 16 can be a plurality of expanded sections.
  • composite fabric 10 can find use in a decorative garment where feature 16 is provided to add a pattern or design to the garment.
  • composite fabric 10 is described above by way of example in use as a garment. Of course, it is contemplated by the present disclosure for composite fabric 10 to find use in other non-garment applications.
  • Fabric layer 12 can be adhered to foam layer 14 by any known method.
  • fabric layer 12 is adhered to foam layer 14 by a solvent-based adhesive 18 such as, but not limited to, a web adhesive, a film adhesive, a dot adhesive, and others.
  • a solvent-based adhesive 18 such as, but not limited to, a web adhesive, a film adhesive, a dot adhesive, and others.
  • fabric layer 12 and foam layer 14 it is contemplated by the present disclosure for fabric layer 12 and foam layer 14 to be adhered to one another by other methods such as, but not limited to, sonic welding. It is further contemplated by the present disclosure for fabric layer 12 and foam layer 14 to be adhered one another continuously or discontinuously across their mating surfaces.
  • composite fabric 10 is described herein having fabric layer 12 adhered to one side of foam layer 14 .
  • composite fabric 10 it is also contemplated by the present disclosure for composite fabric 10 to have a second fabric layer (not shown) adhered to the opposite side of foam layer 14 so that the composite fabric defines a three layer structure having a middle foam layer.
  • Feature 16 is molded in composite fabric 10 after fabric layer 12 and foam layer 14 are adhered to one another.
  • the materials of fabric layer 12 and foam layer 14 are configured for use with one another in composite fabric 10 as both can be molded at low molding temperatures and short molding times.
  • fabric layer 12 is made of materials that can be molded at temperatures of less than about 300 degrees Fahrenheit for about 20 seconds.
  • foam layer 14 is made of a material that can withstand the molding temperatures composite fabric 10 is exposed to during the molding process.
  • fabric layer 12 is a non-woven fabric having a web of randomly disbursed fibers or filaments (hereinafter “fibers”), where the web preferably has uniform fiber orientation in all directions. It is also preferred that the fibers be bonded to and/or entangled with one another.
  • the individual fibers can be mono-component, multi-component, or any combinations thereof.
  • Fabric layer 12 can be substantially inelastic or inextensible (hereinafter “rigid”) or can be substantially elastic depending on the end use of composite fabric 10 .
  • fabric layer 12 provides hand feel acceptable for soft fabric applications.
  • the hand feel, as well as other physical characteristics (e.g., elasticity) of 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 combinations thereof.
  • fabric layer 12 can include about 100% of a polymer such as, but not limited to, nylon, polypropylene, polyester, and other polymers. It is also contemplated by the present invention for at least a portion of the fibers in fabric layer 12 to be natural fibers (e.g., cotton, wool, hemp).
  • a polymer such as, but not limited to, nylon, polypropylene, polyester, and other polymers. It is also contemplated by the present invention for at least a portion of the fibers in fabric layer 12 to be natural fibers (e.g., cotton, wool, hemp).
  • fabric layer 12 includes multi-component fibers having a blend of polymers such as fibers having a blend 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 structural stability to the fabric.
  • the low-melting temperature polymer allows the non-woven fabric to be molded at temperatures of less than about 300 degrees Fahrenheit.
  • fabric layer 12 can include at least two different mono-component fibers. One of the mono-component fibers has a low-melting temperature polymer, while another of the mono-component fibers has a high-melting temperature polymer.
  • fabric layer 12 can include fibers having two or more different diameters.
  • fabric layer 12 to have individual fibers sized, positioned, configured, and composition of materials sufficient to provide the physical characteristics desired for composite fabric 10 .
  • Fabric layer 12 can be produced using a non-woven process such as, but not limited to, a melt-blowing process, a spun-bonding process, a hydroentanglement process, a carding process, or any combinations thereof.
  • a non-woven process such as, but not limited to, a melt-blowing process, a spun-bonding process, a hydroentanglement process, a carding process, or any combinations thereof.
  • An exemplary non-woven fabric suitable for fabric layer 12 used in soft fabric applications includes EVOLON, which is commercially available from Freudenberg Nonwovens of Durham, N.C. EVOLON is made using a spunbonding and hydroentangling process.
  • the spunbonded fibers are multi-component fibers having 70% PET and 30% NYLON. During the hydroentanglement portion of the process, the fibers are split into segments.
  • foam layer 14 is made of foams also having a low molding temperature such as, for example, polyethylene foam.
  • foam layer 14 is low-density polyethylene foam.
  • Polyethylene foam is cheaper than the TPU foams used in the prior art.
  • polyethylene foam does not yellow or discolor when exposed to ultraviolet radiation present in ambient light and, thus, composite fabric 10 eliminates the need for facing of foam layer 14 with additional protective layers. As such, composite fabric 10 can be made lighter and less expensive than prior art faced foams.
  • the thickness, softness and level of stretch of foam layer 14 and/or fabric layer 12 can be selected to match the desired end-use of composite fabric 10 .
  • FIGS. 2 and 3 a molding step according to the present invention for feature 16 is illustrated generally by reference numeral 20 .
  • Composite fabric 10 is illustrated in FIG. 2 before the molding of feature 16 and is illustrated in FIG. 3 during the molding of the feature.
  • Molding step 20 includes a heating station 22 and a molding station 24 .
  • Heating station 22 can include, for example, one or more radiant heating plates for heating composite fabric 10 as it is moved past the heating station in a machine direction 26 towards molding station 24 .
  • Heating station 22 heats composite fabric 10 so that the composite fabric is heated to a predetermined temperature. For example, heating station 22 heats composite fabric 10 to a temperature of less than about 375 degrees Fahrenheit. In a preferred embodiment, heating station 22 heats composite fabric 10 to about 300 degrees Fahrenheit.
  • molding step 20 moves the heated composite fabric 10 to molding station 24 .
  • Molding station 24 includes a molding cavity 28 having a desired shape.
  • molding cavity 28 has a shape for forming a breast cup for a brassiere.
  • molding station 24 is a vacuum molding station that draws the heated composite fabric 10 into cavity 28 in a molding direction 30 .
  • Molding station 24 maintains composite fabric 10 in cavity 28 for a predetermined dwell time. For example, molding station 24 maintains composite fabric 10 in cavity 28 for less than about 30 seconds. In a preferred embodiment, molding station 24 maintains composite fabric 10 in cavity 28 for about 20 seconds.
  • the predetermined temperature and dwell time of molding step 20 are less than those currently used in the manufacture of composites having TPU foam and knit fabric (e.g., 400 degrees Fahrenheit for about 120 seconds).
  • molding step 20 can form composite fabric 10 into the desired shape faster and more economically than prior processes.
  • manufacturing process 40 includes a washing or agitation step 42 and a lamination step 44 .
  • fabric layer 12 is first exposed to agitation step 42 , then the fabric layer and foam layer 14 are adhered to one another during lamination step 44 to define composite fabric 10 , and finally the composite fabric is molded during molding step 20 .
  • agitation step 42 exposes the desired non-woven fabric 12 to mechanical agitation, more preferably in the presence of a wetting agent such as, but not limited to, water and/or fabric softener.
  • a wetting agent such as, but not limited to, water and/or fabric softener.
  • agitation step 42 it is contemplated for agitation step 42 to be carried out in a typical household washing machine or a typical industrial dyeing process (processed with or with out dyes).
  • agitation step 42 subjects fabric layer 12 to agitation in the presence of the wetting agent to permit the individual fibers of the non-woven fabric to achieve a desired position with respect to each other as discussed immediately below.
  • agitation step 42 introduces an element of freedom to the individual fibers of the non-woven fabric 12 . It is believed that this freedom allows the fibers to move and/or slide with respect to one another to mitigate tearing of the fabric during subsequent lamination and molding steps. For example, it is believed that the agitation of agitation step 42 weakens and/or breaks at least some of the bonds and/or entanglements between the individual fibers of the non-woven fabric 12 .
  • the agitation step includes the use of 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 with respect to one another.
  • fabric layer 12 and foam layer 14 are adhered to one another in lamination step 44 .
  • fabric layer 12 is adhered to foam layer 14 by, for example, applying an adhesive to the fabric and/or foam layers and compressing the layers together to define composite fabric 10 .
  • manufacturing process 40 can include a perforating step 46 before lamination step 44 .
  • Many of the low molding temperature foams available for use as foam layer 14 e.g., low-density polyethylene foam
  • foam layer 14 e.g., low-density polyethylene foam
  • perforating step 46 removes material from foam layer 14 to provide the desired permeability.
  • perforating step 46 can punch a plurality of holes through foam layer 14 .
  • manufacturing process 40 exposes the composite fabric to molding process 20 to define one or more molded features 16 in the composite fabric.
  • process 40 is described above having lamination step 44 before molding step 20 . However, it is also contemplated by the present disclosure for the lamination and molding steps to occur simultaneously with one another.
  • molded composite fabric 10 can be used in the formation of a brassiere 50 as illustrated in FIG. 5 .
  • Brassiere 50 includes a garment body 52 and a pair of breast cups 54 .
  • Garment body 52 includes only non-woven fabric layer 12
  • breast cups 54 include both the non-woven fabric layer and foam layer 14 .
  • brassiere 50 includes composite fabric 10 only in the areas of the breast cups, which are molded to a desired cup depth.
  • Brassiere 50 can be configured so that foam layer 14 of breast cups 54 is in contact with the user when worn as shown.
  • brassiere 50 can be configured so that fabric layer 12 of breast cups 54 is in contact with the user when worn.
  • Brassiere 60 includes a garment body 62 and a pair of molded breast cup inserts 64 .
  • Garment body 62 can be one or more layers of woven and/or non-woven fabrics.
  • Inserts 64 are formed from composite fabric 10 and, thus, include both non-woven fabric layer 12 and foam layer 14 .
  • Inserts 64 can be secured to garment body 62 using any known method such as, but not limited to, sewn seams, adhesives, welds, and others.
  • inserts 64 are secured to garment body 62 so that foam layer 14 is in contact with the garment body and fabric layer 12 is in contact with the user when worn as shown in FIG. 6 .
  • inserts 64 can be secured to garment body 62 so that fabric layer 12 is in contact with the garment body and foam layer 14 is in contact with the user when worn.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Corsets Or Brassieres (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
US11/267,358 2004-11-05 2005-11-04 Molded composite fabrics and methods of making Abandoned US20060189238A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/267,358 US20060189238A1 (en) 2004-11-05 2005-11-04 Molded composite fabrics and methods of making

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US62549104P 2004-11-05 2004-11-05
US66960405P 2005-04-08 2005-04-08
US11/267,358 US20060189238A1 (en) 2004-11-05 2005-11-04 Molded composite fabrics and methods of making

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US20060189238A1 true US20060189238A1 (en) 2006-08-24

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US11/267,358 Abandoned US20060189238A1 (en) 2004-11-05 2005-11-04 Molded composite fabrics and methods of making
US11/267,242 Active 2028-03-15 US7846005B2 (en) 2004-11-05 2005-11-04 Molded non-woven fabrics and methods of molding
US12/888,967 Active 2025-12-08 US8221187B2 (en) 2004-11-05 2010-09-23 Molded non-woven fabrics and methods of molding

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US11/267,242 Active 2028-03-15 US7846005B2 (en) 2004-11-05 2005-11-04 Molded non-woven fabrics and methods of molding
US12/888,967 Active 2025-12-08 US8221187B2 (en) 2004-11-05 2010-09-23 Molded non-woven fabrics and methods of molding

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US (3) US20060189238A1 (fr)
CA (2) CA2525611A1 (fr)
MX (1) MXPA05011971A (fr)

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US8513147B2 (en) * 2003-06-19 2013-08-20 Eastman Chemical Company Nonwovens produced from multicomponent fibers
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US8512519B2 (en) * 2009-04-24 2013-08-20 Eastman Chemical Company Sulfopolyesters for paper strength and process
US9273417B2 (en) 2010-10-21 2016-03-01 Eastman Chemical Company Wet-Laid process to produce a bound nonwoven article
US8840758B2 (en) 2012-01-31 2014-09-23 Eastman Chemical Company Processes to produce short cut microfibers
US20140263033A1 (en) * 2013-03-13 2014-09-18 2266170 Ontario Inc. Process For Forming A Three-Dimensional Non-Woven Structure
US9303357B2 (en) 2013-04-19 2016-04-05 Eastman Chemical Company Paper and nonwoven articles comprising synthetic microfiber binders
US9605126B2 (en) 2013-12-17 2017-03-28 Eastman Chemical Company Ultrafiltration process for the recovery of concentrated sulfopolyester dispersion
US9598802B2 (en) 2013-12-17 2017-03-21 Eastman Chemical Company Ultrafiltration process for producing a sulfopolyester concentrate
DE102015112187A1 (de) * 2015-07-27 2017-02-02 Fiber Engineering Gmbh Textiles dreidimensionales Formteil und Verfahren zur Herstellung eines textilen dreidimensionalen Formteils
DE102019202385A1 (de) 2019-02-21 2020-08-27 Adidas Ag 3D Vlies-BH und Herstellungsverfahren
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Also Published As

Publication number Publication date
US20110068507A1 (en) 2011-03-24
US20060189241A1 (en) 2006-08-24
US7846005B2 (en) 2010-12-07
CA2525315A1 (fr) 2006-05-05
US8221187B2 (en) 2012-07-17
MXPA05011971A (es) 2006-09-07
CA2525611A1 (fr) 2006-05-04
CA2525315C (fr) 2010-02-23

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