US20070069423A1 - Method of manufacturing fabric - Google Patents

Method of manufacturing fabric Download PDF

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Publication number
US20070069423A1
US20070069423A1 US11/236,667 US23666705A US2007069423A1 US 20070069423 A1 US20070069423 A1 US 20070069423A1 US 23666705 A US23666705 A US 23666705A US 2007069423 A1 US2007069423 A1 US 2007069423A1
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US
United States
Prior art keywords
fabric
thermoplastic elastomer
composite fabric
minutes
composite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/236,667
Inventor
Chi-Jung Wang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
JIUNDAR INDUSTRIAL Co Ltd
Jiundar Ind Co Ltd
Original Assignee
Jiundar Ind Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jiundar Ind Co Ltd filed Critical Jiundar Ind Co Ltd
Priority to US11/236,667 priority Critical patent/US20070069423A1/en
Assigned to JIUNDAR INDUSTRIAL CO., LTD. reassignment JIUNDAR INDUSTRIAL CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WANG, CHI-JUNG
Publication of US20070069423A1 publication Critical patent/US20070069423A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • 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
    • 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
    • B32B5/26—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 also being fibrous or filamentary
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite 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
    • B32B2274/00—Thermoplastic elastomer material
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • 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
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • 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
    • B32B2307/726—Permeability to liquids, absorption
    • 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
    • B32B2307/728—Hydrophilic
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • 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
    • B32B2319/00—Synthetic rubber
    • 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
    • B32B2398/00—Unspecified macromolecular compounds
    • B32B2398/20—Thermoplastics
    • 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
    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins

Definitions

  • the present invention relates to fabric manufacturing and more particularly to a method of manufacturing composite fabric with improved characteristics including being waterproof, highly absorbent, and highly flexible.
  • Fabric has been widely used as diapers, clothes, or the like.
  • fabric comprises a number of layers.
  • a composite fabric comprises an absorbent layer (A layer), an adhesive layer (S layer), and a waterproof layer (M layer).
  • a layer absorbent layer
  • S layer adhesive layer
  • M layer waterproof layer
  • a composite fabric can have an enhanced absorption if pulp or a highly absorbent material is employed as material of an intermediate layer.
  • a composite fabric can have an enhanced adhesiveness if carbon fiber is employed as material of an intermediate layer.
  • a composite fabric can have an enhanced rigidity if pulp and plastic powder are employed as material of an intermediate layer.
  • Fabric having an outer A layer (i.e., highly absorbent) and an inner M layer (i.e., waterproof) can be employed as material of manufacturing diapers.
  • fabric having an outer M layer (i.e., waterproof) and an inner A layer (i.e., highly absorbent) can be employed as material of manufacturing surgical clothes.
  • a composite fabric having characteristics including being waterproof, highly absorbent, and highly flexible has not been available on the market.
  • It is therefore an object of the present invention to provide a method of manufacturing a fabric comprising drying TPU material or thermoplastic elastomer at about 50° C. to 150° C. for about predetermined hours; adding a bridge agent in the dried TPU material or thermoplastic elastomer for mixing and heating at about 60° C. to 280° C. for about 30 seconds to 5 minutes for melting; pouring the melted material into an endless shallow mold to form a continuous film; contracting a fabric material at about 50° C. to 180° C. for about 1 second to 5 minutes; placing the fabric material onto top and bottom surfaces of the film and pressing same at about 50° C. to 250° C. to form a composite fabric; cooling and shaping the composite fabric at about 5° C. to 60° C.; and drawing the shaped composite fabric around a roll to produce the finished fabric.
  • the finished fabric comprises an upper layer formed of fabric, a lower layer formed of fabric, and an intermediate layer formed of TPU material or thermoplastic elastomer.
  • FIG. 1 is a cross-sectional view of fabric manufactured according to the invention.
  • FIG. 2 is a flowchart depicting a process for manufacturing fabric according to the invention.
  • TPU thermoplastic polyurethane
  • step d placing the fabric material onto top and bottom surfaces of the film and pressing same at about 50° C. to 250° C. to form a composite fabric
  • step e cooling and shaping the composite fabric at about 5° C. to 60° C.
  • step f lowering temperature to a predetermined temperature and drawing the shaped composite fabric around a roll to produce the finished fabric in the shape of a roll.
  • the finished fabric comprises an upper layer 9 formed of fabric, a lower layer 11 formed of fabric, and an intermediate layer 10 formed of TPU material or thermoplastic elastomer. Most importantly, the fabric is waterproof, highly absorbent, and highly flexible.

Landscapes

  • Laminated Bodies (AREA)
  • Absorbent Articles And Supports Therefor (AREA)

Abstract

A method of manufacturing waterproof, highly absorbent, and highly flexible fabric comprises drying TPU material or thermoplastic elastomer at about 50° C. to 150° C. for about predetermined hours, adding a bridge agent in the dried TPU material or thermoplastic elastomer for mixing and heating at about 60° C. to 280° C. for about 30 seconds to 5 minutes for melting, pouring the melted material into an endless shallow mold to form a continuous film, contracting a fabric material at about 50° C. to 180° C. for about 1 second to 5 minutes, placing the fabric material onto top and bottom surfaces of the film and pressing same at about 50° C. to 250° C. to form a composite fabric, cooling and shaping the composite fabric at about 5° C. to 60° C., and drawing the shaped composite fabric around a roll to produce the finished composite fabric.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of Invention
  • The present invention relates to fabric manufacturing and more particularly to a method of manufacturing composite fabric with improved characteristics including being waterproof, highly absorbent, and highly flexible.
  • 2. Related Art
  • Fabric has been widely used as diapers, clothes, or the like. Conventionally, fabric comprises a number of layers. In one example, a composite fabric comprises an absorbent layer (A layer), an adhesive layer (S layer), and a waterproof layer (M layer). Also, a composite fabric can have an enhanced absorption if pulp or a highly absorbent material is employed as material of an intermediate layer. Alternatively, a composite fabric can have an enhanced adhesiveness if carbon fiber is employed as material of an intermediate layer. Still alternatively, a composite fabric can have an enhanced rigidity if pulp and plastic powder are employed as material of an intermediate layer.
  • Fabric having an outer A layer (i.e., highly absorbent) and an inner M layer (i.e., waterproof) can be employed as material of manufacturing diapers. Alternatively, fabric having an outer M layer (i.e., waterproof) and an inner A layer (i.e., highly absorbent) can be employed as material of manufacturing surgical clothes. However, so far as the present inventor is aware, a composite fabric having characteristics including being waterproof, highly absorbent, and highly flexible has not been available on the market. Thus, it is desirable to provide a novel method of manufacturing fabric (e.g., composite fabric) having above advantages in order to overcome the inadequacies of the prior art and contribute significantly to the advancement of the art.
    • SUMMARY OF THE INVENTION
  • It is therefore an object of the present invention to provide a method of manufacturing a fabric comprising drying TPU material or thermoplastic elastomer at about 50° C. to 150° C. for about predetermined hours; adding a bridge agent in the dried TPU material or thermoplastic elastomer for mixing and heating at about 60° C. to 280° C. for about 30 seconds to 5 minutes for melting; pouring the melted material into an endless shallow mold to form a continuous film; contracting a fabric material at about 50° C. to 180° C. for about 1 second to 5 minutes; placing the fabric material onto top and bottom surfaces of the film and pressing same at about 50° C. to 250° C. to form a composite fabric; cooling and shaping the composite fabric at about 5° C. to 60° C.; and drawing the shaped composite fabric around a roll to produce the finished fabric.
  • In one aspect of the present invention, the finished fabric comprises an upper layer formed of fabric, a lower layer formed of fabric, and an intermediate layer formed of TPU material or thermoplastic elastomer.
  • The above and other objects, features and advantages of the present invention will become apparent from the following detailed description taken with the accompanying drawings.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a cross-sectional view of fabric manufactured according to the invention; and
  • FIG. 2 is a flowchart depicting a process for manufacturing fabric according to the invention.
    • DETAILED DESCRIPTION OF THE INVENTION
  • Referring to FIG. 2, a flowchart depicting a process for manufacturing fabric (e.g., composite fabric) in accordance with the invention comprises drying a TPU (thermoplastic polyurethane) material or thermoplastic elastomer at about 50° C. to 150° C. for about a number of hours (step a), adding a bridge agent in the dried TPU material or thermoplastic elastomer for mixing and heating at about 60° C. to 280° C. for about 30 seconds to 5 minutes for melting (step b), pouring the melted material into an endless shallow mold to form a continuous film (step c), contracting a fabric material at about 50° C. to 180° C. for about 1 second to 5 minutes (step d), placing the fabric material onto top and bottom surfaces of the film and pressing same at about 50° C. to 250° C. to form a composite fabric (step e), cooling and shaping the composite fabric at about 5° C. to 60° C. (step f), and lowering temperature to a predetermined temperature and drawing the shaped composite fabric around a roll to produce the finished fabric in the shape of a roll.
  • Referring to FIG. 1, the finished fabric comprises an upper layer 9 formed of fabric, a lower layer 11 formed of fabric, and an intermediate layer 10 formed of TPU material or thermoplastic elastomer. Most importantly, the fabric is waterproof, highly absorbent, and highly flexible.
  • While the invention herein disclosed has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims.

Claims (2)

1. A method of manufacturing a fabric comprising:
drying a TPU material or thermoplastic elastomer at about 50° C. to 150° C. for about predetermined hours;
adding a bridge agent in the dried TPU material or the thermoplastic elastomer for mixing and heating at about 60° C. to 280° C. for about 30 seconds to 5 minutes for melting;
pouring the melted material into an endless shallow mold to form a continuous film;
contracting a fabric material at about 50° C. to 180° C. for about 1 second to 5 minutes;
placing the fabric material onto top and bottom surfaces of the film and pressing same at about 50° C. to 250° C. to form a composite fabric;
cooling and shaping the composite fabric at about 5° C. to 60° C.; and
drawing the shaped composite fabric around a roll to produce the finished fabric.
2. The method of claim 1, wherein the finished fabric comprises an upper layer formed of fabric, a lower layer formed of fabric, and an intermediate layer formed of the TPU material or thermoplastic elastomer.
US11/236,667 2005-09-28 2005-09-28 Method of manufacturing fabric Abandoned US20070069423A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/236,667 US20070069423A1 (en) 2005-09-28 2005-09-28 Method of manufacturing fabric

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/236,667 US20070069423A1 (en) 2005-09-28 2005-09-28 Method of manufacturing fabric

Publications (1)

Publication Number Publication Date
US20070069423A1 true US20070069423A1 (en) 2007-03-29

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Application Number Title Priority Date Filing Date
US11/236,667 Abandoned US20070069423A1 (en) 2005-09-28 2005-09-28 Method of manufacturing fabric

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US (1) US20070069423A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109797604A (en) * 2019-02-18 2019-05-24 杭州西红柿环保科技有限公司 A kind of environment-friendly paper pulp mould-forming method and product

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109797604A (en) * 2019-02-18 2019-05-24 杭州西红柿环保科技有限公司 A kind of environment-friendly paper pulp mould-forming method and product

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Legal Events

Date Code Title Description
AS Assignment

Owner name: JIUNDAR INDUSTRIAL CO., LTD., TAIWAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:WANG, CHI-JUNG;REEL/FRAME:017041/0928

Effective date: 20050811

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION