US2433270A - Method of coating stitched fabric - Google Patents

Description

Dec. 23, 1947. 1. Y. GOLDMAN 2,433,270

METHOD OF COATING STITCHED FABRIC Filed April 6, 1944 2 Sheets-Sheet l 9 1 /IN VEN TOR.

Dec. 23, 1947. 1. Y. GOLDMAN 7 12,433,270

METHOD OF COATING STITCHED FABRIC Filed April 6, 1944 2 Sheets-Sheet 2 Patented Dec. 23, 1947 UNITED STATES PATENT OFFICE 2,433,270 Mirriiol) oF coA'rrNG STITCHED FABRIC Ida Y. Goldman, Brooklyn, N. Y. Application April 6, 1944, Serial No. 529,729 1 Claim. (01. 117 .6a)

1 This invention relates to articles which combine certain water absorbing and water resisting characteristics, and has further reference to methods of making such articles.

One object of the invention is to provide a sheeting the component parts of which are interconnected to form a one-piece structure to be sold in the trade as a garment producing fabric, which sheeting has the capacity for the rapid and substantial absorption of liquids to thus increase the comfort ef the wearer, combined with the characteristic of arresting the flow of liquids through the heeting where the absorption capacity thereof should be exceeded or where a time element is required for distribution of the liquid for uniform absorption by the sheeting.

, The particular utility of such a sheeting will be instantly apparent by considering its embodiment in a diaper. From the standpoint of the manufacturer of the diaper, he need merely cut the sheeting into blanks and bind the edges to complete the article. From the point of view of the user, the diaper can quickly and fully absorb all liquids, substantially prevent leakage and soiling of bedding and outer garment and avoiding wetting of exposed portions of the body of the child, thus reducing the opportunity for chilling thereof, with resultant colds. Such a diaper, moreover, is highly compact, remains in proper position without slippage of various layers or sheets, and is quick and easy to apply. The Waterproofing component is soarranged that it does not prevent complete and rapid absorption of liquids, but arrests the spread thereof, prevents too rapid evaporation with undue cooling of the childs body, and always presents a neat and clean exterior appearance, free of discoloration. It will thus appear that the diaper is soft, warm, and

comfortable to the tender skin of a baby.

The manufacturer of the sheeting may cheaply and quickly construct the Same by the use of quilting machinery, a water resistent coating being applied by him preferably thereafter.

Another object of the inventionis to furnish an improved article of the character described wherein a quilt-like sheeting is provided with an exterior coating of water resistent material that completely closes and seals the openings at the multitude of stitches. v

Where cotton batting is used as a filler, it is of considerable advantage to close the stitch openings, especially because the cotton efiiciently transmits liquid by capillary action and because the body of the cotton shrinks when it is fully wetted, permitting considerable slackening of the stitches.

Another object of the invention is the provision of an improved quilt-like article having an impregnating coating on a side closing the stitch openings in combinationwith a very soft, completely-filling batting which provides a: backin for the stitch openings to permit theplastic coating material to actually seal the stitch openings instead of only partly easing the same. I

Another object of the i" :entiohfstd provide an improved article of the attire set forth wherein the absorbent side may be relatively coarse for rapid absorption of liquid, and the other side densely woven to require a minimum of coating material and to render the same water proof with only one or two coats, so that the article may be cheap and efficient in a high degree.

A further object of the invention is to provide improved methods of making an article ofthe character described to assure sealing of the stitch openings without interference by the stitches; to avoid pulling and distortion of the stitches; and to assure uniform coating of the textile at points varying in distance from the stitches.

It has been observed that a plastic for waterproofing a textile must be, accurately and uniformly applied on its very first coat, and if small parts are not properly coated, solidification of the first coat may prevent rectification by a subsequent coating, and hence the invention aims to provide the necessary high degree of uniformity.

Other objects and advantages of the invention will become apparent as thespecification' proceeds.

With the aforesaid objects in View, the invention comprises the novel features; combinations and arrangements of partshereinafter described in their preferred embodiments, pointed out in the subjoined claim, and illustrated in the annexed drawing, wherein like parts are'designated by the same reference characters throughout the several views.

In the drawing:

Figure 1 is a fragmentary plan view of a sheeting embodying the invention, with parts removed to show its components.

Fig. 2 is an enlarged sectional view;

Fig. 3 is a fragmentary greatly enlarged view of a portion of the article. l

Fig. 4 is a plan view, partly in perspective, showing a garment, such as a diaper, embodying the novel fabric.

Fig. 5 is a diagrammatic viewshowing a method of practising the invention.

Fig. 6 is a similar view showing modified method.

The advantages of the invention as here outlined are best realized when all of its features and instrumentalities are combined but, useful embodiments may be produced involving less than the whole.

It will be obvious to those skilled in the art to which the invention appertains, that the same may be incorporated in several different constructions. The accompanying drawing, therefore, is submitted merely as showing a preferred exemplification of the invention.

Referring in detail to the drawing, I denotes an article such as a sheeting, embodying the invention. The same may include a quilt-like body having opposed sheets of material I I, :2, between which is disposed a batting I3 of intertwined, fibrous, moisture absorbent material, such as a cotton or other vegetable fiber. Interconnecting the sheet members II and I2 is a field of stitching coextensive with the article, and including spaced intersecting rows of stitching I4 extending preferably diagonally to the weave of the fabrics II, I2 for a reason hereinafter described. This stitching passes through the filler I3 and thus affords a unitary structure, and prevents shifting of the filling. The fabric II is intended to be a relatively coarse fabric having large interstices through which water can readily pass, and yet sufliciently small to confine the fibers of the padding I3. The fabric I I may be an open mesh knitted material, but the best results are obtained with the use of a textile whose weave may be approximately 30 by 40. To the contrary, the fabric I2 is preferably densely woven and may have, illustratively, a weave of 60 by 80 so as to be adapted to be rendered waterproof by a minimum application of plastic. Of course the fabrics II and I2 may both be alike, in which case the weave may be intermediate of the coarse and dense weaves above mentioned. With conventional cotton batting and ordinary thin textiles, the thickness of the article In need not exceed about one-eighth of an inch, but it may be as little as one-sixteenth and as much as threesixteenths of an inch and realize the objects of the invention. 0n the outer face of the textile I2 is a coating I 5 of water resistant material such as a vinyl resin plastic, this coating having an average thickness preferably not exceeding a few thousandths of an inch. This plastic is impregnated into the textile I2 and into the thread of the stitching I4, and is sufficient to fully close the interstices of the cloth and the holes therein produced by the needle in forming the stitching I4. In fact, the external parts of the stitching thread may adhere to the cloth I2 by reason of the plastic. These results may be accomplished by using approximately one to three ounces of the plastic per square yard of the article ID. For some purposes, an article such as I0 may be made by the use of a precoated fabric I2, but leakage through the stitch holes will occur especially because the batting, if soaked with liquid and then squeezed as by pressure of the wearers body, will force liquid through the stitch holes.

It is noteworthy that the cotton batting I3 whose fibers are very fine, will closely extend around the threaded portions I6 within the article I0 and hence engage in or at the stitch holes I! thus affording a backing I8 for the application of the plastic. This backing is increased by the compression of the batting due to the stitching.

This nap-like backing is important because without it, the stitch holes would not be closed unless an exceptional weight of plastic were used. Without a proper backing, the plastic would merely form a rim or lip around the edges of the holes, if a reasonabl thin coating is to be used, or a minimum number of applications of the coating. Satisfactory results may be accomplished even if only moderate stitch tension is used. Since the thread becomes united to the coating 55 slippage of the thread is avoided, as where the cotton batting becomes soggy with moisture and loses volume, causing a reduction in stitch tension. Such slippage, if it occurred, would eventually enlarged the stitch holes. By the instant structure, the plastic coating 25 is continuous over the fabric I2 and the stitching I6 affording a fairly smooth and uniform outer surface which will not collect dirt and the like.

It will now be seen that the article I8 constitutes a. sheeting well adapted to be made by a quilt manufacturer with his existing equipment. Such manufacturer may then apply the coating I5 to complete the article. This article it may be sold as a sheeting to be cut and made into garments by ordinary methods. The article has the capacity for absorbing a substantial quantity of liquid at high speed due to the character of the cloth II and the cotton I3. The waterproofing coating I5 cooperates to prevent the liquid from striking through and to arrest and deflect the liquid for distribution in the cotton batting. The sheeting I0 is virtually a one-piece structure, whose parts will not shift, and which is capable of being easily sewn and worked to produce garments of substantial strength and durability.

In Fig. 4 is shown an article such as a diaper 20 embodying the novel fabric. Otherwise the same may be of an conventional construction, and is preferably shaped for at least a partial form fit. It may have a body embracing wall 2! made of the sheeting I0. For this purpose, the latter is merely cut to shape and a binding 22 is stitched to its edges to enclose the padding I3 and finish the article. Any suitable fastening means may be secured to the article such as tapes or snap fasteners 23. Thus the diaper consists virtually entirely of the sheeting Ill and affords the protection thereof around the body and crotch of the child with proper leg receiving openings at 24. The liquid will be rapidly absorbed and distributed in the filling I3 before it can readily leak out through these openings. The absorbent inner face of the diaper is soft and smooth to the skin of the child. The water resistent outer face will not show soiling or leakage, with the coating I5 resisting wear and preventing rupture of the stitches I4 if the child is sitting on or sliding itself along the floor. The diaper is of a good insulating character for warmth, and prevents excessive evaporation of liquid and consequent chilling of the childs body. It may be readily washed since it fully opens up'fiat, and is then fairly quick drying. Diiferent color effects may be obtained since the inner cloth I I may be white while the outer fabric I2 may be pink, or the plastic coating may itself be colored. The appearance is thus very neat, the stitching being partially obscured by a translucent coating as suggested in Fig. 1, but the coating may also be substantially opaque as by using a sufiicient color.

The sheeting II] is susceptible of embodiment in various other articles, such as under-arm shields and in many other relations where excessive perspiration is to be absorbed. It may be made into head coverings to be used by women who go to bed after washing their hair. These and other instances are intended to be merely illustrative of the advantages obtainable with the invention.

In Fig. 5 is shown an apparatus 25 to illustrate a preferred method of making the article It, preferably with reference to the provision of the coating l5. Here a sheeting 26 is shown consisting of the article Ill less the coating Hi. This sheeting is trained over suitable rollers 21, 28 and is fed along under tension applied by any suitable rollers not shown. Intermediate of the rollers 21, 28 the sheeting 26 is permitted to sag to form a trough as at 29 for receiving coating material in plastic condition as at 30. Acting on this plastic is a doctor blade 3! which is vertically and angularly adjustable. Disposed within the trough 29 in advance of the doctor blade is a means for working the plastic into the upper face of the sheeting 26 to enter the stitch openings I1 and to penetrate into and around the exposed part of the thread of the stitching l4, and to penetrate the textile I2 to close the pores thereof. The means referred to may include rollers 32, 33 rotating in opposite directions in order to approach the exposed stitch threads from opposite sides to thoroughly work in the plastic in course of a single run or coating operation. In other words the plastic is kneaded into and against the fabric and the stitching, with a shifting and turning of the exposed stitch thread and a forcing of the plastic from different directions before any part of the plastic has had an opportunity to set. A complete adequately penetrative action is assured by succeeding operation of the different kneading rollers 32, 33. The second roller 33 applies the plastic rightward against the direction of the action of the doctor blade, so that there are thus three successive plastic applying actions. The doctor blade performs a final Working-in of plastic, smooths the coating and scrapes 01f excess plastic. The coated product 34 now enters a dryer, not shown, in which the coating is hardened to produce the sheeting Ill.

By diagonally disposing the lines of stitching, excessive pull or distortion at the stitch threads is avoided, and yet there is a lateral component of force applying plastic to and at the threads. Hence it is better to position the lines of stitching on the bias than parallel or at right angles to the length of the goods.

By reason of the fine cotton filling l3, as previously described in connection with Fig. 3, a suitable backing I8 at the stitch openings I1 is provided to support the plastic to close and seal these openings. Without this backing, the plastic cover would either break like a bubble, or never deposit except at the edges of the openings. In that sense, the provision of the cotton batting may be regarded as an element of the process or method of coating.

If the first coat is imperfect, it is difficult or impossible to close any openings that may be left by applying succeeding coats. The coating l5 may be applied in one or several coating operations.

The tensions exerted by the different rollers 32, 33 may or may not neutralize each other, but the roller 33 may travel much faster than the roller 32, because roller 33 rotates counter-clockwise.

In Fig. 6 is shown a modified apparatus 35 lllustrating a different method embodying the invention. This apparatus includes feed or guide rollers 36, 31 acting on a fabric 26a like that at 26, with a doctor blade 38 at the roller 31, and a kneading means comprising opposed rollers 39, 40 like those at 32, 33. In operation, the method involved is like that for the apparatus 25, with the exception that the doctor blade is applied at a point where the fabric 26a is convexed in order to stretch the fabric l2 more than the fabric II, this result being aided by the intermediate filling l3. This assures perfect smoothness for the fabric l2 that is being coated, and causes the portions of the stitching 14 that are exposed above the fabric l3 to be stretched taut so that the blade may ride with perfect smoothness and evenness over the stitches and over the adjacent parts of the fabric l2.

With both methods, the stitch holes or large interstices in a very coarse Weave are closed by the plastic entering thereinto and actually bonding onto the adjacent cotton padding which serves as a backing for the plastic, this backing being pressed against the holes by the stitching. Thus a difficult problem is overcome, and even garment seams can be waterproofed at the stitches by disposing a thin line of soft cotton batting within the seams and then stitching along that line to construct the seam, and finally coating.

It is thus seen that there are provided new articles of manufacture and improved methods of making the same to realize all the various objects and advantages of the inventions disclosed.

I claim:

The method of coating a stitched fabric so as to impregnate the latter and close the holes formed by the stitching, including applying plastic coating material to the fabric at one side thereof, kneading the plastic material into the fabric by moving the plastic first in one direction then in a different direction at an angle to the direction of the stitches, and then scraping the fabric to remove excess of plastic material, the kneading and scraping being performed in a single coating operation and before the plastic that is being worked has had an opportunity to harden.

IDA Y. GOLDMAN.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 342,494 Baldwin May 25, 1886 882,832 Moss Mar. 24, 1908 1,289,507 Mason Dec. 31, 1918 1,345,693 Pye July 6, 1920 1,465,092 Respess Aug. 14, 1923 1,533,973 Cohen Apr. 14, 1925 2,016,601 Hlavaty Oct, 8, 1935 2,117,432 Linscott May 17, 1938 2,146,664 Wolff Feb. 7, 1939 2,364,505 Bennett Dec. 5, 1944 FOREIGN PATENTS Number Country Date 453,267 Great Britain Sept. 8, 1936

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