WO2013190385A2 - Feuilles extensibles comprenant diverses couches et zones et procédés de production de tels produits - Google Patents

Feuilles extensibles comprenant diverses couches et zones et procédés de production de tels produits Download PDF

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Publication number
WO2013190385A2
WO2013190385A2 PCT/IB2013/001807 IB2013001807W WO2013190385A2 WO 2013190385 A2 WO2013190385 A2 WO 2013190385A2 IB 2013001807 W IB2013001807 W IB 2013001807W WO 2013190385 A2 WO2013190385 A2 WO 2013190385A2
Authority
WO
WIPO (PCT)
Prior art keywords
different
zones
sheet
materials
fibers
Prior art date
Application number
PCT/IB2013/001807
Other languages
English (en)
Other versions
WO2013190385A3 (fr
Inventor
Reuven Melamed
Ehud Giloh
Original Assignee
Tamicare 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
Priority claimed from US13/531,024 external-priority patent/US9731319B2/en
Application filed by Tamicare Ltd. filed Critical Tamicare Ltd.
Priority to EP13762221.3A priority Critical patent/EP2864536B1/fr
Priority to KR1020157000998A priority patent/KR102282010B1/ko
Priority to BR112014032317-8A priority patent/BR112014032317B1/pt
Priority to CN201380036761.6A priority patent/CN104471131B/zh
Priority to CA2877494A priority patent/CA2877494C/fr
Priority to JP2015517873A priority patent/JP6302898B2/ja
Priority to MX2014016116A priority patent/MX359589B/es
Publication of WO2013190385A2 publication Critical patent/WO2013190385A2/fr
Publication of WO2013190385A3 publication Critical patent/WO2013190385A3/fr
Priority to IL236344A priority patent/IL236344B/en

Links

Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H13/00Other non-woven fabrics
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00Physical properties
    • D10B2401/06Load-responsive characteristics
    • D10B2401/061Load-responsive characteristics elastic

Definitions

  • the present invention relates to products and sheets such as two-dimensional and three-dimensional products and sheets, composed of flexible, stretchable and/or elastic materials such as natural elastomers and other synthetic polymers.
  • the invention also relates to methods for layering additional material such as fibers, in order to make 2D and 3D stretchable and/elastic products.
  • the present invention is related to methods for producing a variable layered sheet of stretchable, elastic or shape-retaining products, composed principally of materials such as resilient elastomers including, but not limited to, natural latex rubber or polyurethane, using variety of controlled spraying units for spraymg the principal material or materials onto a surface of a wall such as a workpiece former.
  • the resulting product is a sheet having at least two different zones unified within the sheet.
  • the present invention is also directed to improved methods for preparing products having a single or double-sided surface coating of same or different types of loose fibers, and a method for generating same or different microporosity regions in such products.
  • the present invention discloses a sheet with different thicknesses, composites and structures in different areas.
  • the creation of such sheet or fabric is very similar to "3D printing.”
  • Creating nonwoven disposable fabric, by using the disclosed technology, is in fact 3D printing of fabric.
  • the invention provides sheets comprising two or more zones, wherein at least one zone is characterized by a different composite and features than one of the remaining zones; and the sheet is strctchahie and non-woven.
  • the invention provides methods for producing a stretchable workpiece comprising applying one or more materials on a conveyor or a mold using different machines or compartment or different materials in different layouts so to produce a workpiece having two or more zones, wherein at least one zone comprises a different material feature than one of the remaining zones.
  • Fig. 1 represents a section through a sheet of this invention, the sheet having two zones - Zone 1 (left) and Zone 2 (right). Each zone comprises three layers.
  • the upper layer of both zones is made out of composite 1.
  • the middle layer of Zone 1 is made out of composite 2, while the middle layer of zone 2 is made out of composite 3.
  • the bottom layer of zone 1 is made out of composite 3, while the bottom layer of zone 2 is made out of composite 2.
  • Fig. 2 represents a section through a sheet of this invention, the sheet having the same structure as described in Fig 1, and further comprising additional layer of composite 4 built on top of the upper layer (composite i) at a specific location, covering zone 1 in full but only part of zone 2.
  • This specific structure creates differences in the thickness of the different areas of the sheet.
  • the present invention is generally related to stretchable, elastic or shape-retaining products composed of principal materials comprising resilient elastomers such as natural latex rubber, polyurethane or other synthetic materials, in a spray able liquid state, and methods for producing such products, using a controlled spraying of the liquid material onto a surface of a wall such as a workpiece former.
  • the resulting product is a sheet having at least two different zones as desired.
  • the present invention is also directed to products having a single or double-sided fiber flocked surface, and products such as non-woven sheets having desired level of porosity at each different zone, in order to gain breathability or permeability at the different zones of such products.
  • the present invention is also directed to products produced by the inventive methods. T ' he product produced by the invention has improved specifications and feeling on both sides of the product.
  • the unified sheet allows the creation of a product with different perfonnances at different areas, without the need to attach together different sheets of different materials.
  • the phrase 'unified within the sheet' means the composites of two zones adjacent one to the other, are blended at their connection lines, creating a continuous seamless sheet.
  • lock or “flocking” refers to the process of applying, attaching, or adhering loose fibers onto a surface.
  • a former or mould is an object made of any desired shape or size and serves as shape former for the making of products. For example, if a product in th e shape of a face mask is desired, then a former or mould may be constructed that displays the shape and size of desired face mask.
  • the former may be flat and two-dimensional such as a flat belt conveyor. Alternatively, the former may be three-dimensional and have a complex shape to which a workpiece substantially conforms.
  • the former may be made of any suitable material such as metal (e.g., aluminium), porcelain, ceramic, plastics, or composite (e.g., metal and plastic).
  • Stretchabie, elastic products have a variety of uses including, without limitation, industrial use such as pipes, seals, membranes sheets, filtering membranes; food industry such as breathable stretchabie wrappers or coverings for objects including perishables such as food; medical industry for medical products such as dressings and bandages; sanitation, athletic, and personal hygiene industries such as garments including protective garments and undergarments like brassieres, undershorts, socks, or gloves and any other garment, undergarment or dressing for veterinary or outdoor use.
  • loose fibers refers to any suitable loose flocking fiber material including natural or synthetic materials and may be hydrophilic, hydrophobic, or a combination of the two.
  • Hydrophilic fibers include wettable fibers, i.e., hydrophobic fibers that have been treated to render them hydrophilic, absorbent fibers, and superabsorbent polymer fibers.
  • wettable fibers include bicomponent fibers, polypropylene fibers, and polyester fibers that have been treated, for example with surfactants.
  • Example of wettable fibers are polyester fibers, such as DuPont -Akra Polyester Type i 1A Bright commercially available from DuPont Company treated with a surfactant such as Tween 20 commercially available from TCI Americas Inc.
  • Absorbent fibers are hydrophilic fibers.
  • Absorbent fibers may comprise rayon fibers, acrylic fibers, nylon fibers, polyvinyl alcohol fibers, and fibers of natural or regenerated celtulosics.
  • Example of absorbent fiber is rayon fibers.
  • Superabsorbent polymer fibers are hydrophilic fibers that are sweilable and capable of absorbing greater than about 5 grams per gram (of fiber weight) of 1% saline solution.
  • superabsorbent polymer fibers are polyacrylate fibers, fibers of grafted cellulose, and fibers of maleic acid.
  • examples of superabsorbent polymer fibers include OASIS Type 101 , commercially available from Technical Absorbents Limited and CAMELOT, commercially available from Camelot, Alberta, Canada.
  • a preferred fiber for use in the invention is cotton fibers. Any suitable method for delivering the loose fibers so that they may be applied to the surface can be used. For instance, the loose fibers can be sprayed or blown onto the surface of the wall as well as electrostatically and or pneumatically flocked.
  • product material comprises suitable stretchabie material such as natural or synthetic polymers.
  • a natural polymer includes, without limitation, latex rubber.
  • a synthetic polymer includes, without limitation, polyurethane.
  • emulsions, suspensions, or solutions of the product material e.g., liquid latex rubber, are generally used.
  • the product material is preferably allowed to dry before it is removed from a surface.
  • the drying process may include curing or setting processes, depending on the choice of product material. For example, when latex rubber is used as the product material, the latex rubber would cure as it dries.
  • the preferred product material is natural latex rubber, which forms durable, flexible, stretchabie, elastic shape-retaining products.
  • the term "wall” may refer to a flat or two-dimensional work piece former such as a flat conveyor belt or any suitable shaped flat surface to which a product substantially conforms.
  • the wall may be a three-dimensional workpiece former having a complex shape to which a workpiece substantially conforms.
  • the wall may be non-flat, embossed or complex shaped conveyor belt, perforated conveyor belt, or combination thereof.
  • the wall may be made of any suitable materials such as plastic, rubber, composite (e.g., of metal and plastic or ceramic), ceramics, metal such as aluminum or stainless steel.
  • the present invention provides a surprising and significant improvement over technologies known in the art by reducing the number of process steps and entailed costs. Moreover, the present invention provides a surprisingly effective and economical way to produce thin products, sheets and non-woven fabrics that combine different zones, which performs differently in the same unified sheet and may be flocked with fibers at least on one surface.
  • a method for producing a stretchabie workpiece comprising the steps of: (a) applying at least one type of wetting agent onto a surface of a wall; (b) applying a first layer of at least one type of loose fibers onto at least a portion of the surface of the wall to produce at a partially fiber-coated surface.
  • the loose fibers are flocked electrostatically or by any other suitable way so that they hit the wall substantially perpendicular to its surface; and (c) spraying a liquid product material of at least one type onto the upright standing fibers to form a product material layer of predetermined thickness on the fiber-coated surface and produce a stretchable workpiece, wherein the product material layer has an inner and outer surface and fibers are attached to the inner surface of the product material layer.
  • Another embodiment further comprises the step of applying a second layer of loose fibers onto at least a part of the outer surface of the product material layer, wherein the product material layer is uncured or partially uncured.
  • the method further comprises the steps of: allowing the product material layer to dry; and removing the stretchable workpiece from the surface.
  • the preceding methods may further comprise using different machine components or different materials in different configurations to produce zones of different qualities in the product.
  • the method for producing a stretchable workpiece can comprise applying one or more materials on a conveyor or a mold at the same time using different machines or compartment or different materials in different layouts so to produce a workpiece having two or more zones, wherein at least one zone features a different material character than one of the remaining zones.
  • Each material applied may be a liquid material as defined above.
  • At least two different spraying nozzles are used side by side in conveyor cross direction to spray material (e.g., liquid material) in parallel, so that one zone of the product will comprise lower density then the other part.
  • material e.g., liquid material
  • Each nozzle may spray the same material or different materials.
  • the nozzles may be arranged in a row.
  • a first nozzle can spray at wider angle than a second nozzle to thicken a section of the product by providing thicker elastomeric layer.
  • the nozzles are configured to apply at the same time the same or different materials in different rates so to control amount of material sprayed in the different areas.
  • the nozzles are configured to apply at the same time the same or different materials in different rates so to control amount of material sprayed in the different areas and to create areas of different porosity.
  • Such nozzle arrays may be used, for example, in step (c) as described above to spray different product materials.
  • two different materials may be sprayed in two or more zones at the same time.
  • different materials may be layered by applying a first material layer and then applying a second material layer over the first.
  • the polymers may differ in: polymer type, formulation or any property or feature, such as, but not limited to any mechanical property, viscosity, color, scents or any other desired feature.
  • the different polymers can be selected independently from natural rubber, high modulus natural rubber, low modulus natural rabber, poiyurethane, silicones, and the like.
  • the polymer applied to one of the zones of the product has a higher modulus than the polymer applied to at least one other zone.
  • the polymer applied to a first zone of the product has a higher modulus than the polymer applied to a second zone.
  • At least two flocking machines are used to apply different types of fibers.
  • Such flocking machines may be used, for example, in step (b), as described above, to apply different types of loose fibers, to the different zones of the product.
  • different types of fibers may be applied to the wetting agent in adjacent zones or one type of fibers may be applied to the wetting agent (one surface of the product material layer), and a second type of flock applied over the second surface of the product material layer.
  • At least two flocking machines are used to apply different fibers, the fibers may differ in type, material, length, diameter, color, odor, eompostability, water retention, hydrophobicity or any other desired feature.
  • the flock may be sprayed on top of the same product material or different product material.
  • different flocks are applied to at least two different zones and the flocks are sprayed onto the same product material.
  • different flocks are applied to at least two different zones and each type of flock is sprayed onto a different product material.
  • the wetting agent is coated with a first flock, the first flock is sprayed onto one or more product materials in one or more zones, and a second flock is appli ed to the outer surface of the product material.
  • the preceding methods may be used to form unified stretchabie non-woven sheets having two or more zones, wherein at least one zone has a different feature than one of the remaining zones.
  • the stretchabie non-woven sheets may comprise three or more zones; or four or more zones; or five or more zones.
  • the stretchabie non-woven sheets may comprise two to ten zones; or two to five zones; or two to four zones; or two or three zones, in yet other embodiments, the stretchabie non-woven sheets can have two zones; or three zones; or four zones; or five zones; or as many zones as necessary for a given purpose. All zones produced as a unified sheet.
  • Each of the zones of the stretchable non-woven sheets can be, for example, but not limited to (1) the upper surface and the bottom surface; (2) the right side and the left side; (3) a longitudinal, middle portion and the remaining side parts; (4) cross direction stripes; or any other desired zone definition or combination thereof.
  • the product zones each comprise different elastomeric materials, such as, but not limited to, natural latex rubber, polyurethane or other synthetic materials.
  • each of the zones may differ in any property or, such as, but not limited to, polymer type, formulation, compostability, basis weight, thickness, porosity, water or any other liquid permeability, breathabiiity, tear strength, elongation at break, retractive force after extension, tensile strength, any other mechanical property, color, odor, tactile, or feel.
  • the stretchable non-woven sheet comprise different loose fibers, at different zones, the fibers may differ in type, material, length, diameter, color, odor, compostability, water retention, hydrophobicity or any other desired feature.
  • the product zones comprise different porosity levels.
  • the sheet may comprise a first zone having a first material and first flock and a second zone, adjacent to the first zone, having the first material and a second flock.
  • the sheet may comprise a first zone having a first material and first flock; a second zone, adjacent to the first zone, having the first material and a second flock: and a third zone, adjacent to the first or second zone, having a second material and the first flock.
  • layers may be sprayed one on top of the other, such that a sheet may comprise adjacent zones each where the stacks of applied layers are different in each zone. That may get different sandwiches side by side unified on the same sheet.
  • at least one of the zones of the sheet may comprise a polymer having a different modulus from the polymer of the remaining zones. Such sheets can be useful for medical usage to provide a bandage having different local pressure requirements.
  • different materials may be using in different zones to create a "breathable" area in the sheet; or an improved leak proof area.
  • different fibers may be applied to the inner and outer surfaces of a sheet, such as providing cotton fibers to the inner surface and artificial fibers to the outer surface.
  • a sheet such as providing cotton fibers to the inner surface and artificial fibers to the outer surface.
  • Such sheets may be useful, for example, in manufacturing pants or other garments.
  • different zones may be provided with different colored flock. Such different colors may be applied in adjacent zones on one surface of the sheet to produce a desired design effect; or one color flock may be provided to an inner surface of the sheet and another color fl ock to the outer surface of the sheet.
  • the methods and products provided herein can be used in the non-woven industry, as a sheet of stretchabie non-woven fabric to be used as is, or in combination with other materials such as, but not limited to, woven and non-woven fabrics, to create finished ready to use products such as, but not limited to, diapers, sanitary napkins, bandages, packaging means, beddings upholsteries, curtains, apparels, outdoor and military accessories and the like.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention se rapporte à des procédés pour produire des feuilles et des produits flexibles, extensibles et/ou élastiques possédant deux zones, ou plus, ayant des caractéristiques et des performances de matériau différentes. Les produits peuvent être composés d'un matériau tel que des élastomères naturels et autres polymères synthétiques. Le procédé de production de produits extensibles consiste à pulvériser un matériau de produit de différents types sur différentes zones d'un gabarit de pièce ou bande transporteuse.
PCT/IB2013/001807 2012-06-22 2013-06-20 Feuilles extensibles comprenant diverses couches et zones et procédés de production de tels produits WO2013190385A2 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
EP13762221.3A EP2864536B1 (fr) 2012-06-22 2013-06-20 Feuilles extensibles comprenant diverses couches et zones et procédés de production de tels produits
KR1020157000998A KR102282010B1 (ko) 2012-06-22 2013-06-20 다중 층들 및 구역들을 포함하는 신축성 시트 및 이러한 생성물 제조방법
BR112014032317-8A BR112014032317B1 (pt) 2012-06-22 2013-06-20 lâminas elásticas compreendendo uma variedade de camadas e zonas, e métodos para produção de tais produtos
CN201380036761.6A CN104471131B (zh) 2012-06-22 2013-06-20 一体形成的非织造片材、产品及其生产方法
CA2877494A CA2877494C (fr) 2012-06-22 2013-06-20 Feuilles extensibles comprenant diverses couches et zones et procedes de production de tels produits
JP2015517873A JP6302898B2 (ja) 2012-06-22 2013-06-20 多種の層および帯域を備えていている伸縮性シートおよび当該製品を生産する方法
MX2014016116A MX359589B (es) 2012-06-22 2013-06-20 Laminas estirables que comprenden una variedad de capas y de zonas y metodos para producir tales productos.
IL236344A IL236344B (en) 2012-06-22 2014-12-18 Stretchable sheets containing various layers and joints and methods of creating these products

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/531,024 2012-06-22
US13/531,024 US9731319B2 (en) 2004-11-05 2012-06-22 Stretchable sheets comprising a variety of layers and zones and methods to produce such products

Publications (2)

Publication Number Publication Date
WO2013190385A2 true WO2013190385A2 (fr) 2013-12-27
WO2013190385A3 WO2013190385A3 (fr) 2014-02-20

Family

ID=49165785

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2013/001807 WO2013190385A2 (fr) 2012-06-22 2013-06-20 Feuilles extensibles comprenant diverses couches et zones et procédés de production de tels produits

Country Status (9)

Country Link
EP (1) EP2864536B1 (fr)
JP (1) JP6302898B2 (fr)
KR (1) KR102282010B1 (fr)
CN (1) CN104471131B (fr)
BR (1) BR112014032317B1 (fr)
CA (1) CA2877494C (fr)
IL (1) IL236344B (fr)
MX (1) MX359589B (fr)
WO (1) WO2013190385A2 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180186058A1 (en) * 2015-06-29 2018-07-05 Covestro Deutschland Ag Method for producing 3-d objects
CN108291342B (zh) * 2015-09-29 2020-11-06 普莱玛有限公司 可吹絮状隔热材料及其制备方法
JP6724141B2 (ja) * 2016-07-28 2020-07-15 株式会社エアウィーヴ 寝具および寝具用カバーシート
WO2020133228A1 (fr) * 2018-12-28 2020-07-02 深圳市柔宇科技有限公司 Substrat étirable et son procédé de fabrication
CN110450414B (zh) * 2019-08-21 2021-09-14 华育昌(肇庆)智能科技研究有限公司 一种绒毛制品3d打印组件

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US5961757A (en) * 1997-06-02 1999-10-05 The Procter & Gamble Company Process for making an absorbent composite web
EP1184501A2 (fr) * 2000-08-28 2002-03-06 Uni-Charm Corporation Feuille composite
EP1184163A2 (fr) * 2000-09-01 2002-03-06 Uni-Charm Corporation Feuille composite étirable élastiquement et procédé de fabrication
WO2005039467A1 (fr) * 2003-10-22 2005-05-06 Tamicare Ltd. Articles absorbants comportant des zones fonctionnelles definies
US20080292788A1 (en) * 2004-11-05 2008-11-27 Tamicare Ltd. Methods to Produce Stretchable Products

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JPS55147171A (en) * 1979-05-08 1980-11-15 Duskin Franchise Co Ltd Manufacture of multicolored flocked sheet
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FR2838936B1 (fr) * 2002-04-30 2004-12-24 Oreal Dispositif d'application d'un produit, notamment cosmetique, recouvert d'un floquage de differents types de fibres
US20050142339A1 (en) * 2003-12-30 2005-06-30 Price Cindy L. Reinforced elastic laminate
US20060143767A1 (en) * 2004-12-14 2006-07-06 Kaiyuan Yang Breathable protective articles
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Publication number Priority date Publication date Assignee Title
US5961757A (en) * 1997-06-02 1999-10-05 The Procter & Gamble Company Process for making an absorbent composite web
EP1184501A2 (fr) * 2000-08-28 2002-03-06 Uni-Charm Corporation Feuille composite
EP1184163A2 (fr) * 2000-09-01 2002-03-06 Uni-Charm Corporation Feuille composite étirable élastiquement et procédé de fabrication
WO2005039467A1 (fr) * 2003-10-22 2005-05-06 Tamicare Ltd. Articles absorbants comportant des zones fonctionnelles definies
US20080292788A1 (en) * 2004-11-05 2008-11-27 Tamicare Ltd. Methods to Produce Stretchable Products

Also Published As

Publication number Publication date
MX2014016116A (es) 2015-11-30
EP2864536A2 (fr) 2015-04-29
IL236344B (en) 2018-04-30
MX359589B (es) 2018-10-03
KR102282010B1 (ko) 2021-07-27
EP2864536B1 (fr) 2018-03-21
BR112014032317B1 (pt) 2021-07-06
JP6302898B2 (ja) 2018-03-28
WO2013190385A3 (fr) 2014-02-20
CN104471131B (zh) 2017-06-13
CN104471131A (zh) 2015-03-25
JP2015521695A (ja) 2015-07-30
CA2877494A1 (fr) 2013-12-27
CA2877494C (fr) 2020-08-04
IL236344A0 (en) 2015-02-26
KR20150023763A (ko) 2015-03-05
BR112014032317A2 (pt) 2017-06-27
BR112014032317A8 (pt) 2021-04-06

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