CA2108078A1 - Stretchable and water-resistant laminated fabric composition and process for making the same - Google Patents

Stretchable and water-resistant laminated fabric composition and process for making the same

Info

Publication number
CA2108078A1
CA2108078A1 CA002108078A CA2108078A CA2108078A1 CA 2108078 A1 CA2108078 A1 CA 2108078A1 CA 002108078 A CA002108078 A CA 002108078A CA 2108078 A CA2108078 A CA 2108078A CA 2108078 A1 CA2108078 A1 CA 2108078A1
Authority
CA
Canada
Prior art keywords
fabric composition
pieces
fabrics
laminated fabric
adhesive
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
CA002108078A
Other languages
French (fr)
Inventor
Robert Balit
Esther Larkin
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to US08/134,568 priority Critical patent/US5406646A/en
Priority to CA002108078A priority patent/CA2108078A1/en
Publication of CA2108078A1 publication Critical patent/CA2108078A1/en
Abandoned legal-status Critical Current

Links

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
    • 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
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41C—CORSETS; BRASSIERES
    • A41C5/00—Machines, appliances, or methods for manufacturing corsets or brassieres
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/18—Elastic
    • A41D31/185—Elastic using layered materials
    • 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
    • B29C51/002—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 characterised by the choice of material
    • B29C51/004—Textile or other fibrous material made from plastics 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
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • 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
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • 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
    • B32B5/04—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 characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • 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
    • B29K2105/0097—Glues or adhesives, e.g. hot melts or thermofusible adhesives
    • 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
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0046—Elastic
    • 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
    • B29L2009/00—Layered products
    • 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
    • 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
    • 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide 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
    • 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
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1362—Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31562—Next to polyamide [nylon, etc.]
    • 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]
    • Y10T442/3008—Woven fabric has an elastic quality
    • Y10T442/3024—Including elastic strand or strip
    • 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]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/3602—Three or more distinct layers
    • Y10T442/3667—Composite consisting of at least two woven fabrics bonded by an interposed adhesive layer [but not two woven fabrics bonded together by an impregnation which penetrates through the thickness of at least one of the woven fabric layers]

Abstract

The stretchable and water resistant laminated fabric composition comprises two layers of stretchable fabrics bonded together by a heat activated adhesive comprising a urethane polymer suspended in a toluene containing solvent, in a proportion of about 40 % by weight of urethane polymer. Such an adhesive leaves stretchability properties of the fabrics of the layers substantially intact and provides a water resistant bond between said layers. The process for making the laminated fabric composition comprises the steps of: selecting two pieces of fabrics having given stretchability properties; coating at least one of the pieces with the adhesive; lying each coated piece in a ventilated atmosphere until the solvent in the adhesive is substantially evaporated: assembling and pressing both pieces of fabrics together for producing the laminated fabric composition; and lying the assembled laminated fabric composition in a temperate atmosphere for a predetermined period of time until the urethane polymer is substantially polymerized. The process may comprises, after the step of assembling and pressing, the additional steps of: heating the laminated fabric composition at a predetermined heating temperature; and molding the laminated fabric composition for producing a three-dimensional shaping. The fabric composition is particularly useful for making swimsuits.

Description

2 1 ~ .3 Q 7 8 BACXGROU~D OF TH~ INv~N'~E~:

Field o~ the invention:

The invention relate~ to a stretchable and water resistant laminated fabric co~position and a proce~ ~or making such a fabric compositlon. This fabric compo~ition is specially useful for making swimsuiks, and more particularly a bra portion of a woman swimsuit.
Descri~tio~ o~ e related ar~:

Conventional woman swimsuits are often provided with a bra portion having lateral gathers or similar artifices for enhancing the three-dimensional shaping effect. They are also often provided with an inner lining to ensure sufficient opacity. These characteristics however tend to flatten the breast, and the inner lining is also o~ten uncomfortable.
Various laminating and molding processes have been proposed in the art, for providing fabrics entering in the making of woman swimsuits without inner lining. But th~
fabrics resulting from these processes have no elasticity or stretchability, or yet loose them rapidly over wear.
Furthermore, these fabrics are generally thick and uncomfortable.

Known in the art is US patent no. 5,165,113 (HY~MS et al.), which describes padded straps for brassieres for improving the comfort, wear, washability, the look and feel.
Preferably, the fabric entering in the making of the straps 2 1~3J~

has given resilience properties, as ~or example with nylon-lycra materials. The selected pieces of fabric are bonded and laminated together to ~orm a moldable, integral piece.
Once the laminating step is ~inished, the laminated piece is subjected to a molding step under pressure ~or shaping the laminated piece as desired. The patent alludes that the bonding o~ the pieces of ~abric may be carried ou~ wikh a toluene-based adhesive, without however giving any ~urther indication. The snag is that such a type of adhesive may affect and particularly reduce the stretchability and elasticity properties of the fabric, which is highly undesirable for a swimsuit. Moreover, the patent does not make a single consideration regarding the use of an adhesive for leaving the stretchability properties o~ the ~abric substantially intact, especially once the laminating step is achieved.

Also known in the art is US patent no. 5,166,300 (RUMON
et al.), which describes the use of an adhesive based on a polyurethane prepolymer suitable ~or bonding ~abric materials. The adhesive has good resistance to high temperature t humidity and sustained W radiation. As mentioned in the patent, the polyurethane may be uGed in conjunction with solvents such as ~oluene and ketone.
However, like the previous case, the patent does not make a single consideration regarding the stretchability properties of a laminated fabric.

I Also known in the art is US patent no. 5,110,668 (MINNICK), which describes a ~lexible laminate involving the use of a copolyetherester resin ~or obtaining laminated pieces made of aromatic polyamide resin fibres. US patent 8 ~ 7 8 no. ~ 8,322 (JACARUSO et al.) describes a laminated product suitable for making molded bra cups, which is durable, soft and ætrong. Also known in the art are US
patents nos. 3,225,768 (GALITZKI et al.); 3,616,013 (BOCCHI); 3,684,639 (KEBERLE et al.); 3,867,248 (BAUEX);
4,036,924 (SHISHOO et al.); 4,048,001 (REMLEY et al.);
4,109,543 (FOTI); 4,258,093 (BENEDYK); 4,287,143 (SEARS
Jr.); 4,384,083 (BAKER); 4,~32,364 (M~RTINI); 4,435,45~
(HILL); 4,637,851 tUENO et al.); 4,916,755 (FEIGENBAUM et al.); 5,15~,659 tGLUCKIN); and Canadian patents no~. 692,541 (LOFTIN); 960,,801 (HOW~RD~; and 1,195,802 (COL~ et al.).
These patents describe various fabric products, proceææes for making such products, etc., of which none attempts neither succeeds to settle the problem of leaving th4 stretchability properties of laminated and molded fabrics substantially intact, while b~ing water resistant.

O~CT OF ~HE INVENTION:
It is therefore an object o~ the present invention to provide a stretchable and water resistant laminated fabric composition and a manufacturing process thereof/
particularly suitable for making swimsuits, so as to overcome the aforesaid drawbacks of the prior art.

It is a subsidiary object o~ the present invention to provide a woman swimsuit çomprising a bra portion made from such a stretchable and water resistant laminated fabric composition, which ensures suf~icient opacity without an inner lining, enhanceæ the shape of the breast portion, is water resistant, and maintainæ its stretchability over wear.

~.. , . - .: : : . :

?,.~0~7~

SU~MARY OF THE TNV~NTION:

According to the present invention, there ~s provided a stretchable and water resistant laminated fabric composition comprising two layers o~ stretchable ~abrias bonded together by a heat activated adhesive comprisiny a urethane polymer 6uspended in a toluene containing solvent, whereby said adhesive leaves strstchability properties o~
the fabrics of said layers substantially intact and provides a water resistant bond ~etween sa.id layQrs.

Preferably, the adhesive contains ~rom 39 to 41 % by weight of said urethane polymer.
According to the present invention, there is also provided a process for making a stretchable and water resistant laminated fabric composition comprising steps of:
a) selecting two pieces of fabrics having given stretchabilit~ properties;
b) coating at least one of said pieces with an adhesive comprising a urethane polymer suspended in a toluene containing solvent;
c) lying said at least one of said pieces in a ventilated atmosphere until the sol~ent in said adhesive is substantially evaporated;
d) asse~nbling and pressing both pieces of fabrics together for producing said laminated fabric ~: composition; and e) lying said laminated fabric composition in a temperate atmosphere for a predetermined period of time until the urethane polymer is substantially 2~ g)~78 polymerized;
whereby said adhesive leaves the stretchability properties of the fabrics of said pieces substantially intact and provides a water resistant bond between said pieces.

According to an alternative embodiment o~ the invention, the process preferably further comprises, after said step e), the additional steps of:
heating said laminated fabric composition at a 10predetermined heating temperature; and molding ~aid laminated fabric composition for producing a three-dimensional shaping.

15BRT~F D~SCRIP~ION ~F TH~ ~AWINGS:

In order to impart full understanding o~ the manner in which these and other objectives are attained in accordance with the present invention, preferred embodiments thereof are described hereinafter with reference to the accompanying drawings wherein:

Figure 1 is a side view o~ a portion of a stretchable and water resistant laminated fabric composition in accordance with the present invention;

Figure 2 is a schematic side view illustrating a step of coating a piece of fabric in accordance with the present !invention;
Figure 3 is a schematic side view illustrating a step of assembling and pressing two pieces of fabrics in --- 2 1 ~ ~ ~) 1 8 accordance with the present invention;

Figure 4 is a schematic side view illustratlng a st~p o~ molding a laminated ~abric composition in accordance wi~h khe pre~ent invention; and Flgure 5 is a perspective view of a woman ~wimsuit having a hra portion made with a fabric compo~ition according to the present invention.

D~TAIL~ SCRIPTION OF THB DRAWIN~S:

In the following description and in the drawings, the same numerals will re~er to the same or similar elements.

Referring to Figure 1, a ~tretchable and water resistant laminated fabric composition according to the present invention comprises two layers 2, 4 of a stretchable fabrics bonded together by a heat activated adhesive 6 comprising a urethane polymer su~pended in a toluene containing solvent, whereby the adhesive leaves stretchability properties of the fabric~ of the layers 2, 4 substantially intact and provides a water resistant bond betw~en the layers 2, 4.

Pre~erably but not restrictively, the adhesive contains about 40 % by weight o~ the urethane polymer, and more particularly from 39 % to 41 %. It was ~ound that the MOR-AD (registered mark) N-340 adhesive manufactured by MORTON
CHEMICAL DIVISION, Chica~o, Illinois, has the required characteristics for manufacturing the laminated fabric , . , ~, . . ., . ,.. . . , . . . - - --. ~

~:lO~7~

composition according to the present invention.

Also preferably but not restrictively, the ~abrics of the layers 2, 4 are tricots comprising about 80% of nylon and ahout 20% of spandex.

Referring now to Figures 2, 3 and 4, the stretchable and water resistant laminated ~abric compoæltion accordiny to the present invention is made by carrying the step~ o~
the process described hereinafter" The ~irst step consists of selecting two pieces 2, 4 o~ fabrics having given stretchability properties which suit the type of garment ~or which the fabric composition is intended. At least one of the pieces 2, 4 of fabrics is coated with the adhesive 6.
The coating can be carried out by ~gun) spraying the adhesive 6 onto the piece of fabric 2, as shown in Figure 2.
Each coated piece 2 of fabric is then laid in a ventilated atmosphere until the solvent in the adhesiva 6 is substantially evaporated. Both pieces 2, 4 of ~abrics are then assembled and pressed together, as shown in Figure 3, for producing the laminated fabric composition. The laminated fabric composition is then laid in a temperate atmosphere for a~out twelve hours so as to let the urethane polymerized completely. As a result, the laminatsd fabric composition is water resistant and the stretchability properties of the fabrics of the pieces 2, 4 are left substantially intact.

The pressing step, which is shown in Figure 3, is preferably but not restrictively carried out at a temperature of about 65 C and at a pressure of 15 cm Hg (3 psi) for a time period determined ~s a function o~ the 2 ~ O ~ ~ 1 8 nature oE the fabrics used.

Once the urethane is polymerized completely, the laminated fabric composition may be heated at a predetermined heating temperature, and mold ~or producing a three-dimensional shaping, as shown in Figure 4.

The heating and molding steps may be carried out b~
applying a mechanical force with heating male pieces 10 pushed across the laminated eabric composition for a predetermined,period of time within a heating ~hamber (not shown) at the heatiny temperature. The temperatures of the heating cha~ber and the heating male piece~ 10, and the period oE time are determined as a function of the nature o~
the fabrics used. For example, Por a 80 % nylon / 20 %
spandex fabric, the temperature of the heating chamber is about 180 C, the temperature of the heating male pieces is about 205 C, and the molding time is about 20-30 seconds.
The heating male pieces 10 form two protruding membersi 12, 14 for form~ng breast receiving areas 16, 18 in the laminated fabric composition, whereby the laminated fa~ric composition is usable as a bra portion Eor a women swimsuit.

Referring to Figure 5I there is shown such a woman swimsuit ~here the bra portion 20 is made from the laminated fabric composition in accordance with the present invention.
By following the aforesaid process, the bra portion can ba shaped to hold the breaets of the woman for natural look and gentle support without preeisure, cups or wires, and no loose linings and elastic straps.

The laminated fabric composition according to the /
2 ~ 7 8 present invention can also be used to make a man swimsuit, and more particularly the male genitals-receivin~ portion of such a swimsuit~ In this case, during the process, only one heating male piece forming a protruding member i8 used ~or forming the male genitals-receiving part.

The aforesaid temperatures and time periods ~hould be selected with respect to the nature o~ the adhesive used during the assembling and pressing ~tep so that the adhesive reacts correctly during the molding.

Although the present invention has been explained hereinafter by way of preferred embodiments therso~, it should be pointed out that any modi~ications to these preferred embadiments, within the scope of the appended cl~ims, are not deemed to change or alter the nature and scope of the present invention.

Claims (16)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A stretchable and water resistant laminated fabric composition comprising two layers of stretchable fabrics bonded together by a heat activated adhesive comprising a urethane polymer suspended in a toluene containing solvent, whereby said adhesive leaves stretchability properties of the fabrics of said layers substantially intact and provides a water resistant bond between said layers.
2. A fabric composition according to claim 1, wherein said adhesive contains about 40 % by weight of said urethane polymer.
3. A fabric composition according to claim 2, wherein said adhesive contains from 39 to 41 % by weight of said urethane polymer.
4. A fabric composition according to claim 1, wherein said fabrics are tricots comprising about 80 % of nylon and about 20 % of spandex.
5. A garment comprising at least some portion made from the fabric composition of claim 1, 2, 3 or 4.
6. A woman swimsuit comprising a bra portion made from the fabric composition of claim 1, 2, 3 or 4,
7. A woman swimsuit according to claim 6, wherein said bra portion includes two breast-receiving areas molded to form respectively two three-dimensional bulging shapes.
8. A process for making a stretchable and water resistant laminated fabric composition, comprising steps of:
a) selecting two pieces of fabrics having given stretchability properties;
b) coating at least one of said pieces with an adhesive comprising a urethane polymer suspended in a toluene containing solvent;
c) lying said at least one of said pieces in a ventilated atmosphere until the solvent in said adhesive is substantially evaporated;
d) assembling and pressing both pieces of fabrics together for producing said laminated fabric composition; and e) lying said laminated fabric composition in a temperate atmosphere for a predetermined period of time until the urethane polymer is substantially polymerized;
whereby said adhesive leaves the stretchability properties of the fabrics of said pieces substantially intact and provides a water resistant bond between said pieces.
9. A process according to claim 8, wherein said adhesive contains about 40 % by weight of said urethane polymer.
10. A process according to claim 9, wherein said predetermined period of time is about twelve hours.
11. A process according to claim 8, 9 or 10, wherein said step of coating is carried out by spraying said adhesive onto said at least one of said pieces of fabrics.
12. A process according to claim 8, 9 or 10, wherein said step of pressing is carried out at a temperature of about 65°C and at a pressure of about 15 cm Hg.
13. A process according to claim 8, 9 or 10, further comprising, after said step e), the additional steps of:
heating said laminated fabric composition at a predetermined heating temperature; and molding said laminated fabric composition for producing a three-dimensional shaping.
14. A process according to claim 13, wherein said heating and molding steps are carried out by applying a mechanical force with heating male pieces pushed across said laminated fabric composition for another predetermined period of time within a heating chamber at said heating temperature.
15. A process according to claim 14, wherein said heating male pieces form two protruding members for forming breast-receiving areas in said laminated fabric composition, whereby said laminated fabric composition is usable as a bra portion for a women swimsuit.
16. A process according to claim 14 or 15, wherein said fabrics are tricots comprising about 80 % of nylon and about 20 % of spandex, said predetermined period of time is about twelve hours, said step of coating is carried out by spraying said adhesive onto said at least one of said pieces of fabrics, said step of pressing is carried out at a temperature of about 65°C and at a pressure of about 15 cm Hg, said heating temperature of the heating chamber is about 180 C, said heating male pieces have a temperature of about 205°C, and said another period of time is about 20-30 seconds.
CA002108078A 1993-10-08 1993-10-08 Stretchable and water-resistant laminated fabric composition and process for making the same Abandoned CA2108078A1 (en)

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