Note: Descriptions are shown in the official language in which they were submitted.
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1
1 IMPROVEMENTS IN AND REhATING TO FABRIC BONDING
2
3 The present application relates in general to the field of
4 fabric bonding, One aspect of the invention is related to
mass-produced specialist gloves and related covers. Another
6 aspect relates to siliconised materials, non-stick materials
7 such as polytetrafluoroethylene (PTFE) and other materials
8 which cannot readily be joined with adhesive or by welding.
9
The technique is applicable throughout fabric technology, but
11 a particular application in the formation of airbags is given
12 as an example.
13
14 The application relates to new methods for constructing such
goods which results in an easy to use product at an economical
16 cost .
17
18 Specialist protective clothing, such as gloves and boots and
19 liners are required for many applications. For example,
waterproof gloves are used in the outdoor leisure industry;
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1 heat insulated gloves are used for handling very hot or cold
2 items in industry and fireproof gloves are used by firemen.
3
4 Tt is known to mass produce gloves for these industries by
joining together two flat fabric sheets, for example,
6 according to the method of Patent Application WO 99/64240 to
7 Z;iteliner, being a continuation in part of US Serial Number
8 08/697648 (now US Patent 5,766,400).
9
Such gloves are two-dimensional, with two correspondingly
11 shaped pieces of fabric joined by seams. A hand is three
12 dimensional, with an opposed thumb, and so these two-
13 dimensional gloves do not fit well and limit the free flexing
14 of fingers. Therefore, two dimensional gloves are typically
made oversized. This results in them being very bulky, with
16 considerable excess material and not particularly flexible.
17
18 Gloves which more accurately fit the shape of the hand are of
19 course everyday items, but are made from several or many piece
of material with multiple seams. (An exception is the method
21 used to make latex gloves; however, this is applicable only to
22 materials which can be formed from a spray and is not usable
23 with waterproof breathable fabrics) An item with multiple
24 seams has, in general, less mechanical strength and durability
of waterproofing than a comparable item with one seam.
26 Needless to say, configuring the sealing apparatus of
27 W099/64240 to produce a glove with multiple seals would not be
28 cost effective.
29
One aim of the present invention is to provide articles and
31 methods of~making articles which are more accurately shaped to
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1 fit the three dimensional shape of a user whilst requiring a
2 minimum number of seams.
3
4 Furthermore, the joining technique disclosed in W099/64240 and
many other fabric joining techniques require piece of material
6 to be joined along a flat (i.e. two-dimensional) intersection.
7 A further aim of the present invention is to provide three-
8 dimensional articles and method of making such articles which
9 involve two -dimensional joins, thereby enabling the articles
to made with a range of joining techniques.
11
12 According to a first aspect of the present invention there is
13 provided a method for making a shaped object from sheets of
14 synthetic material comprising the steps of:
(a) placing a first sheet of material in proximity to a
16 second sheet of material such that the edges of the
17 first and second sheets of material correspond; and
18 (b) sealing together the edges of said sheets of
19 material;
characterised in that a mould is disposed between the
21 first and second sheets of material, the mould having an
22 upper surface for contact with the first sheet of
23 material and a lower surface for contact with the second
24 sheet of material, the mould being shaped such that the
surface area of the upper and lower surfaces are
26 different and also being shaped such that the first and
27 second sheets of material are in contact where they are
28 to be. sealed together or are separated only by layers
29 intended to be incorporated into the final seam.
31 Preferably, the first sheet of material will be placed against
32 the mould by laying a first edge of the first sheet of
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1 material along one part of the mould and then moving
2 sequentially across the mould, pressing the rest of the first
3 sheet of material against the mould progressively. In one
4 embodiment, the first sheet is pressed sequentially from one
edge of the mould. Alternatively, the first sheet is pressed
6 progressively from a high point of the mould to a low point.
7
8 More preferably, a progressive tool will be used to press said
9 first sheet of material against the mould and the second sheet
of material.
11
12 Alternatively or additionally, vacuum draw-down may be used to
13 bring a sheet of material into contact with the mould.
14
The first and second sheets of material may be separated where
16 they are to be sealed together by a thermoplastic joining
17 film.
18
19 The shaped object may be selected from a group including
gloves, boots, jackets and trousers.
21
22 According to a second aspect of the present invention there is
23 provided a shaped object comprising two sheets of flexible
24 material, the edges of which correspond, joined around part of
their perimeter by a waterproof seal, wherein one sheet of
26 flexible material is of greater surface area than the other
27 sheet of material.
28
29 The shaped object may be selected from a group including
gloves, boots, jackets and trousers.
31
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1 According to a third aspect of the present invention there is
2 provided a method of making a composite garment comprising the
3 steps of:
4 (a) forming a laminate of a synthetic membrane and a
5 fabric sheet, the synthetic membrane having an adhesive
6 layer thereon;
7 (b) joining edges of two fabric sheets or two parts of
8 the same fabric sheet to each other around part of their
9 perimeter so as to form an insert for a garment;
(c) inverting said insert for a garment and placing said
11 insert for a garment within an outer layer of a garment;
12 (d) placing a shaped inner layer of a garment within said
13 insert, said inner layer having an adhesive layer
14 thereon;
(e) lasting the inner layer and insert to the outer layer
16 of a garment and applying heat thereto so as to melt the
17 adhesive layers and form a composite garment.
18
19 The edges of two fabric sheets or two parts of the same fabric
sheet may be joined using a thermoplastic joining layer.
21
22 According to a fourth aspect of the present invention there is
23 provided a method of making a composite garment, the method
24 comprising the steps of:
(a) forming a garment shaped fibrous layer around a
26 mould,
27 (b) placing a garment liner around said garment shaped
28 fibrous layer, the garment liner having a surface in
29 contact with the garment shaped fibrous layer, the
surface having a thermally activated adhesive thereon;
31 and
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1 (c) heat activating the thermally activated adhesive,
2 thereby joining the garment liner to the garment shaped
3 fibrous layer.
4
The garment may be placed within an outer garment layer.
6
7 The garment shaped fibrous layer may be formed around a mould
8 using the method of the first aspect.
9
The present invention aims to provide a better shaped glove,
11 or other shaped fabric product, using a simple sealing method
12 related to that of W099/64240 and minimal, preferably one,
13 sealing steps.
14
A further aim of the invention is to provide an improved
16 manufacturing process for a garment, according to the fifth
17 aspect .
18
19 According to a fifth aspect of the invention, there is
provided a method for forming a garment, the method comprising
21 the steps of:
22 - providing an outer surface of a first insert with an
23 adhesive;
24 - placing the first insert over a moulding, said moulding
having a hollow centre and perforations formed in a surface
26 thereof;
27 - placing a second insert over the first insert;
28 - reducing the pressure within the moulding, thereby drawing
29 the second insert towards the first insert, and;
- bonding the first and second inserts together.
31
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1 The adhesive may be scattercoated on the outer surface of the
2 first insert. The adhesive may be applied to the first insert
3 before or after it is placed over the moulding.
4
According to a sixth aspeot of the invention, there is
6 provided a method for forming a garment, the method comprising
7 the steps of:
8 - placing a first insert over a moulding, said moulding having
9 a hollow centre and perforations formed in a surface thereof;
- providing an inner surface of a second insert with an
11 adhesive;
12 - placing the second insert over the first insert;
13 - reducing the pressure within the moulding, thereby drawing
14 the second insert towards the first insert, and;
- bonding the first and second inserts together.
16
17 The adhesive may be scatter coated on the inner surface of the
18 second insert.
19
The adhesive is preferably a heat sensitive adhesive, for
21 example a thermoplastic.
22
23 The method may include the additional step of heating the
24 first and second inserts, subsequent to the step of drawing
the inserts together. The heating may be accomplished by
26 applying Infra Red radiation to the inserts. Alternatively,
27 the heat may be applied to the inserts via the moulding.
28
29 According to a seventh aspect of the invention, there is
provided a method of forming a garment, said method comprising
31 the steps of:
32 - placing a first insert over a moulding;
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1 - providing at least one protruding portion of the first
2 insert with one or more adhesive cups;
3 - placing a second insert over the first insert including the
4 one or adhesive cups, and;
- bonding the first and second inserts together.
6
7 The garment may be a glove, in which case the moulding is
8 hand-shaped and the protruding portions are digits of the
9 glove.
11 The adhesive cups may be thimble-shaped. They preferably
12 extend to a distance no further than the first joint from the
13 tip of a finger.
14
In another embodiment, the garment may be a sock or a lining
16 for a boot, in which case the mould is in the shape of a foot.
17 The protruding portion may be the toe-cap region, and the
18 adhesive cups preferably extend no further than the balls of
19 the feet. Adhesive cups may also be provided over a heel
region.
21
22 The adhesive cups may be manufactured from molten adhesive by
23 a dip process. Alternatively, they may be pre-formed from a
24 sheet adhesive.
26 At the present time a wide variety of techniques are known for
27 the joining of fabric material sheets. A subset of these
28 techniques.are also suitable for forming airtight or
29 watertight seals. Fabrics are conventionally joined by
stitching seams together and, if a waterproof seal is
31 required, taping the seams. Recent innovations such as WO
32 99/64240 (to ZiteZiner Technology) have led to improvements in
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1 waterproof joins for fibrous but non,-containable fabric
2 composites. However, there remain important categories of
3 material for which there is currently no convenient joining
4 process which can be applied economically on an industrial
scale. This applies particularly to siliconised fabrics or
6 fabrics containing or coated with polytetrafluraethane (PTFE).
7 These categories of materials are made in sheets and there is
8 no economically viable way presently known to join these
9 sheets together in a mechanically strong and waterproof seal.
11 One aim of the present invention is to provide a mechanically
12 strong method for joining sheet materials in general. The
13 method being particularly relevant for joining of materials
14 such as siliconised or PTFE fabrics which cannot readily be
joined by adhesive or conventional welding techniques.
16
17 A particular technological field where this lack of a
18 industrially effective joining technique is felt is the airbag
19 industry. Currently, concern is growing in the airbag
manufacturing industry about litigation cases, with airbag
21 manufacturers being held responsible for abrasive damage being
22 caused to passengers when air-bags are activated. Therefore,
23 it would be desirable to make air bags from the smoothest
24 possible materials such as siliconised fabrics, PTFE or
fluorocarbon sheets. However, this has so far proved
26 difficult. In order to use these materials it is necessary to
27 devise an economically viable and substantially airtight
28 joining technique to form the sheets into a bag.
29
An additional aim of the present invention is therefore to
31 provide a method of joining sheets of materials together which
32 is suitable for joining together smooth fabrics for use in
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1 airbags. At the present time, airbags are made from smoothly
2 woven fibrous materials and recent innovation has tended
3 towards finding smooth coatings for airbags rather than new
4 materials for the airbags per se. Recent examples of such
5 developments are described in, for example, US5,928,721 to
6 Milliken and US5,881,776 to Safety Components Fabric
7 Technologies.
8
9 According to an eighth aspect of the present invention there
10 is provided a method of joining sheet materials wherein two
11 sheet materials have join regions to be joined to each other,
12 the method comprising the steps of:
13 (a) forming a plurality of holes in the join regions of
14 two material sheets;
(b) arranging said material sheets so that the join
16 regions are in face to face contact with a thermoplastic
17 joining layer which separates them;
18 (c) applying heat to said join regions in such a way as
19 to cause the thermoplastic joining layer to melt and flow
through holes; and
21 (d) allowing the thermoplastic joining layer to cool,
22 forming a bond between the material sheets.
23
24 Preferably, the material sheets are siliconised materials.
26 Alternatively, the material sheets may be PTFE-containing
27 materials.
28
29 The plurality of holes may be formed using a pulsed laser.
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1 The plurality of holes may be formed using a perforating
2 member. Alternatively, the plurality of holes may be formed
3 using ultrasound.
4
Preferably, heat will be applied to the region of material
6 sheets which are to be joined by an RF source.
7
8 The material sheets may be underlaid and overlaid with further
9 thermoplastic joining layers.
I1 Covering layers may be situated between the regions of
12 material which are to be joined and a source of said heat to
13 prevent unwanted adhesion.
14
According to a ninth aspect of the present invention there is
16 provided a method of joining sheet materials wherein two sheet
17 materials have join regions to be joined to each other, the
18 method comprising the steps of:
19 (a) forming a plurality of holes in the join regions of
two material sheets;
21 (b) arranging said material sheets so that the join
22 regions are in face to face contact; and
23 (c) applying a molten thermoplastic material to said join
24 regions in such a way as to cause the molten
thermoplastic material to melt and flow through holes;
26 and
27 (d) allowing the thermoplastic material to cool, forming
28 a bond between the material sheets.
29
Preferably, the molten thermoplastic material consists of two
31 thermoplastic sheets in face to face contact with the join
32 regions so the both join regions are sandwiched between the
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1 thermoplastic sheets, wherein said thermoplastic sheets are
2 then melted.
3
4 According to a tenth aspect of the present invention there is
provided an article comprising two or more sheets of material
6 joined using the method of the eighth or ninth aspect.
7
8 According to an eleventh aspect of the present invention there
9 is provided an airbag made by joining two sheets of low-
friction material to each other using the method of the eighth
1l or ninth aspect.
12
13 The first aspect of the invention will now be illustrated with
14 reference to the following Figures in which:
16 Figure 1 is an exploded cross-sectional view of a
17 composite fabric seam assembly according to the present
18 invention;
19
Figure 2 shows the mould for use in the present
21 invention;
22
23 Figure 3 shows a glove according to the present invention
24 whilst worn from a) the side; b) underneath; c) looking
down on and d) edge on;
26
27 Figure 4 shows, in perspective view, a glove according to
28 the present invention without a hand therein and at rest;
29
Figure 5 is a perspective view of a glove end on, showing
31 the gussets between two fingers;
32
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1 Figure 6 shows progressive tooling according to the
2 present invention from a) above and b) end on;
3
4 Figure 7 shows a cross-section through a seam joined
using a thermoplastic joiner layer;
6
7 Figure 8 shows a cross-section through a waterproof
8 insert; and
9
Figure 9 shows a cross-section through a comfort insert.
11
12 Figure 10 shows a moulding in accordance with one
13 embodiment of the invention.
14
Figure 11 shows a bonding method in accordance with one
16 embodiment of the invention.
17
18 Figure 12 shows a bonding method in accordance with an
19 embodiment of the invention.
21 Figure 13 shows a bonding method in accordance with the
22 invention.
23
24 Figure 14 shows a plan view of a sheet material joining
assembly;
26
27 Figure 15 shows a close-up plan view of a plurality of
28 holes in sheet material;
29
Figures 16a through 16d shows various conformations of
31 material and joining layer in cross-section envisaged by
32 the present invention; and
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1
2 Figure 17 shows a cross-section of a join formed between
3 two sheets of material.'
4
Figures 18 and 19 show apparatus for forming microholes
6 in a sheet material
7
8 The present invention is a shaped garment or other cover and a
9 method for manufacturing the same. By way of an example, a
glove and method of manufacturing the glove will be shown.
11
12 Figure 1 is an exploded cross-sectional view of the various
13 layers of material which are assembled around a mould to
14 produce the final product. Fabric pieces cut into the shape
of a glove 10a, 10b are overlaid and underlaid with membranes
16 11a, 11b. A thermoplastic joiner film 12 is sandwiched
17 between the glove shape 10a, 10b and as in WO 99/64240 is
18 positioned so as to straddle the edges of the glove shape 10a,
19 10b. An optional mesh fabric layer 13 can be used.
Additional layers for specialised applications eg tie layers
21 to reduce approved mechanical strength should be used where
22 required.
23
24 Alternatively, only one layer might be used above and below
the mould. For example, an aramid fibre material with a
26 waterproof scrim might be used for each of'the top and bottom
27 sheets .
28
29 The layers of fabric are assembled around a glove shaped mould
14. The example mould shown in Figure 2 has a flat underside
31 and curved upper surface. This means that when material is
32 fitted over and under this mould, there is a larger surface
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1 area of material overlaying the top surface than underlying
2 the bottom surface. The method by which the material is
3 fitted over the mould is important and is described further
4 below.
5
6 The layers of fabric are then joined together. In one
7 example, non-containable fibres as defined in W099/64240 may
8 be joined using induced melting of the joiner layer
9 substantially as described in W099/64240. The resulting glove
10 is then trimmed and, for many applications, turned inside out.
11 Alternatively any fabric joining technique suitable for the
12 type of material used may be employed. In some embodiments no
13 joining layer will be required.
14
15 As there is a larger surface area of material above the mould,
16 the resulting glove tends to curve, more naturally fitting the
17 shape of a real hand. In particular, the thumb sits naturally
18 below the line of the other fingers and, by selection of
19 appropriate design parameters, sits in the correct opposable
position of a hand.
21
22 The resulting glove is shown in Figures 3 and 4. Glove 30 has
23 a surface 31 made from a non-containable fabric eg, KEVLAR~
24 brand aramid. The upper surface 31 is joined to the lower
surface (not shown) via an encapsulated seam 33. It can be
26 seen from the diagram that this glove has a fold line 35 which
27 is above the thumb, therefore when this glove is worn the
28 thumb will sit naturally at the appropriate angle to make it
29 most comfortable to wear and use.
31 A second design feature is most clearly seen in Figure 5. The
32 upper material surface 31 is folded down the gap between two
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1 fingers thereby forming a gusset 34. This contrasts with the
2 arrangement in a simple glove made from two pieces placed flat
3 on top of each other before seaming. In the previously known
4 form, the material fingers have to be much wider than a
wearers fingers; as there is no slack in the material when it
6 is welded, they have to be wide to encompass the full
7 circumference of the wearers finger. Such gloves are hard for
8 the wearer to flex.
9
In the present invention, although the lower material surface
11 32 is simply a two-dimensional cut out, the upper surface 31,
12 being folded down, has slack once the mould is removed,
13 leaving it in the shape of a finger, with appropriate
14 gussetting to allow the fingers to be flexed.
16 As a result of this, the glove is substantially more flexible
17 and easy to use than the previously known two-dimensional
18 form. The process has the additional benefit of being more
19 economical than the prior techniques. The reduced cost results
from a reduced amount of fabric used and a reduced amount of
21 joiner is required, due to the shorter joing seam at the
22 perimeter.
23
24 In order to achieve the features of (a) having more material
in the top surface than the lower surface, thereby disposing
26 the glove to fit the curve of a hand and (b) of having a
27 gusset structure between fingers, a new method of positioning
28 the material has been devised.
29
A simple construction process could use a tool to press the
31 top material layers down, onto the mould, against the lower
32 material layers. This would, however, lead to creasing and
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1 stretching in the material. A better finished product would
2 be prepared by allowing the upper material to be moved across
3 the mould with a progressive drawing tool. An example
4 arrangement is shown in Figure 6 which shows two fingers 36 of
the mould from above. Individual tools 40 are engaged to press
6 the material down onto the mould sequentially running in one
7 direction across the mould. In Figure 6b, one finger can be
8 seen end-on and in cross-section through line AA. By
9 automatically placing consecutive tools in turn, the material
l0 flows across the mould. The tools may be shaped as in Figure
11 6b so that they push the material downwards as well as
12 pressing it against the mould, further helping it to flow
13 across the mould. This invention allows the production of
14 gloves and boots and other shaped items to be made using a
simple one-step sealing technology.
16
17 Alternatively, a progressive tool may be used to sequentially
18 press down the fabric starting from the highest point on the
19 mould (for example the centre of the back of the hand), and
progressively moving outwards to the lower points. Instead of
21 using a number of consecutive tools, it may be possible to use
22 a one piece tool.
23
24 Alternatively, vacuum draw-down might be used to pull the
upper layer down over and around the mould, as described
26 later .
27
28 Although one specific sealing technology and one specific
29 arrangement of fabric layers is described here, it will be
clear to one skilled in the art that many other joining
31 techniques could be used and many types of fabrics joined. An
32 important benefit of the present invention is that the
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1 junction region between the upper and lower fabric layers is
2 flat, making it easy to apply a press to the junction.
3
4 The resulting materials are well-shaped to be used on real
three-dimensional objects such as hands and feet and so the
6 invention has provided an economic method of producing high
7 quality garments and inserts for garments.
8
9 There is additionally disclosed herein an improvement to the
l0 construction of shaped garments made using a lasting process.
11 Within the prior art it is known to form linings within
12 garments such as boots using a lasting process and known to
13 use this to form boots having a waterproof, breathable fabric
14 such as microporous PTFE therein.
16 These materials can be difficult to work with. For example,
17 PTFE membranes with microscopically minute pores are readily
18 broken and rendered non-waterproof by sewing or stitching.
19 One solution to the problem of incorporating such a membrane
within a garment is disclosed in US Patent Number 4,520,056 to
21 Jackrel. In this construction, a glove or other garment
22 involves an inner insulating layer and an external covering
23 layer sewn to the inner insulating layer around the wrist
24 portion wherein a gas-permeable liquid impermeable membrane is
confined within the recess between the inner and outer layers
26 but left unattached to either layer. Were this membrane to be
27 sewn to either the inner or external layer its waterproof
28 properties would be damaged.
29
A construction such as this does however remain limited in
31 terms of mechanical rigidity. It would therefore be desirable
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1 to join the waterproof layer to the inner or outer layers of a
2 garment without damaging the waterproof layer.
3
4 US Reissue Patent 34,890 to Gore Enterprise Holdings Inc
provides a shoe with a sock-like waterproof liner joined to
6 the outer of the shoe only round the ankle portion.
7
8 US Patent 5,766,400 and PCT Application WO 98/09011 both to
9 Liteliner LLC disclose methods of producing pre-fabricated
multi-layered products in which a thermo- plastic joining film
11 strategically placed between layers and melted in place is
12 used to enhance bonding. This technology provides very strong
-13 joins, but can be difficult to use for gloves which need to
14 tolerate high temperatures. For example, gloves in the fire
industry must withstand temperatures well in excess of 100°C;
16 however, thermoplastic films with melting temperatures above
17 around 80°C have been found by us to be hard to use in forming
18 these products as it is difficult to get them to melt in situ
I9 and form an appropriate strength bond. Therefore, it would
also be desirable to provide a method for joining fabric
21 materials to each other and to synthetic films which is better
22 adapted for use in high temperature applications.
23
24 Figures 7 to 9 .illustrate an alternative configuration; in
this example, the garment is a boot. This boot comprises an
26 outer waterproof insert which fits.within a standard shoe and
27 an inner insert which is a comfort insert that fits within the
28 waterproof layer. The teaching of the prior art documents
29 referenced above is that there is no good way to fixably join
the waterproof insert to the comfort insert and outside of the
31 shoe .
32
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1 We herein propose a method of better joining the layers of a
2 multilayer garment, enclosing a waterproof breathable membrane
3 therein. Figure 7 shows a cross-section through a waterproof
4 insert 20. The hydrophilic or microporous membrane 21 may be
5 joined to a fibrous backing fabric 22 using the techniques of
6 W099/64240 to Zineliner. A seam may be formed at the location
7 shown in Figure 8 by then joining the fabric layers 22 to each
8 other using either a thermoplastic adhesive 23, using the
9 technique of US Patent 5,766,400 or PCT Application 98/09011
10 or 99/64240, or using any other joining technique appropriate
11 to the materials.
12
13 By putting a scatter coat adhesive 24 on the microporous
14 membrane 21 the insert can be readily joined to a comfort
15 insert 25 which is lasted therein and consists of comfort
16 layer such as foam or felt 26a overlaid with a face fabric 26b
17 and joined by an appropriate method. In the comfort insert
18 there is no waterproof layer to be damaged and so stitching 27
19 may be used to join these layers. The resulting product is a
20 comfortable waterproof shoe in which individual layers therein
21 are joined to each other rather than being free to move,
22 improving the lifespan of the product and reducing any
23 discomfort for the wearer due to movement of the layers. It
24 will be clear to one skilled in the art that this construction
can be used to provide many different types of article such as
26 gloves, boots, jackets, socks, shirts, trousers etc.
27
28 A further embodiment is now described. A prefabricated inner
29 glove made from a layer of any type of fibrous material
(aramid, acrylic, wool, cotton etc.) is placed around a 3D
31 mould using the technique of the first or second embodiment of
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1 the present invention. Alternatively a 2D mould could be used
2 and the fabric might be simply placed around the mould.
3
4 A glove liner laminate comprising a plurality of layers
selected from membranes (particularly waterproof, breathable
6 membranes) and tricots and coated with scattercoat adhesive is
7 placed around the inner glove, with the adhesive in contact
8 with the inner glove. The adhesive is then activated by
9 heating, giving a finished glove liner assembly. The glove
IO liner assembly is then placed within a known outer glove,
11 selected depending on the end use of the glove, by standard
12 glove manufacturing techniques.
I3
14 Figure 10 shows a moulding 110 in the shape of a hand. The
figure shows a section 111 cut away from the moulding in order
16 to display the interior of the moulding. The moulding is
17 hollow, and the surface of the moulding 112 is covered in
I8 perforations 113. Attached to the base of the moulding is a
19 tube 116 which is attached to a vacuum pump (not shown). A
second tube 117 is optionally provided, attached to a
21 compressor for providing a pressure (not shown). The moulding
22 is attached to a steel plate by means of a steel tube weld
23 118 .
24
Figure 11 shows the moulding used in the manufacturing
26 process. In use, a preformed or knitted comfort insert is
27 placed over the moulding 110. A second insert 122, for example
28 a waterproof, fireproof or gas-proof insert, to be placed over
29 the comfort insert on the moulding is provided with adhesive
on its internal surface. The adhesive is a heat sensitive
31 adhesive such as a thermoplastic, and is scatter coated on the
32 internal surface.
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1
2 The second insert is placed over the comfort insert, and a
3 clamp (not shown) is provided around the wrist portion of the
4 two inserts to provide an airtight seal between the two
layers. The clamp may be of any suitable type, for example an
6 elastic band, or an inflatable collar. The clamp prevents air
7 from being drawn in between the two inserts when the vacuum
8 pump is activated.
9
The vacuum pump is activated by a foot-operated valve (not
11 shown), The vacuum pump, attached to the moulding via tube
12 116, causes the pressure to be lowered within the moulding,
13 The resulting effect is that the outer insert is drawn down
14 onto the comfort insert, providing a good .contact between the
two inserts.
16
17 Subsequently, heat is applied to the inserts in order to raise
18 the temperature, thereby melting the scattercoat adhesive and
19 bonding the two inserts together. The heat may be supplied by
any suitable source, for example an infra red radiation
21 source. Alternatively, the moulding may be provided with
22 heating elements in order to heat the inserts form the inside,
23 or hot air may be used.
24
When the inserts are bonded, the vacuum is released. The glove
26 may then be blown off the moulding by increasing the pressure
27 inside the moulding via a compressor (not shown) attached to
28 the moulding via tube 117.
29
As an alternative to the vacuum pump, a simple cylinder may be
31 used to reduce the pressure in the moulding. The same cylinder
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1 could also be used to supply the increased pressure with the
2 moulding.
3
4 In an alternative method, the scattercoat adhesive may be
added to the external surface of the comfort insert, instead
6 of, or in addition to, the inside of second insert. In this
7 case, the adhesive may be applied to the comfort insert before
8 or after it is in position on the moulding.
9
If required, further layers may be provided in the garment.
11 This aspect of the invention is intended to embrace the
12 joining of any two suitable fabrics layers by the techniques
13 described herein.
14
In this regard, although the term "insert" has been used in
16 order to describe the second layer of fabric, placed over the
17 comfort insert, it is evident that the above method can be
18 used to bond a single insert to an outer layer of a glove,
19 such as a leather or fabric layer.
21 In addition, although the above embodiment discloses the
22 formation of a glove, it will be obvious to one skilled in the
23 art that the techniques can be applied to other articles. In
24 particular, a sock, or lining for a boot or shoe could be made
with the above techniques, using a moulding in the shape of a
26 foot.
27
28 It is clear that the features of the first aspect of the
29 invention can be combined with the fifth aspect above.
Specifically, the comfort insert, the second insert (eg a
31 waterproof, fireproof or gas-proof insert) or any additional
32 layers may be formed using the techniques of the first aspect
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1 of the invention. By using the perforated moulding in place of
2 moulding 14, and using an upper fabric sheet with a greater
3 surface area than the lower fabric sheet, a layer or insert
4 with natural curvature can be obtained.
6 The moulding fixed to a sheet may be used with adapted joiner
7 films and upper and lower membranes so that the 3-d layer is
8 fabricated in situ, prior to the vacuum drawn bonding
9 technique. Alternatively, the perforated moulding may be
detachable from the sheet and tubes, so that the techniques of
11 the first aspect can be carried out in an appropriate
12 location. Subsequently, the moulding may be fixed to the bench
13 and the vacuum drawing technique enacted. As another
14 alternative, it may be preferable to form the 3-d shaped
layers on a separate moulding, placing them onto the
16 perforated moulding when they are formed.
17
18 There will now be described an embodiment in accordance with a
19 seventh aspect of the invention.
21 Figure 12 shows an inner layer 120 of a glove formed in
22 accordance with the first aspect of the invention, or by any
23 previously known technique. The inner layer is placed over a
24 moulding, and adhesive cups 121 are placed over the ends of
the fingers on the layer 120, to form the structure shown at
26 120a.
27
28 An outer layer 122 is then placed over the layer including the
29 adhesive cups, and heat is applied in order to bond the outer
layer to the inner layer. As before, the heat can be applied
31 from an infra-red source, or alternatively via heating
32 elements disposed within the mould.
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2 The adhesive cups are made from a thermoplastic material, and
3 can be formed from molten adhesive in a dip process, or
4 preformed from adhesive sheet materials. If a dip process is
5 used, the moulding and inner layers themselves may be dipped
6 into the molten adhesive. Alternatively, a second mould may be
7 used for the dip process, with the cups being transferred onto
8 the inner layer thereafter.
9
l0 The adhesive cups are preferably formed to be no deeper than
11 the typical distance from the tip of a finger to the first
12 joint of the finger. This is because the cups provide
13 additional structural strength to the finished glove, and
14 increase the rigidity of the finger. In order to maintain the
15 flexibility in the fingers, it is important that the adhesive
16 cups do not extend beyond the first joint. A typical distance
17 would be l6mm to l9mm.
18
19 The concept of adhesive cups can also be used to provide
20 protective regions of the garment. For example, needle-proof
21 gloves can be made by placing cups of needle-proof plastics or
22 turtle skin over the adhesive cups. The outer layer can then
23 be placed over the needle-proof cups and bonded thereto,
24 either via additional adhesive cups or by other means.
26 It is envisaged that open ended cups may be used as part of
27 the above process. Cups of this type would enable greater
28 sensitivity to be retained in the glove. Open ended
29 protective regions and open-ended adhesive cups may be used in
any combination with the described method.
31
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1 The above techniques are not limited to the manufacture of
2 gloves. Other garments may be made using the adhesive cups
3 over the protruding portions of an inner layer. In particular,
4 the method is applicable to the formation of socks, and
linings for boots and shoes. Figure 13 shows a boot lining 130
6 which is provided with first and second adhesive cups 131 and
7 132. The first adhesive cup is formed over the toe-cap region
8 of the lining, and extends to a point not beyond the point of
9 flexing on the foot. The second adhesive cup 132 is provided
over the heel area. A second layer 134 may be placed over the
11 first layer 130 and the adhesive cups 131 and 132.
12 Alternatively, the layer 130 could be bonded directly to the
13 inside of a boot.
14
The layers bonded may be any type of fabric layer. For
16 example, the inner layers 120, 130 may be comfort inserts, and
17 the layers 122, 134 may be outermost layers of gloves or
18 socks. Alternatively, the layers may be intermediate layers in
19 a multilayered garment.
21 The methods disclosed herein are suitable for manufacturing
22 multilayer garments, incorporating fireproof, waterproof, or
23 gas proof, comfort inserts, and outer cover layers. The
24 adhesive cups provide a strong bond between two layers of
material, without resorting to stitching. Further, by
26 restricting the size of the adhesive cups so that they do not
27 extend beyond the joint of the foot or finger, the garment
28 remains flexible and functional. The garments have the added
29 benefit that the adhesive cups can be used to provide extra
protection for the fingertips, toes or heels of a person
31 wearing the garment.
32
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1 It is evident that the embodiments of the first, fifth and
2 seventh aspects may be combined in order to form a process
3 which includes the steps of vacuum drawing a second insert
4 towards a first insert and bonding the two together, and
subsequently bonding an outer layer over the combined inserts
6 via a number of adhesive cups. The assembly can take place on
7 any suitable mouldings, and in particular the whole process
8 can take place on the perforated moulding of figure 10. The
9 final garment can be blown from the moulding by the
application of pressure to the inside of the moulding.
11
12 Figure 14 shows in plan view apparatus for joining sheets of
I3 material. Upon a backing plate 1 are Laid the sheets of
14 fabric 2,3 which are to be joined. Joining sheets and cover
sheets not shown in Figure 1 may be added underneath, above
16 and between the sheets as discussed below.
17
18 The method of the present invention begins by forming a
19 plurality of microscopic holes 5, through the sheets of
material. In this illustration these holes are placed all the
21 way up to the edge 4 of the sheets, however, they may readily
22 be placed anywhere within a sheet of material. The
23 microscopic holes are preferably made with a pulsed laser
24 which can readily and automatically make such holes. In one
example, a 5-l0mm strip of fabric is perforated with holes
26 .004 inches (0.lmm) wide, spaced .008-.012 inches (0.2 to
27 0.3mm) apart in a regular grid using a pulsed laser and a
28 numerically controlled coordinate table. Clearly, there is
29 considerable scope for variation in the size and distribution
of holes.
31
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1 Figure 15 shows a close-up of a region of Figure l4 showing
2 how a plurality of holes can be laid out in an array. No
3 restriction is envisaged on the layout of array. The array
4 configuration, hole spacing hole size, laser type, power and
pulse width will be selected depending on the method of
6 manufacture, the particular materials and the particular
7 configuration in which. materials are to be joined.
8
9 Figure 16a shows one configuration of the present invention.
Two sheets of material 2 and 3 to be joined are laid flat,
11 separated by a joining layer 6. The sheets of materials have
12 had microholes made in them 5. The joiner film is made from a
I3 thermoplastic material. The assembly is then heated, melting
14 the thermoplastic joiner film which then proceeds to flow out
of the holes 5, forming the configuration shown in Figure 17.
16 As shown in Figure 17, the plastic joining material can flow
17 outwith the circumference of the holes forming a structure
18 which behaves mechanically like a rivet. Therefore once it is
19 cooled a mechanically strong bond is formed between sheets 2
and 3. Furthermore, as the thermoplastic joining material is
21 continuous, an airtight seal can readily be produced.
22
23 An alternative arrangement has the thermoplastic sheets placed
24 so that they extend beyond the edges of the fabric sheets, and
over lap at these points. When the joiner sheets are melted,
26 they merge at the edges of the fabric to provide an continuous
27 thermoplastic sheet around both fabric sheets.
28
29 Numerous variations to this configuration are envisaged. For
example, Figure 26b shows a configuration identical to that in
31 Figure 16a, other than that top and bottom layers made from a
32 non-stick material, are put in place to allow heating and
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1 machinery to come into close contact with the sheets to be
2 joined, but without actually coming into direct contact with
3 the thermoplastic joining film therefore becoming stuck.
4
Figure 16c shows a configuration where the joining film is
6 present not just between the sheets to be joined but above and
7 below them as well, improving waterproofing. Figure 16d shows
8 a configuration where the joining layer is above, below and
9 between the sheets and there is also provided a non-stick
coating layer 7 above and below.
11
12 In another embodiment, the thermoplastic joining layer is not
13 positioned between the sheets to be joined before heating. In
14 this embodiment, the sheets to be joined are placed in contact
and thermoplastic joining layers are placed around the
16 sandwiched sheets. Heat is applied so that the thermoplastic
17 joining layer remains molten sufficiently long to enable the
18 thermoplastic joining layers to pass through the holes and
19 join with each other and so set to form a solid bond when the
heat source is removed. Indeed, in this configuration, the
21 thermoplastic material may be applied to the join already
22 molten.
23
24 Heating may be by any of a number of means. It is
particularly envisaged that RF heating techniques be used.
26 Alternatively, any heating methods suitable for melting the
27 joining layer can be used.
28
29 In the example Figures, the holes are made before laying the
sheets above and below the joining film. However, it will be
31 clear to one skilled in the art that it would be possible to
32 make the holes in situ and melt the joining layer 6, in a
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1 single manufacturing step using an appropriately configured
2 laser.
3
4 In the present invention, the solidified thermoplastic joining
5 layer functions like a very high density of small rivets. In
6 the example of Figure 14, holes are made around a perimeter of
7 two sheets of material in order to form bag suitable for use
8 as an airbag. By allowing airbags to be made from smooth
9 materials a substantial improvement in the safety of air hags
10 will be achieved.
11
12 The joining layer will serve to form an airtight bond as it
13 will flow throughout the whole region of the join between the
14 two sheets. This technique will allow the use of totally
15 airtight materials such as PTFE in airbags. The joining layer
16 may be shaped to correspond to the shape of the join between
17 sheets
18
19 Instead of using a laser, mechanical means might be used to
20 make the plurality of microholes. For example, perforating
21 members or fine ultrasound beams may be used to make the
22 microholes. Figures 18 and 19 show a rotating wheel 10 with a
23 plurality of teeth 11. An ultrasound horn 12 emits ultrasound
24 onto a sheet of fabric which is interspersed between the horn
25 12 and wheel 10, leading to formation of microholes. The
26 wheel 10 might be mechanically milled or may be electronically
27 machined or etched in a fine pattern.
28
29 Two sheets made of the same material may be joined to each
30 other, alternatively composites may be made. For example, a
31 silicon type coating might be joined to a rip stop woven
32 material.
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Further modifications may be made within the scope of the
invention herein intended.
