Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-07-29
2001-02-20
Yao, Sam Chuan (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S179000, C156S230000, C156S249000, C156S289000, C156S291000, C427S208600, C427S282000
Reexamination Certificate
active
06190482
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to a method of laminating multiple layers of textile and/or polymer materials together, and relates particularly to a method of laminating multiple layers of textile and/or polymer materials by means of an adhesive layer into which a void pattern has been introduced.
BACKGROUND OF THE INVENTION
In producing a “breathable” textile material, it is known in the art to laminate a substrate fabric to a second layer of material by means of an adhesive layer. In order to impart certain permeability characteristics to the resulting laminates, e.g., air permeability or moisture permeability, it is also known in the art to apply the adhesive discontinuously, i.e., leave certain areas of the laminates unbonded. A variety of bonding methods have been utilized in the past to achieve the aforementioned discontinuous adhesive layer, but these methods suffer from significant disadvantages.
One method disclosed in U.S. Pat. Nos. 5,342,469 and 5,705,011 involves introduction of a discontinuous adhesive in the form of linear filaments between the fabric layers to be laminated. An obvious drawback of this method is that there is no way to control the number and locations of the voids in the adhesive layer. Another method disclosed in U.S. Pat. No. 5,560,974 involves applying an adhesive layer at discrete, spaced-apart locations, which adhesive layer may form a series of spots or a lined pattern. Other techniques which have been utilized in attempts to create a discontinuous adhesive layer between laminate layers include controlled extrusion through a die applicator, rotogravure, dot gravure, flexographic, screen printing, melt-blowing and ink-jet printing. An exemplary technique, disclosed in U.S. Pat. No. 4,761,324, involves the use of a printing roll that has a void pattern. In this known technique, the printing roll transfers the adhesive to the fabric only where the roll contacts the fabric. In screen printing, selected sections of the screen are blocked off and adhesive is applied through the remaining portions of the screen.
The above-mentioned prior art techniques have some significant cost and technical disadvantages. Regarding the printing-roll adhesive application method and the screen-print adhesive application method, engraving new or modified patterns into metal/ceramic rolls or screens is costly. Furthermore, roll changes required between successive adhesive-application jobs are very time consuming, requiring adhesive cleanups. In addition, fine, adhesive void patterns are difficult to achieve, especially when a thick adhesive layer is desired. Regarding the process for controlled extrusion of adhesive through a die applicator, the initial capital investment for the necessary equipment is relatively high. Furthermore, fine adhesive void patterns are difficult to achieve with this method.
Accordingly, it would be desirable to have a method for applying a discontinuous layer of adhesive for textile lamination, which method eliminates the disadvantages associated with previously known techniques.
SUMMARY OF THE INVENTION
In accordance with the present invention, a process of laminating textiles for producing air-permeable or moisture-permeable laminated textile materials involves generating a discontinuous layer of adhesive with a precise pattern of voids by means of temporarily introducing sets of parallel yarns or, alternatively, cris-crossing sets of parallel yarns or a mesh-like web in contact with an initially uniform layer of adhesive temporarily carried on a release-coated carrier. After the adhesive layer and the mesh-like web have been pushed into contact with a first fabric layer, the release-coated carrier is stripped away, along with the mesh-like web, from the first fabric layer. The adhesive layer remaining on the first fabric layer will exhibit a discontinuous pattern that is complementary to the mesh-like web pattern. Subsequently, a second fabric, or film, is bonded to the exposed adhesive surface on the first fabric to create a laminated material exhibiting air permeability or moisture permeability.
The laminating process according to the present invention significantly increases the ability to control the extent and pattern of voids in the adhesive layer of a laminated fabric material without incurring significantly added cost or time for manufacturing. The increased ability to control the extent and pattern of voids results in several benefits. When two fabric layers are laminated using the process according to the present invention, the process enables accurate control of the resulting laminate's wind resistance to specific target values. Furthermore, the process enhances control over the resulting laminate's handle and drape. When a fabric is laminated to a barrier film, the process according to the present invention enables accurate control of adhesive coverage/pattern to easily balance the bond strength against the following conflicting properties: a) moisture-vapor permeability, when a moisture vapor permeable film is used as one of the laminate layers; and b) soft handle and drape. Furthermore, the process according to the present invention is able to impart novel surface patterns and textures to the film layer.
REFERENCES:
patent: 4163822 (1979-08-01), Walter
Enterprise Coatings
Kenyon & Kenyon
Yao Sam Chuan
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