Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Woven fabric – Including strand precoated with other than free metal or alloy
Reexamination Certificate
2002-01-11
2004-06-01
Boykin, Terressa M. (Department: 1711)
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Woven fabric
Including strand precoated with other than free metal or alloy
C428S35500R, C442S190000, C524S425000
Reexamination Certificate
active
06743741
ABSTRACT:
TECHNICAL FIELD
The present invention relaters to a method for the manufacture of a heat-fusion bonding adhesive. Further, the present invention also relates to a heat-fusion bonding adhesive obtained by this method. Moreover, the present invention also relates to a heat-fusion bonding adhesive obtained by thermally fusing the heat-fusion bonding adhesive to the surface of a base fabric.
BACKGROUND ART
Base materials of various types have been provided with a variety of functional properties such as oil resistance, solvent resistance, chemical resistance, wear resistance, gas shielding ability, adhesive properties, and the like by coating a thermoplastic resin thereon and forming a coating film. Among them, adhesive fabrics obtained by using a fiber-containing cloth or nonwoven fabric as a base fabric and coating a thermoplastic resin on the surface of the base fabric have been used mainly as adhesive interlinings in the field of clothing.
For example, Japanese Patent Application Laid-open No. H6-145413 disclosed an adhesive interlining fabricated by the following method. First, a composition prepared by adding silica and a silane coupling agent to an acrylic polymer emulsion such as acrylate resin was coated on a fiber-containing nonwoven fabric serving as a base fabric and dried. Then, a powder of a thermoplastic resin such as a polyamide resin, polyester resin, polyethylene resin, ethylene-vinyl acetate resin, polyvinyl chloride resin, and the like was scattered over the coating and melted to obtain an adhesive interlining.
A variety of methods such as a scattering method, powder dot method, spray method, paste dot method, double dot method, and the like are employed for heating and fusing the thermoplastic resin powder to the base fabric surface, and the appropriate method is selected according to the type of base fabric. With the scattering method, a thermoplastic resin powder is uniformly scattered over the base fabric surface, heated, and fused. With the powder dot method, a thermoplastic resin powder is first caused to adhere to a gravure roll, then transferred to the base fabric surface, heated, and fused. With the spray method, a paste prepared by dispersing a thermoplastic resin powder in water is sprayed as-is on the base fabric surface, thermally dried, and fused. With the paste dot method, a paste prepared by dispersing a thermoplastic resin powder in water is dot-like coated on the base fabric surface by using a coating screen having fine holes, thermally dried, and fused. The double dot method comprises the steps of dot-like coating an acrylic emulsion on the base fabric surface by using a coating screen having fine holes, scattering a thermoplastic resin powder over the obtained dot-like coating, removing the excess thermoplastic resin powder, and thermally drying and fusing the thermoplastic resin powder remaining on the base fabric. The thermoplastic resin powder thermally fused to the base fabric surface by those methods is used as a heat-fusion bonding adhesive and thermally fuses the base fabric to a surface fabric when reheated during usage.
Adhesive fabrics, in particular, adhesive interlinings mainly serve to supplement the properties of the surface fabrics in order to give a final three-dimensional touch to a dress, to facilitate sewing and also to provide shape stability so as to prevent loss of shape in wearing or washing and dry cleaning. They are usually used for collars, cuffs, lapels of men's business suits, women's suits and the like and the required properties thereof differ depending on the application and place where they are used. For this reason, the optimum adhesive interlining is selected upon consideration of various conditions such as the type of thermoplastic resin powder, heat sealing method, type of base fabric, and the like.
The thermoplastic resin powder can be prepared by a mechanical grinding method by which a thermoplastic resin such as a copolyamide resin, copolyester resin, ethylene-vinyl acetate copolymer resin, polyethylene resin, polyurethane resin, and the like is mechanically ground at normal temperature, or by a freeze grinding method by which grinding is conducted under freezing.
In recent years, in addition to the above-mentioned application to women's suits, thin cloths for women have been actively developed and a need has increased for adhesive interlinings which do not degrade aesthetic shaping ability that provides feel and draping ability necessary to obtain beautiful silhouette and aesthetic functions especially required for clothing. However, when a thermoplastic resin powder is used as a hot-sealable adhesive, the resin powder is required to have a weight-average particle size of no more than 20 &mgr;m if an adhesive interlining with a satisfactory feel is to be obtained. However, such a fine resin powder is very difficult to manufacture by the mechanical grinding method or freeze grinding method.
Adhesive interlining prepared by thermally fusing a thermoplastic resin powder with relatively coarse particles having a size within a range of 60-500 &mgr;m to the surface of a base fabric, for example, by a scattering method is typically used in clothing such as women's suits. However, if such an adhesive interlining is used for thin cloths, in particular, thin cloths for women, satisfactory feel is difficult to obtain. Thus, the cloths become rigid to the touch and problems are associated with their draping ability.
Furthermore, in the powder dot method, in order to improve powder separation when the powder is transferred from the gravure roll onto the base fabric, the base fabric has to be preheated to a temperature of 180-250° C. Certain basic fabrics are shrunk by such preheating and the feel thereof is degraded.
On the other hand, the paste dot method uses a paste of a resin powder with a comparatively small particle size within a range of 5-80 &mgr;m, which somewhat improves the feel. However, though the particle size range is referred to as a 5-80 &mgr;m range, the peak of particle size distribution within the range is actually shifted to a large size. As a result, the weight-average particle size is usually about 30-50 &mgr;m, easily causing clogging of fine openings in the coating screen. For this reason, it is difficult to employ the screens with fine holes having a diameter of no more than 200 &mgr;m. As a result, dot spacing is increased which results in a decreased adhesive force and degraded feel.
Furthermore, paste-like adhesives used in the spray or paste dot method are manufactured by dispersing a thermoplastic resin powder in water. As a result, it is difficult to increase the resin concentration to more than 40 wt %. Therefore, drying is time consuming and productivity is poor.
The double dot method resolves the above-described problems. With this method, a resin powder is scattered over an acrylic resin coating obtained by dot-like coating and the resin powder which adhered only to the zones coated with the acrylic resin is used as a hot-sealable adhesive. If the excess powdered resin is removed by suction after scattering, the resin powder should remain only on the acrylic resin dots. However, in reality, the powder cannot be completely removed by suction and the powder remaining outside the dots degrades the feel. Another problem is that the resin powder that adhered to the acrylic resin can peel therefrom, decreasing the adhesive strength.
DISCLOSURE OF THE INVENTION
It is an object of the present invention to provide a method for manufacturing a heat-fusion bonding adhesive suitable for obtaining adhesive interlinings which do not degrade the feel of the clothing, maintain shape stability, and demonstrate sufficient draping ability even when the adhesive is used for thin cloths, in particular, thin cloths for women.
Another object of the present invention is to provide a heat-fusion bonding adhesive obtained by such manufacturing method.
Still another object of the present invention is to provide an adhesive fabric obtained by heating and fusing such heat-fusion bonding
Araki Eiichi
Manabe Hiroshi
Nakao Kaichiro
Sugihara Norihiro
Takei Tooru
Boykin Terressa M.
Merchant & Gould P.C.
Sumitomo Seika Chemicals Co. Ltd.
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