Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Woven fabric – Strand material is composed of two or more polymeric...
Reexamination Certificate
2000-07-14
2004-04-06
Juska, Cheryl A. (Department: 1771)
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Woven fabric
Strand material is composed of two or more polymeric...
C442S076000, C442S086000, C442S088000, C442S200000, C442S201000, C442S289000, C442S311000, C442S361000, C442S363000, C442S364000, C428S057000, C428S058000, C002S275000
Reexamination Certificate
active
06716778
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to a seam formed between when two or more laminates are joined together.
PRIOR ART
High technology apparel garments made of waterproof textile laminates are state of the art. These laminates contain a waterproof, windproof and breathable membrane onto which is laminated at least one textile layer.
The joining together of two textile laminates present a problem if the seam at which the two textile laminates are to be sealed is to be made waterproof. Various methods have been tried. For example, W.L.Gore & Associates has developed a method in which two GORE-TEX® laminates are heat sealed at a seam using a GORE-SEAM® seam sealing tape.
The principles of sealing are well known. Generally, to get a sealed joint or a seam, a sealant, an energy source, and structural joining are required. There are a number of prior art methods which demonstrate this. The sealants available are numerous and can be added to the laminates or are part of the native materials. The energy sources which can be used for sealing are numerous and include, but are not limited to heated tools, radio frequency, thermal impluse, and ultrasonic welding methods. Under the proper conditions structural joining of the textile laminates will take place and a joint or seam will be formed.
The prior art discloses a number of seam-forming methods involving the fusion of a thin strip of thermoplastic material to bind two layers of textile materials together and thus form a seam. These are disclosed, for example, in U.S. Pat. No. 3,387,307 (Blatz) assigned to Handgards, Inc. A similar method is taught in GB-A-1 465 343 in which a thin thermoplastic strip is placed between two fabric pieces to form the seam. The use of this method results in a stiff seam being formed between the two fabric pieces.
Other prior art is known in which the laminates are adhered together using adhesives. European Patent EP-B-0 345 730 (Kleis) assigned to W.L.Gore & Associates GmbH teaches the use of adhesive beads to produce the seams in a glove or other clothing application. Glove insert products made according to this invention are available from W.L.Gore & Associates GmbH in Feldkirchen, Germany, under the trade mark DIRECT GRIP®. In order to ensure absolute waterproofness of the seams, it is necessary for the adhesive to penetrate the whole depth of the textile layer up to the membrane. In particular for voluminous textile layer, the seams have to be glued over a wide area. The seams thus produced are strong but relatively stiff and uncomfortable.
U.S. Pat. No. 5,003,902 describes a seam construction for use on protective clothing which involves overlapping the fabric pieces and bonding them together by use of a melt-adhesive film between them. A liquid-proof thread is sewn through the overlap in order to secure the two pieces of fabric to each other. The completed seam is then heated to melt-bond the adhesive film to the fabric pieces and to seal any apertures left by the sewing thread. The seams produced according to the teachings of this patent are also strong but relatively stiff and therefore uncomfortable to the wearer.
One of the problems encountered with these prior art seam sealing methods for waterproof laminates is that the seams have had to be fairly wide in order to ensure that the seams are waterproof. This results in a stiff seam which reduces the comfort of the garment to the wearer. In, for example, sock or glove applications, the width and/or the stiffness of the seams is particularly noticeable. Some attempts have been made at producing narrower seams. However, these have not been durably waterproof or softer because of the added sealant material.
It has been possible with prior art methods to construct narrower seams which are waterproof and flexible. However, these seams have proven to be weak in the transverse, i.e. cross-seam, direction. This weakness results in a lack of durable waterproofness.
U.S. Pat. No. 3,625,790 (Ayres) teaches a glove made of a non-breathable laminate of an elastic fabric and a thermoplastic layer. Two pieces of a laminate are welded together to form a glove in which the seams are formed by fusion of the thermoplastic layers using dielectric heating means. The use of electromagnetic waves at radio frequencies to form seams limited to those materials textiles which incorporate materials having dipolar molecules, such as polyvinyl chloride (PVC) or some polyurethanes (PU). This insert seam while flexible is not very strong. Particularly in manufacturing processes this is a severe disadvantage since the textile laminates have to be handled carefully in order to avoid damage.
Further prior art known to the inventors includes U.S. Pat. No. 4,545,841 (Jackrel) which teaches an insert that is formed by heat sealing and U.S. Pat. No. 5,036,551 (Dailey) which teaches a glove that is formed by heat sealing a laminate. In both these examples, the insert seam while flexible is not very strong.
The problem with the prior art examples in which sealant material is added to form the seam is that the seam whilst strong is not flexible, i.e. they feel stiff to the wearer. The use of these seams is thus limited because of the discomfort to the wearer, especially in those applications in which a close fit is required.
The problem with the prior art examples in which the sealant material is supplied from the native material is that the seams whilst flexible are weak. The use of these seams is limited because of durability in tough applications and, particularly in manufacturing processes this is a severe disadvantage since the textile laminates in which such seams are incorporated have to be carefully handled in order to avoid damage.
Further problems with prior art seams, such as those made from polyamide or polyester is that these materials tend to shrink when these materials are heated to their melt points. This causes the laminates to deform.
There is therefore a need for a strong, durable and flexible seam for tough end uses and close fitting applications.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to improve the comfort of the seams in garments made of waterproof laminates.
It is furthermore an object of this invention to reduce the width of the seams in garments made of waterproof laminates.
It is therefore an object of this invention to produce long-lasting, durable seams in garments made of waterproof laminates.
It is furthermore an object of the invention to provide seams which are both strong and flexible.
It is furthermore an object of the invention to provide seams which are strong in the transverse (cross-seam) directions.
A further object of the invention is to provide seams which have a low shrinkage.
A further object of the invention is to provide seams which have a high stretch.
It is preferred that the laminates from which the seams are to be made are breathable, i.e. water vapour permeable.
These and other objects of the invention are solved by providing a laminate with a waterproof and preferably breathable functional layer on which is laminated a second textile layer comprising at least a first component and a second component, preferably in the form of a conjugate fibre. The first component is made of a material which is stable to a first temperature and the second component is made of a material which melts at a second temperature. The first temperature is higher than the second temperature. Such a laminate can be supplied with energy, e.g. by heating, to reach a temperature higher than the second temperature but lower than the first temperature. The second component melts and provides sealant material (adhesive) for joining the laminate to another substrate or a laminate.
Both the first component and the second component participate in the structural joint. The second component encapsulates the first component whilst the first component remains stable. The second component provides the waterproof barrier and the first component provides structure and strength to the seam.
Using these laminates, it is not necessary to use
Befumo Jenna Leigh
Boland Kevin J.
Juska Cheryl A.
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