GB1568404A

GB1568404A - Method of manufacturing a laminated fabric

Info

Publication number: GB1568404A
Application number: GB11555/76A
Authority: GB
Original assignee: MYOTT J
Current assignee: MYOTT J
Priority date: 1977-03-11
Filing date: 1977-03-11
Publication date: 1980-05-29

Description

(54) METHOD OF MANUFACTURING A LAMINATED FABRIC (71) I, JOHN PATRICK MYOTT, a British Subject, of "Pine Lodge", 108/110 Bramfield Road, Bulls Green, Datchworth, Hertfordshire and ALBERT ROBBINS, a British Subject, of Salburton, Dedworth, Oakley Green, Windsor, Berkshire, do hereby declare this invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention concerns a method of manufacturing a composite fabric, and more particularly a fabric comprising a layer of textile material, having a polyurethane film layer bonded on one side thereof, so as to render the textile material substantially waterproof and/or to provide a substantially continuous and substantially impervious surface layer thereover.

Various proposals have hitherto been made for connecting together textile and polyurethane film layers: usually such proposals involve the use of an adhesive between the layers, or the provision between the layers of a polyurethane foam lamina, the combining being effected by flamebonding which involves subjecting the polyurethane foam to the heat of a flame to form an adhesive.

The present invention is based upon the appreciation that with the use of appropriate techniques, the combination of a textile material layer with a polyurethane film layer can be effected in a very simple and convenient manner without providing an adhesive or a polyurethane foam layer therebetween, so that one obtains the advantages, inter alia: (a) that the cost of effecting the combination is considerably less expensive than the prior known methods; (b) that there is no risk of .causing the formation of tiny holes, like pinholes, through the film, which risk is particularly prevalent where molten foam is used as adhesive; and (c) that there is no possibility of there being, between the film and the textile layer, a stratum which can retain moisture and promote bacteria growth, as is the case where molten foam is used as adhesive.

Pursuant hereto, the present invention provides a method of making a laminate comprising a textile fabric layer bonded to one side of a polyurethane film layer characterised in that the two layers are brought together and are subjected to heat and pressure by a heated roller or drum such that the film layer is fused and thereby bonded to the textile fabric without the use of adhesive.

Where the laminate consists solely of the fabric layer with the film layer bonded to one side thereof, a release paper is advantageously provided between the film layer and the heated roll or drum, thereby to ensure that the film does not contact the roll or drum.

The laminate may, however, further include a second textile fabric layer bonded to the side of the film remote from the firstmentioned layer, so that said laminate is in a form of a sandwich comprising the two textile fabric layers with the film therebetween and fused to both said textile fabric layers.

In carrying the method of the invention into effect, a web of transfer-printing paper may be supplied to the textile fabric layer or one of the textile fabric layers so that the heat and pressure applied to the fabric at the heated roll or drum effects printing of the outer surface of the fabric layer.

The invention will be described further, by way of example, with reference to the accompanying drawings, which illustrate various preferred practical methods of carrying the invention into effect, it being understood that modifications may be made to the details given herein.

In the drawings: Fig. 1 is a diagrammatic part-sectional elevation illustrating a first way of carrying the invention into effect, substantially in its simp lest form; a single fabric web having a film laminated thereto; Fig. 2 is a fragmentary view, comparable with Fig. 1, but showing a modification in which the resultant laminated fabric is rolled up together with a release paper web which is used in connected with the laminating; Fig. 3 is a fragmentary view similar to Fig.

2, but illustrating another modification of the Fig. 1 method, in which modification the fabric is printed simultaneously with the laminating thereof; Fig. 4 is a fragmentary view similar to Figs.

2 and 3, but illustrating a modification of the Fig. 3 method, in which modification the resultant printed laminated fabric is rolled up together with the release paper in the same way as in the Fig. 2 method; Fig. 5 is a fragmentary view similar to Figs.

2, 3, and 4, but illustrating another modification of the Fig. 1 method, in which modification two fabric webs are laminated together; Fig. 6 is a fragmentary view similar to Figs.

2 to 5, but illustrating a modification of the Fig. 5 method, in which modification the use of a release paper is dispensed with; and Fig. 7 is a view similar to Figs. 2 to 6, but illustrating a modification of the Fig. 5 method, in which modification the fabric is printed simultaneously with the laminating thereof, in the same way as in the method of Figs. 3 and 4.

For carrying the invention into effect in all the methods illustrated in the drawings, use is made of a heated driven calender roller 10 around which is a pressure blanket 11, guide rollers 12, 13, 14, 15 and 16, a guide element 17 and smoothers 18 and 19 being provided to enable webs, drawn from respective supply reels (as will be described later), to be supplied to the calender roller 10, to travel around the latter. A further guide element 20, and guide rollers 21, 22, 23 and 24 serve to guide the webs, upon doffing from the calender roller 10, to pass to one or more wind-up rollers as will be described later.An appropriate mechanism, illustrated diagrammatically at 25, and acting for example on the guide elements 17 and 20, with the opposite ends of the blanket 11 being connected to the guide elements 17, 20, enables the pressure applied by the blanket 11 to be adjusted; the temperature of the calender roller 10 is adjustable; and the peripheral speed of the calender roller loins adjustable.

For performing the method of the invention substantially in its simplest form, as shown in Fig. 1, three supply reels are employed, these being respectively a reel 26 of a continuous web of silicone-coated release paper, a reel 27 of polyurethane film and a reel 28 of textile fabric, e.g. a woven or knitted fabric of man-made fibres, such as nylon tricot. The paper web 29 from the reel 26 is fed to the calender roller 10 so as to abut the outer curved surface of the latter. In turn, the polyurethane film 30 from the reel 27 is fed so as to abut against the release paper web 29, so that the paper web 29 is disposed between the film 30 and the outer surface of the roller 10.The textile fabric 31 from reel 28 moves to the roller 10 so as to contact the film 30 at its side remote from the release paper 29; thus, the fabric 31 passes to between the pressure blanket 11 of the apparatus and the film 30.

The temperature of the calender roller 10 and the speed of the latter, as well as the pressure applied by the blanket 11 are so chosen, according to the thicknesses of the fabric 31, the film 30 and the paper 29, and the nature of the fabric 31, that the film 30 is heated sufficiently to fuse it and cause it to become bonded to the fabric 31. After passing from the calender roller 10, the resultant assembly consisting of the paper 29 and the fabric/film laminate 32 are separated and the laminate 32 is guided over a sufficiently long path for the fused film 30 in the laminate to cool and solidify. The paper 29 and the laminate 32 are, thereupon, rolled up on separate wind-up reels 33, 34 respectively, the guide roller pair 22, 23 serving to ensure that the rewound paper web 29 is smooth so as to be suitable for reuse.

The fabric/film laminate 32 is substantially waterproof and can be employed in various practical environments. For example, it may simply be used as a waterproof fabric for making up into garments, such as shower-proof coats, overalls, and the like, in which case the film layer will probably not be visible in the finished garment, although it may be provided on the outside in some instances, for example in so-called "wetlook" garments. The film may, on the other hand, constitute an outer or finish surface of the fabric, the latter being used, for example, in the manufacture of articles normally made out of leather or imitation leather.

As already mentioned, the pressure applied by the blanket 11, the temperature of the calender roller 10 and the speed of the roller 10 are appropriately adjusted or selected to obtain proper fusing of the film 30 and bonding thereof to the fabric 31. These perameters may be, for example, in the following ranges:- Calender roller temperature: 100"C to 240"C: pressure applied to the fabric/film assembly passing around the roller 10: up to 50 lbs per square inch; and calender roll speed: such as to provide for the fabric/film assembly to remain in contact therewith for a period in the range 10 seconds to 60 seconds. In a typical example, the calender roller temperature is 210 C, the applied pressure is 40 Ibs per square inch, and the period of contact with the calender roller 10 is 20 to 25 seconds.

Figs. 2 to 7 of the drawings illustrate vari ous modifications of the above-described method conforming to the invention, and in all of these figures similar reference numerals have been allocated to similar parts.

In Fig. 2, the release paper 29, the film 30 and the fabric 31 are all fed to the roller 10 in the same way as in Fig. 1. After fusing together of the film 30 and the fabric 31, the resultant laminate 32, instead of being separated from the paper 29, is maintained in contact with the latter so that the laminate 32 and paper 29 are wound up together as a single reel (not shown). The laminate is allowed to set in this condition, rolled up with the paper which can be left in place or removed by a rewinding operation, as may be dictated by the subsequent use of the laminate 32.

Fig. 3 illustrates another modification of the method of Fig. 1. In this, an additional web 50 of pattern-transfer paper, printed with a pattern in sublimable dyestuffs, is supplied to the roller 10 so as to pass thereto over the guide element 17 and pass around the roller 10 in contact with the outer surface of the fabric 31, between the latter and the blanket 11. Both the release paper 29 and the spent pattern-transfer paper (indicated at 51) are separated from the resultant fabric/film laminate (indicated at 52) as the latter leaves the roller 10. It will readily be understood that with this modification, the fabric 31 is transfer printed at the same time as being laminated to the polyurethane foam film 30.

Fig. 4 illustrates, diagrammatically, the method of Fig. 2 also modified for the fabric 31 to be simultaneously transfer printed in the same way as in the proposal of Fig. 3.

Thus, in this instance, although the spent pattern-transfer paper 51 is separated from the resultant fabric/film laminate 52, the release paper 29 is not so separated and the resultant assemblage of laminate and release paper with the fabric printed, is reeled up.

Re-reeling and/or separating of the release paper, can then be effected later as may be desired.

The method illustrated by Fig. 5 represents yet a further modification of the basic method of Fig. 1. In this instance, however, a second fabric web 60 is also supplied to the roller 10, and the film 30 serves to bond the two fabric webs 31 and 60 together. Accordingly, the web 60 is supplied, from a respective reel (not shown) to reach the roller 10 between the film 30 and the release paper 29.

As with the Fig. 1 proposal, the release paper 29 is separated from the resultant laminate (indicated here by the numeral 61) as the latter leaves the roller 10, but of course the arrangement could be such that the laminate 61 and the paper 29 are reeled up together in the same way as illustrated in Fig. 2.

Turning now to Fig. 6, this illustrates the use of the method of the invention to laminate together two fabric webs 31 and 60 in the same way as in Fig. 5. In this instance, however, no release paper 29 is used, care being taken to ensure that the film 30 does not at any time come into direct contact with the outer curved surface of the roller 10. This can be achieved, for example, by using a film web 30 somewhat narrower than the fabric web 60 and if necessary, subsequently trimming the longitudinal edges of the eventual laminate 61.

Finally, Fig. 7 illustrates the method of Fig.

6 modified by the feeding of a pattern transfer paper web 50 in the same way as has already been described with reference to Figs. 3 and 4, thereby to print the outer surface of the fabric web 31, giving a two-ply fabric laminate 70, from which the spent transfer paper web 51 is separated as it passes from the roller 10, with the fabric web 31 thereof printed on its exposed surface. It will readily be understood that a second pattern transfer paper web (not shown) could be supplied to between the second fabric web 60 and the roller 10 thereby to apply a pattern to the exposed surface of the fabric web 60, and it would be possible then to print only the web 60, in which case the pattern transfer paper web 50 for printing the first fabric web 31 may be omitted.

Other variations are, of course, possible within the scope of the following claims.

WHAT WE CLAIM IS: 1. A method of making a laminate comprising a textile fabric layer bonded to one side of a polyurethane film layer characterised in that the two layers are brought together and are subjected to heat and pressure by a heated roller or drum such that the film layer is fused and thereby bonded to the textile fabric without the use of adhesive.

2. A method as claimed in Claim 1 wherein the textile fabric layer and the film layer are kept out of contact with the heated roller or drum by means of a web of release paper which passes around the roller or drum.

3. A method as claimed in Claim 1 or 2 wherein a second textile fabric layer is supplied to the heated roller or drum so that the two textile fabric layers are bonded together by the polyurethane film.

4. A method as claimed in Claim 1,2 or 3 wherein a pattern transfer paper web is supplied to the heated roller or drum so as to apply a pattern to the said textile fabric layer or the first-mentioned textile fabric layer simultaneously with the bonding of the film thereto.

5. A method as claimed in Claim 3 or Claims 3 and 4 wherein a respective pattern transfer paper web is supplied to the heated roller or drum so as to apply a plya respective pattern to the exposed surface of the second

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Claims

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ous modifications of the above-described method conforming to the invention, and in all of these figures similar reference numerals have been allocated to similar parts.

In Fig. 2, the release paper 29, the film 30 and the fabric 31 are all fed to the roller 10 in the same way as in Fig. 1. After fusing together of the film 30 and the fabric 31, the resultant laminate 32, instead of being separated from the paper 29, is maintained in contact with the latter so that the laminate 32 and paper 29 are wound up together as a single reel (not shown). The laminate is allowed to set in this condition, rolled up with the paper which can be left in place or removed by a rewinding operation, as may be dictated by the subsequent use of the laminate 32.

Fig. 3 illustrates another modification of the method of Fig. 1. In this, an additional web 50 of pattern-transfer paper, printed with a pattern in sublimable dyestuffs, is supplied to the roller 10 so as to pass thereto over the guide element 17 and pass around the roller 10 in contact with the outer surface of the fabric 31, between the latter and the blanket 11. Both the release paper 29 and the spent pattern-transfer paper (indicated at 51) are separated from the resultant fabric/film laminate (indicated at 52) as the latter leaves the roller 10. It will readily be understood that with this modification, the fabric 31 is transfer printed at the same time as being laminated to the polyurethane foam film 30.

Fig. 4 illustrates, diagrammatically, the method of Fig. 2 also modified for the fabric 31 to be simultaneously transfer printed in the same way as in the proposal of Fig. 3.

Thus, in this instance, although the spent pattern-transfer paper 51 is separated from the resultant fabric/film laminate 52, the release paper 29 is not so separated and the resultant assemblage of laminate and release paper with the fabric printed, is reeled up.

Re-reeling and/or separating of the release paper, can then be effected later as may be desired.

The method illustrated by Fig. 5 represents yet a further modification of the basic method of Fig. 1. In this instance, however, a second fabric web 60 is also supplied to the roller 10, and the film 30 serves to bond the two fabric webs 31 and 60 together. Accordingly, the web 60 is supplied, from a respective reel (not shown) to reach the roller 10 between the film 30 and the release paper 29.

As with the Fig. 1 proposal, the release paper 29 is separated from the resultant laminate (indicated here by the numeral 61) as the latter leaves the roller 10, but of course the arrangement could be such that the laminate 61 and the paper 29 are reeled up together in the same way as illustrated in Fig. 2.

Turning now to Fig. 6, this illustrates the use of the method of the invention to laminate together two fabric webs 31 and 60 in the same way as in Fig. 5. In this instance, however, no release paper 29 is used, care being taken to ensure that the film 30 does not at any time come into direct contact with the outer curved surface of the roller 10. This can be achieved, for example, by using a film web 30 somewhat narrower than the fabric web 60 and if necessary, subsequently trimming the longitudinal edges of the eventual laminate 61.

Finally, Fig. 7 illustrates the method of Fig.

6 modified by the feeding of a pattern transfer paper web 50 in the same way as has already been described with reference to Figs. 3 and 4, thereby to print the outer surface of the fabric web 31, giving a two-ply fabric laminate 70, from which the spent transfer paper web 51 is separated as it passes from the roller 10, with the fabric web 31 thereof printed on its exposed surface. It will readily be understood that a second pattern transfer paper web (not shown) could be supplied to between the second fabric web 60 and the roller 10 thereby to apply a pattern to the exposed surface of the fabric web 60, and it would be possible then to print only the web 60, in which case the pattern transfer paper web 50 for printing the first fabric web 31 may be omitted.

Other variations are, of course, possible within the scope of the following claims.

WHAT WE CLAIM IS: 1. A method of making a laminate comprising a textile fabric layer bonded to one side of a polyurethane film layer characterised in that the two layers are brought together and are subjected to heat and pressure by a heated roller or drum such that the film layer is fused and thereby bonded to the textile fabric without the use of adhesive.
2. A method as claimed in Claim 1 wherein the textile fabric layer and the film layer are kept out of contact with the heated roller or drum by means of a web of release paper which passes around the roller or drum.
3. A method as claimed in Claim 1 or 2 wherein a second textile fabric layer is supplied to the heated roller or drum so that the two textile fabric layers are bonded together by the polyurethane film.
4. A method as claimed in Claim 1,2 or 3 wherein a pattern transfer paper web is supplied to the heated roller or drum so as to apply a pattern to the said textile fabric layer or the first-mentioned textile fabric layer simultaneously with the bonding of the film thereto.
5. A method as claimed in Claim 3 or Claims 3 and 4 wherein a respective pattern transfer paper web is supplied to the heated roller or drum so as to apply a plya respective pattern to the exposed surface of the second

textile fabric layer.
6. A method as claimed in Claim 2 wherein the release paper is separated from the fabric/film laminate upon the latter leaving the drum or roller.
7. A method of making a laminate as claimed in any preceding claim wherein the heated roller or drum is maintained at a temperature in the range of 100"C to 2400C, and a pressure of up to 50 Ibs oer square inch is applied to the fabric during its passage around the roller or drum.
8. A method as claimed in claim 7 wherein the drum is heated to 210 C and the applied pressure is approximately 40 Ibs per square inch, the assembly of layers being maintained in contact with the roller or drum for a period of from 20 to 25 seconds.
9. A method of making a laminate substantially as hereinbefore described with reference to and as illustrated in Fig. 1; in Fig. 2; in Fig. 3; in Fig. 4; in Fig. 5; in Fig. 6; or in Fig. 7 of the accompanying drawings.