GB2481289A

GB2481289A - Permanently bonding rubber to fabric

Info

Publication number: GB2481289A
Application number: GB1109713.6A
Authority: GB
Inventors: Hayley Tann
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-06-10
Filing date: 2011-06-10
Publication date: 2011-12-21
Also published as: GB201109713D0; GB201009746D0

Abstract

Ideally silicone rubber is bonded to the fabric of a swimming costume by applying it 1 from a reservoir to regions of the fabric exposed by a stencil 2 clamped 3 to the fabric 4. The rubber may be provided in a vacuum formed mould and the fabric laid on top; or may be brushed on top of a stencil. Preferably the silicone rubber seeps through to the back of the fabric in a controlled way so that there is a portion of it on each side of the fabric and the portions are integrally connected. The rubber may project from the fabric a distance which is governed by the stencil to form a three dimensional pattern. Items such as bead or glitter could be embedded within the rubber or on its surface or the surface can be textured. Rubber could be applied to more delicate materials such as fur. There can be multiple separate formations applied to a single garment differing in terms of volume, area, colour, shape, thickness, surface pattern and/or rubber constituency.

Description

3D SILICON RUBBER BONDING PROCESS ONTO FABRIC Fabric decoration has been around for centuries with a massive market in the fashion and interior industries. Textile printing is the process of applying colour to fabric in definite patterns or designs. However textile printing is oniy coating the surface in a 2D capacity.

Silicon rubber based coating compositions for coating a textile fabric with silicon rubber are used in the industry, e.g., for automobile airbags. However this process is a laminating process which is coated over the whole piece of fabric.

The invention's new process of bonding silicon rubber to fabric in a 3D format creates new ways of decoration in a printing application.

According to a first aspect, the invention may provide a process that permanently bonds silicon rubber onto a variety of fabric.

The process may allow shapes to be different thicknesses in height. The process may provide that the shapes can be strategically placed onto selective parts of the fabric. The process may be applied to swimwear fabric and is waterproof. The process may be applied to delicate fabric, fur, and thicker fabrics using a vacuum forming application process. The process may include changing the colour pigment and/or including a source of glow in the dark pigment.

According to a second aspect, the invention may provide a process for bonding silicon rubber to fabric in a 3D format to create decoration in a printing application.

The process may provide that the shapes have seeped in a controlled way to the back of the fabric and have bonded to the fabric. The process may provide that the fabric is laid over a frame, a clamping system secures a stencil and the silicon rubber is poured through gaps and/or holes in the stencil. The process may provide a vacuum formed mould and that silicon rubber is provided in the mould and the fabric is provided on top. The process may provide that the thickness of the stencil determines the height and the amount poured into the stencil. The process may provide that the height ranges from 2mm up to 1 Onmi or from 1mm up to 10mm.

According to a third aspect, the invention may provide a process for applying a material to a fabric to form a three-dimensional element on the fabric, the method comprising: providing the fabric; positioning a stencil relative to the fabric, the stencil having one or more locations at which the fabric is exposed; introducing a volume of the material to at least one of the one or more locations, the volume of the material forming the three-dimensional element; removing the stencil to leave the three-dimensional element on the fabric.

The process may provide that the material is a silicon rubber. The process may provide that the stencil is positioned on the fabric and then the material is introduced to at least one of the one or more locations. The process may provide that the material is introduced to at least one of the one or more locations and then the fabric is positioned on the stencil. The process may provide that a part of the material passes into the fabric and a part of the material forms the three-dimensional element on a first surface of the fabric. The process may provide that a part of the material passes into and through the fabric to a second surface and a part of the material forms the three-dimensional element on a first surface of the fabric. The process may provide that the part of the material which passes into the fabric and the part of the material forming the three-dimensional element are a unitary piece of material and/or the part of the material which passes into and through the fabric and the part of the material forming the three-dimensional element are a unitary piece of material. The process may provide that a first three-dimensional element is provided and in which a second three-dimensional element is provided. The process may provide that the first and second elements are physically separate pieces of material. The process may provide that the first element has a difference form the second element, the difference being one or more of: the volume of the element; the area of the element; the colour of the element; the shape of the element; the thickness of the element; the surface pattern on the element; the material from which the element is formed; the presence of one or more further materials in the material and/or on the material. The process may provide that one or more items are embedded in the material, such as silicon rubber, and/or in which one or more items are provided on the surface of the material, such as silicon rubber. The process may provide that the items include one or more of buttons, sequins, beads, glitter, pieces of metal. The process may provide that an element is contacted with the exposed surface of the material, such as silicon rubber, to alter the surface of the silicon rubber. The process may provide that the surface is altered by changing the configuration of the surface, for instance by contacting with a textured element to imprint a texture on the surface.

According to a fourth aspect, the invention may provides a process for applying a material to a fabric to form a three-dimensional element on the fabric, the method comprising: providing the fabric; providing a reservoir of the material; transferring a volume of the material from the reservoir to the fabric at one or more locations at which the fabric is exposed.

The process may provide that the material is a silicon rubber. The process may provide that the material is transferred to the fabric using an applicator. The process may provide that the step of transferring a volume of material to the fabric is repeated and there are one or more differences between the steps. The process may provide that the difference is in one or more of: colour, material, content of the material, movement of the applicator, direction of movement of the applicator, pressure applied by the applicator to the fabric, volume of material transferred in the step, the viscosity of the material, the curing time which has passed for the material, the type of applicator used, the surface effect provided in the step. The process may provide that the applicator is a brush. The process may provide that the material transferred in one step is at least partially mixed with the material transferred in an earlier step. The process may provide that the partial mixing provides a pattern in the material and/or on the material. The process may provide that a part of the material passes into the fabric and a part of the material forms the three-dimensional element on a first surface of the fabric. The process may provide that a part of the material passes into and through the fabric to a second surface and a part of the material forms the three-dimensional element on a first surface of the fabric. The process may provide that the part of the material which passes into the fabric and the part of the material forming the three-dimensional element are a unitary piece of material and/or the part of the material which passes into and through the fabric and the part of the material forming the three-dimensional element are a unitary piece of material. The process may provide that a first three-dimensional element is provided and in which a second three-dimensional element is provided. The process may provide that the first and second elements are physically separate pieces of material. The process may provide that the first element has a difference form the second element, the difference being one or more of: the volume of the element; the area of the element; the colour of the element; the shape of the element; the thickness of the element; the surface pattern on the element; the material from which the element is formed; the presence of one or more further materials in the material and/or on the material.

According to a fifth aspect, the invention may provide an item of clothing, the item of clothing being decorated by the process of any of the previous statements or options.

According to a sixth aspect, the invention may provide an item of clothing, the item being provided with a material applied to the item of clothing to form a three-dimensional element on the item of clothing, a part of the material passes into and preferably through, the item to a second surface and a part of the material forming the three-dimensional element on a first surface of the item.

Preferably the item is, at least in part, a fabric item. Preferably a part of the material passes into and preferably through, the fabric to a second surface and a part of the material forms the three-dimensional element on a first surface of the fabric.

The present invention is aimed as a new decorative 3D printing application which permanently bonds RTV Silicon Rubber to fabrics at varying heights with selective compositions onto the fabric.

The bonded combination allows both materials to act as one that is malleable together. The application can be applied to a variety of fabrics; some maybe completed with a slightly different process but still using the same product.

With the RTV Silicon Rubber being a liquid substance, the process has been created and developed to control the application. The ability to print in one or more colours and can be applied in certain parts only and in sharply defined patterns.

The process has been tested to be waterproof and has been applied to swimsuit material.

The technique can also been applied to animal furs and skins however with a slight different application.

Each and all of the aspects of the invention may be combined with any one or more of the features provided for the other aspects of the invention and/or be combined with any one or more of the features, options and possibilities provided in this document.

The invention will be described by way of example and with reference to the accompanying drawings.

Figure 1 shows the side profile of a piece of fabric with the different levels of rubber.

Figure 2 shows another viewpoint looking down to show the different 3D shapes that can be created out of silicon rubber.

Figure 3 shows the back of the fabric the shapes that have seeped in a controlled way, which have bonded to the fabric.

Figure 4 shows the main process of bonding the Silicon Rubber onto fabric.

Number 5 indicates the table/frame number 4 shows the fabric laid over the frame. Number 3 shows the camping system securing the stencil number 2 and number I shows arrows of the direction that the silicon rubber is poured through the gaps/holes of number 2 the stencil.

Figure 5 shows the alternative process for applying the rubber to fabrics such as furs. Number 1 is the vacuum formed mould, number 2 is the Silicon Rubber, number 3 is the fabric on top and no. 4 a flat plate.

Figure 6 is a photograph showing surface details applied to a fabric.

Figure 7 is a photograph showing a pattern formed on the front of a swimsuit.

Figure 8 is a photograph showing a pattern formed on a top.

Figure 9 is a photograph of various elements formed on a fabric.

Figure 10 is a photograph of various elements formed on a fabric.

Figure 4 provides an illustration of a production teclmique. A piece of fabric 4 is positioned on a support, such as a table 5. An adhesive, for example spray mount, is evenly applied to the bottom of the stencil 2. The stencil 2 is placed on the fabric 4 in the desired position. A frame 3 is created and is used to hold the stencil 2 in position on the fabric 4. The frame 3 is then weighted down and clamped to the edge and secured.

The stencil 2 is in the form of one or more wall sections which surround one or more through apertures. The stencil 2 is used to form the shape that the Silicon Rubber will take on the fabric 4. The thickness of the stencil 2 determines the height and the amount poured into the stencil 2 for example ranging from 2mm up to 10mm. The stencil 2 can be made from MDF wood, but more appropriately Perspex or acrylic; it is then laser cut to the required pattern.

Many silicon rubbers can be used, but Tinsel Gel 10 from Polytek Development Corp of 55 Hilton Street, Easton, PA-18042, USA is a preferred option. Platsil Gel 10, also from Polytek, is another preferred option as it has been tested safe for contact with human skin.

The product Tinsil Gel 10 is a room temperature vulcanizing rubber mixed by adding the catalyst supplied with the Tinsil Gel 10 and an additional catalyst, meaning a 50/50 ratio of both catalysts in the ratio of 1/10 of silicon rubber. The additional catalyst may be selected to give the desired curing time, viscosity or other characteristics. A wide variety of such catalysts are available from Dow Corning. It is poured into the through apertures in the stencil 2 and hence onto the outer layer of the fabric 4. By adding the additional catalyst the process of the silicon rubber setting is sped up. It is also given a higher mixed viscosity, therefore allowing more control over the rubber with no seepage onto the material 6 that it isn't required to be on. The right mixture of the two catalysts allows the silicon rubber to absorb into the fabric 4 but not at an excess of the pattern. This prevents bleeding and creates sharply defined patterns or shapes. This method is used with most fabrics such as denims and jersey.

Once the applied silicon rubber has set to the required degree, the frame 3 can be released and the stencil 2 can be removed.

Figures 1, 2 and 3 show simple patterns consisting of two rectangles and two circles.

These shapes stand proud of the fabric 4 and are surrounded by material 6 where no silicon rubber was applied.

Although there are no special restrictions with regard to the type of fabric, a slightly different application process for furs and thinner fabrics, like chiffon, and also thicker fabrics, such as wool is carried out. This involves vacuum forming a stencil 2 to create the mould. Once that is created then RTV Silicone rubber is poured into the mould and then the fabric 4 is laid on top of the liquid rubber until is it set. It is beneficial with thinner fabrics, like chiffon, to use a greater level of catalyst to promote higher initial viscosities and quicker setting times.

The catalyst ratio can stay the same, at 50:50 with the fast catalyst, added to the 1:10 ratio to the Silicon Rubber. To reduce air bubbles, a catalyst formed of only the Tinsil Gel 10 accompanying catalyst at a 1:10 ratio can be used as the curing time is longer allowing more time for the gases to escape. The composition of the catalysts are not fixed and can be adjustable depending on room temperature and the changing curing time.

A variety of colour pigments were sourced from plastic manufacturers that enhance the colour to its best. Glow in the dark pigments can be added to the Silicon Rubber. Other additional features can be added. For instance, it is possible to embed items in the silicon rubber and/or provide items on the surface. Examples include buttons, sequins, beads, glitter, metals and the like to create different effects. It is also possible to contact the exposed surface of the silicon rubber with an element to alter the surface of the silicon rubber. Examples include the use of a textured element to imprint a texture on the silicon rubber surface. Regular and/or irregular patterns and textures can be provided in this way.

A very wide variety of shapes and profiles for those shapes can be constructed on the outside of the fabric. Figure 6 is a photograph of a white jersey fabric upon which various rectangular boxes 10 of silicon rubber have been formed, together with cylindrical elements 12 and recesses 14. Colours, depths, shapes and patterns can be controlled to give a wide variety of products. The various shapes and colours can be deposited in a single stage. It is also possible to deposit the material in a series of stages. For instance, a box 10 may be deposited with a recess 14 in it. In a further stage, a different colour of material may be used to fill the recess, 16, or to give a higher element 18.

Figure 7 is a photograph of a swimsuit 20 which has a pattern formed of dark polygons and lighter polygons in an interlocking pattern.

Figure 8 is a photograph of a top which has a pattern formed of dark polygons provided on top of the fabric in an interlocking pattern. Figures 9 and 10 show further combinations of elements provided on fabrics.

It is also possible for elements to be applied to the fabric in a more free form manner. A piece of fabric 4 is positioned on a support, such as a table 5 and a frame 3 is created and is used to hold the fabric 4 in position. In this instance, a stencil 2 is not needed to control the application of the silicon rubber. However, a stencil 2 could be used to protect one or more areas of the fabric and/or to guide the application of the silicon rubber.

Instead of placing the silicon rubber in the through apertures in the stencil 2, a paint brush or other applicator is used to take an amount of silicon rubber from a container and apply it to the fabric 4. The silicon rubber can be applied by more than one use of the paint brush or applicator as the silicon rubber from different applications combines to form a unitary element. The location and depth of the element can be built up in a more freeform manner in this way. It is also possible to combine different colours or different types of silicon rubber to give further effects. For instance, a base element may have added to it silicon rubber of a different colour before it has set. Different colour layers may be formed. The use of different colours in combination with the movement of the brush or applicator can be used to give swirls, streaks and other patterns in the element formed. A wide variety of painting style effects can be generated in this manner. These include variations in height across the surface of the element, different profiles, colours and textures. Once the silicon rubber has set, these variations become permanent in the element.

Claims

CLAIMS1. A process that permanently bonds silicon rubber onto a variety of fabric.
2. A process that permanently bonds silicon rubber onto a variety of fabric according to claim 1, which allows shapes to be different thicknesses in height.
3. A process that permanently bonds silicon rubber onto a variety of fabric according to claim 1 or claim 2, the shapes can be strategically placed onto selective parts of the fabric.
4. A process that permanently bonds silicon rubber onto a variety of fabric according to claim 1 or claim 2 or claim 3, which can be applied to swimwear fabric and is waterproof.
5. A process that permanently bonds silicon rubber onto a variety of fabric according to claim 1 or claim 2 or claim 3 or claim 4, that can be applied to delicate fabric, fur, and thicker fabrics using a vacuum forming application process.
6. A process that permanently bonds silicon rubber onto a variety of fabric according to claim 1 or claim 2 or claim 3 or claim 4 or claim 5, by changing the colour pigment and/or including a source of glow in the dark pigment.
7. A process for bonding silicon rubber to fabric in a 3D format to create decoration in a printing application.
8. A process according to any preceding claim, in which the shapes have seeped in a controlled way to the back of the fabric and have bonded to the fabric.
9. A process according to any preceding claim, in which the fabric is laid over a frame, a clamping system secures a stencil and the silicon rubber is poured through gaps and/or holes in the stencil.
10. A process according to any of claims 1 to 8, in which a vacuum formed mould, is provided, silicon rubber is provided in the mould and the fabric is provided on top.
11. A process according to any preceding claim, in which the thickness of the stencil determines the height and the amount poured into the stencil.
12. A process according to claim 11 in which the height ranges from 2mm up to 10mm.
13. A process for applying a material to a fabric to form a three-dimensional element on the fabric, the method comprising: providing the fabric; positioning a stencil relative to the fabric, the stencil having one or more locations at which the fabric is exposed; introducing a volume of the material to at least one of the one or more locations, the volume of the material forming the three-dimensional element; removing the stencil to leave the three-dimensional element on the fabric.
14. A process according to claim 13 in which the material is a silicon rubber.
15. A process according to any preceding claim, in which the stencil is positioned on the fabric and then the material is introduced to at least one of the one or more locations.
16. A process according to any preceding claim, in which the material is introduced to at least one of the one or more locations and then the fabric is positioned on the stencil.
17. A process according to any preceding claim, in which a part of the material passes into the fabric and a part of the material forms the three-dimensional element on a first surface of the fabric.
18. A process according to any preceding claim, in which a part of the material passes into and through the fabric to a second surface and a part of the material forms the three-dimensional element on a first surface of the fabric.
19. A process according to claim 17 or claim 18, in which the part of the material which passes into the fabric and the part of the material forming the three-dimensional element are a unitary piece of material and/or the part of the material which passes into and through the fabric and the part of the material forming the three-dimensional element are a unitary piece of material.
20. A process according to any preceding claim in which a first three-dimensional element is provided and in which a second three-dimensional element is provided.
21. A process according to claim 21, in which the first and second elements are physically separate pieces of material.
22. A process according to claim 20 or claim 21, in which the first element has a difference form the second element, the difference being one or more of: the volume of the element; the area of the element; the colour of the element; the shape of the element; the thickness of the element; the surface pattern on the element; the material from which the element is formed; the presence of one or more further materials in the material and/or on the material.
23. A process according to any preceding claim, in which one or more items are embedded in the material, such as silicon rubber, and/or in which one or more items are provided on the surface of the material, such as silicon rubber.
24. A process according to claim 23, in which the items include one or more of buttons, sequins, beads, glitter, pieces of metal.
25. A process according to any preceding claim, in which an element is contacted with the exposed surface of the material, such as silicon rubber, to alter the surface of the silicon rubber.
26. A process according to claim 25, in which the surface is altered by changing the configuration of the surface, for instance by contacting with a textured element to imprint a texture on the surface.
27. A process for applying a material to a fabric to form a three-dimensional element on the fabric, the method comprising: providing the fabric; providing a reservoir of the material; transferring a volume of the material from the reservoir to the fabric at one or more locations at which the fabric is exposed.
28. A process according to claim 27 in which the material is a silicon rubber.
29. A process according to any preceding claim in which the material is transferred to the fabric using an applicator.
30. A process according to any preceding claim, in which the step of transferring a volume of material to the fabric is repeated and there are one or more differences between the steps.
31. A process according to claim 30, in which a difference is in one or more of: colour, material, content of the material, movement of the applicator, direction of movement of the applicator, pressure applied by the applicator to the fabric, volume of material transferred in the step, the viscosity of the material, the curing time which has passed for the material, the type of applicator used, the surface effect provided in the step.33. A process according to any of claims 27 to 31, in which the applicator is a brush.34. A process according to any of claims 27 to 32, in which the material transferred in one step is at least partially mixed with the material transferred in an earlier step.35. A process according to claim 34, in which the partial mixing provides a pattern in the material and/or on the material.36. A process according to any of claims 27 to 35, in which a part of the material passes into the fabric and a part of the material forms the three-dimensional element on a first surface of the fabric.37. A process according to any of claims 27 to 36, in which a part of the material passes into and through the fabric to a second surface and a part of the material forms the three-dimensional element on a first surface of the fabric.38. A process according to claim 36 or claim 37, in which the part of the material which passes into the fabric and the part of the material forming the three-dimensional element are a unitary piece of material and/or the part of the material which passes into and through the fabric and the part of the material forming the three-dimensional element are a unitary piece of material.39. A process according to any of claims 27 to 38, in which a first three-dimensional element is provided and in which a second three-dimensional element is provided.40. A process according to claim 39, in which the first and second elements are physically separate pieces of material.41. A process according to claim 39 or claim 40, in which the first element has a difference form the second element, the difference being one or more of: the volume of the element; the area of the element; the colour of the element; the shape of the element; the thickness of the element; the surface pattern on the element; the material from which the element is formed; the presence of one or more further materials in the material and/or on the material.42. An item of clothing, the item of clothing being decorated by the process of any of claims.1 to 41.43. An item of clothing, the item being provided with a material applied to the item of clothing to form a three-dimensional element on the item of clothing, a part of the material passes into and preferably through, the item to a second surface and a part of the material forming the three-dimensional element on a first surface of the item.44. An item of clothing according to claim 43, in which the item is, at least in part, a fabric item.45. An item according to claim 43 or 44, in which a part of the material passes into and preferably through, the fabric to a second surface and a part of the material forms the three-dimensional element on a first surface of the fabric.