Title: Laminate for wearing apparel and methods for the manufacture of the laminate

What is claimed is:

1. A method for producing a laminate useful in wearing apparel, comprising

(a) selecting in a first selecting step a fibrous web;

(b) selecting in a second selecting step a web of foamed resin;

(c) joining said fibrous web to said foamed resin web to form a pre-laminate; the improvement characterized by

(d) selecting in a third selecting step a resin film web;

(e) adhering said film web to the exposed foam surface of said pre-laminate formed in said joining step by passing said film and said pre-laminate through a pressure nip at elevated temperatures;

(f) creping the said film web in said pressure nip during said adhering step by maintaining said film web, prior to said nip under sufficient tension to elongate said web;

(g) said creping step being carried out by maintaining said pre-laminate web at only enough tension, prior to said nip, to guide said pre-laminate to said nip; and

(h) the pressure in said pressure nip, during said creping step being only at a level to bring the surfaces of said film web and said pre-laminate web together.

2. The method of claim 1, further characterized by

(a) said creping step being carried out at a temperature within the range of between about 265 degrees and 315 degrees F.

3. The method of claim 2, further characterized by

(a) the step of embossing said web from said creping step at elevated pressures.

4. The method of claim 3, further characterized by

(a) said elevated pressure is within the range of between about 100 and 400 pounds per square inch.

5. The method of claim 4, further characterized by

(a) said creping step is carried out at a temperature of 315 degrees F.; and

(b) said embossing step is carried out at a pressure of 200 pounds per square inch.

6. The method of claim 5, further characterized by

(a) said web for said first selecting step is non-woven polyester;

(b) said foam for said second selecting step is polyurethane; and

(c) said film for said third selecting step is polyvinyl chloride.

7. The method of claim 1, further characterized by

(a) said creping step is carried out by maintaining said film web under sufficient tension to produce an elongation thereof of six percent in the resulting laminate.

8. The method of claim 1, further characterized by

(a) said first selecting step is carried out by selecting a non-woven polyester web with a weight within the range of between about 2.5 and 4.5 ounces per square yard.

9. The method of claim 8, further characterized by

(a) said first selecting step is carried out by selecting a non-woven polyester web with a weight of 3.0 ounces per square yard.

10. The method of claim 1, further characterized by

(a) said second selecting step is carried out by selecting a polyurethane web having a thickness within the range of between about 0.10 and 0.03 inches.

11. The method of claim 10, further characterized by

(a) said second selecting step is carried out by selecting a polyurethane web having a thickness of 0.03 inches.

12. The method of claim 1, further characterized by

(a) said third selecting step is carried out by selecting a soft flexible polyvinyl chloride film having a thickness within the range of between about 0.002 and 0.02 inches.

13. The method of claim 12, further characterized by

(a) said third selecting step is carried out by selecting a polyvinyl chloride film having a thickness of 0.006 inches.

14. The method of claim 1, further characterized by

(a) said joining step is by needling carried out with a depth of penetration within the range of between about 0.20 and 0.92 inches.

15. The method of claim 14, further characterized by

(a) said depth of penetration is 0.3 to 0.4 (two barbs) inches.

16. The method of claim 1, further characterized by

(a) said joining step is by needling carried out with a degree of penetration of within the range of between about 200 and 2000 penetrations per square inch.

17. The method of claim 16, further characterized by

(a) said degree of penetration is 550 penetrations per square inch.

18. A laminate for use in wearing apparel, characterized by

(a) a fibrous web;

(b) a synthetic foamed resin web joined to said non-woven fibrous web to form a prelaminate;

(c) the exposed surface of said non-woven fibrous web on said pre-laminate being napped to form the internal surface of wearing apparel formed therefrom.

(d) a resin film web adhered to the exposed foam surface of said pre-laminate; and

(e) the exposed surface of said film web being creped.

19. The laminate of claim 18, further characterized by

(a) said creped film surface having an embossed pattern superimposed thereover.

20. The laminate of claim 18, further characterized by

(a) said fibrous web is non-woven polyester.

21. The laminate of claim 18, further characterized by

(a) said synthetic foamed resin web is polyurethane.

22. The laminate of claim 18, further characterized by

(a) said film is polyvinyl chloride.

23. The laminate of claim 20, further characterized by

(a) said non-woven polyester web has a weight within the range of between about 2.5 and 4.5 ounces per square yard.

24. The laminate of claim 23, further characterized by

(a) said non-woven polyester web has a weight of 3.0 ounces per square yard.

25. The laminate of claim 21, further characterized by

(a) said polyurethane web has a thickness within the range of between about 0.10 and 0.03 inch.

26. The laminate of claim 25, further characterized by

(a) the thickness of said polyurethane web is 0.03 inch.

27. The laminate of claim 23, further characterized by

(a) said polyvinyl chloride film has a thickness within the range of between about 0.002 and 0.02 inch.

28. The laminate of claim 27, further characterized by

(a) said polyvinyl chloride film has a thickness of 0.006 inch.

29. The laminate of claim 18, further characterized by

(a) said pre-laminate is joined together by needling with a density of penetration of within the range of between about 200 and 2000 penetrations per square inch.

30. The laminate of claim 29, further characterized by

(a) said density of penetration is 550 penetrations per square inch.

31. The laminate of claim 18, further characterized by

(a) said pre-laminate is joined together by needling at a depth of penetration of between the range of between about 0.20 and 0.92 inch.

32. The laminate of claim 31, further characterized by

(a) said depth of penetration is 0.3 to 0.4 (two barb) inch.

Other info:


Inventors: Hill, Charles E. (Coshocton, OH)

Application Number: 06/452222
Filing Date: 1982-12-22
Publication_date: 1984-03-06
Assignee: BECTON DICKINSON CO (US)

Primary Class(es): 428/91 156/220, 428/319.700, 428/219, 156/196, 428/213, 428/15
Other Classes: A41D31/02; B32B37/14; B32B38/04; B32B38/06; A41D31/00; B32B33/00; B32B3/26
US Patent Ref:

3810808	May, 1974	Anderson	428/304.4
3956783	May, 1976	Stoller	428/91	Mattress
4305985	December, 1981	Heublein	428/91	Wall covering material

Other Refs:
Primary Examiner: Van, Balen William J.
Assistant Examiner:
Attorney: Grindle, Robert P.