Welded microseam

• US 20060165939A1
• Filed: 06/24/2004
• Published: 07/27/2006
• Est. Priority Date: 06/27/2003
• Status: Abandoned Application

• Current Assignee: Martin Hottner
• Original Assignee: Martin Hottner
• Inventors: Hottner, Martin
• Application Number:
  US10/561,887
• Publication Number:
  US 20060165939A1
• Time in Patent Office: Days
• US Class Current: 428/57
• CPC Class Codes: A41D 27/24 Hems; Seams
• CPC Class Codes: A41D 27/245 made by welding or gluing joining of plastics by welding or gluing B29C65/00; sewing machines for concurrently making thread and welded seams D05B17/00; thermal or chemical fixing of seams and hems D06M
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/10 using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/5021 being multi-layered
• CPC Class Codes: B29C 65/5042 covering both elements to be joined
• CPC Class Codes: B29C 65/62 Stitching
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• CPC Class Codes: B29C 65/7443 by means of ultrasonic vibrations
• CPC Class Codes: B29C 66/03242 of sheets being positioned in abutment, e.g. after folding open of an overlap joint
• CPC Class Codes: B29C 66/0384 the coating material being in tape, strip or band form joining using adhesive tapes covering both elements to be joined B29C65/5042
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/13 Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
• CPC Class Codes: B29C 66/133 Fin-type joints, the parts to be joined being flexible the parts to be joined being rigid B29C66/1312
• CPC Class Codes: B29C 66/135 Single hemmed joints, i.e. one of the parts to be joined being hemmed in the joint area
• CPC Class Codes: B29C 66/20 particular design of the joint lines, e.g. of the weld lines
• CPC Class Codes: B29C 66/221 : being in the form of a sinusoidal wave B29C66/2272 takes precedence
• CPC Class Codes: B29C 66/223 : being in the form of a triangle wave or of a sawtooth wave, e.g. zigzagged
• CPC Class Codes: B29C 66/301 : Three-dimensional joints, i.e. the joined area being substantially non-flat B29C66/5223, B29C66/5224, B29C66/5225 take precedence
• CPC Class Codes: B29C 66/43 : Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/431 : Joining the articles to themselves B29C66/4322 and B29C66/4332 take precedence
• CPC Class Codes: B29C 66/435 : Making large sheets by joining smaller ones or strips together
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/712 : the composition of one of the parts to be joined being different from the composition of the other part
• CPC Class Codes: B29C 66/721 : Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/72341 : for gases
• CPC Class Codes: B29C 66/72343 : for liquids
• CPC Class Codes: B29C 66/727 : being porous, e.g. foam
• CPC Class Codes: B29C 66/729 : Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/7294 : Non woven mats, e.g. felt
• CPC Class Codes: B29C 66/73115 : Melting point
• CPC Class Codes: B29C 66/73116 : of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/83413 : cooperating rollers, cylinders or drums
• CPC Class Codes: B29C 66/91411 : of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
• CPC Class Codes: B29C 66/919 : characterised by specific temperature, heat or thermal flux values or ranges specific electrical resistance values B29C66/81262
• CPC Class Codes: B29C 66/91931 : in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
• CPC Class Codes: B29C 66/91935 : lower than said fusion temperature
• CPC Class Codes: B29K 2001/00 : Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
• CPC Class Codes: B29K 2021/00 : Use of unspecified rubbers as moulding material
• CPC Class Codes: B29K 2023/00 : Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2023/10 : Polymers of propylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2027/12 : containing fluorine
• CPC Class Codes: B29K 2027/18 : PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2033/08 : Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
• CPC Class Codes: B29K 2061/00 : Use of condensation polymers of aldehydes or ketones or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/006 : PBT, i.e. polybutylene terephthalate
• CPC Class Codes: B29K 2069/00 : Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 : Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/085 : Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2223/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2313/00 : Use of textile products or fabrics as reinforcement B29K2105/06 takes precedence
• CPC Class Codes: B29K 2995/0069 : non-permeable
• CPC Class Codes: B29K 2995/0092 : hydrophilic
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2031/485 : Jackets
• CPC Class Codes: B32B 2262/0253 : Polyolefin fibres
• CPC Class Codes: B32B 2262/0261 : Polyamide fibres
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2262/04 : Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2327/18 : PTFE, i.e. polytetrafluoroethylene
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/322 : comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D04H 1/5412 : sheath-core
• CPC Class Codes: D04H 1/5414 : side-by-side
• CPC Class Codes: D04H 1/5418 : Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/549 : Polyamides
• CPC Class Codes: D04H 1/55 : Polyesters
• CPC Class Codes: D04H 1/559 : the fibres being within layered webs
• CPC Class Codes: D04H 13/00 : Other non-woven fabrics
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 428/19 : Sheets or webs edge spliced or joined

Abstract

The invention discloses a welded seam (80) between the two edges of two laminates (1a, 1b), each laminate comprising a waterproof functional layer (50) and a textile layer (30). The textile layer (30) comprising a first component and a second component, the first component being stable to a first temperature and the second component melting at a second temperature. The seam (80) is formed by the melted second component and the non-melted first component of the textile layers of each laminate and the edges are in a substantially edge-to-edge buttes orientation to each other. In this case a waterproof, durable seam with very small dimensions is created.

Claims

1. A method of joining at least two pieces of waterproof laminate by forming a welded seam (80), said method comprising:

a) providing at least two waterproof laminates (1a, 1b), each of said laminates comprising at least a waterproof functional layer (50) laminated to a textile layer (30), said textile layer (30) comprising at least a first component and a second component, the first component being stable to a first temperature and the second component melting at a second temperature, wherein the first temperature is higher than the second temperature, and each of said laminates having at least one edge (60a, 60b);

b) placing the at least two laminates together so that the textile layers contact one another and at least one of the edges (60a) of one of the laminates (1a) is aligned with at least one of the edges (60b) of at least one other laminate (1b) to form an edge area (65);

c) welding and pressing said edge area (65) together at a temperature within the melting range of the second component and below the first temperature such that the second component melts and forms a seam between the pieces;

d) cutting the seam allowance; and

e) welding and pressing the seam together to reorient the said edges of the at least two laminates in an edge-to-edge butted orientation.

2. Method according to claim 1, wherein step c) and step d) are carried out simultaneously.

3. Method according to claim 1, wherein the second component is meltable at a temperature in the range of from 160°

C. to 230°

C.

4. Method according to claim 1, wherein the first component is stable to a temperature of at least 180°

C.

5. Method according to claim 1, wherein the difference in temperature between the first temperature and the second temperature is at least 20°

C.

6. Method according to claim 1, wherein step c) and e) are carried out at the same temperatures.

7. Method according to claim 1, wherein step c) is carried out at a temperature in the range of from 160°

C. to 230°

C.

8. Method according to claim 1, wherein step e) is carried out at a temperature of 160°

C. to 230°

C.

9. Method according to claim 1, wherein step c) and step e) are carried out using ultrasonic energy.

10. Method according to claim 1, wherein step c) and step e) are carried out in an continuous process.

11. Method according to claim 1, wherein the functional layer (50) is made from expanded polytetrafluoroethylene (PTFE).

12. Method according to claim 1, wherein the seam (80) is reinforced by at least one reinforcement.

13. Method according to claim 12, wherein the reinforcement is selected from the group of materials comprising tapes, threads, textile laminates.

14. Method according to claim 13, wherein the reinforcement is selected from the group of threads comprising at least one component melting at a temperature in the range of from 160°

C. to 230°

C.

15. A welded seam (80) between at least two pieces of waterproof laminate (1a, 1b), said seam is obtainable by the method according to claim 1.

16. An article comprising a plurality of pieces of waterproof laminate and having at least one welded seam (80) between at least two of said pieces produced by the method according to claim 1.

17. A combination of at least a first laminate (1a) having a first edge (60a) and a second laminate (1b) having a second edge (60b) joined together at a welded seam (80) in an edge area (65),

each of said laminates comprising:

a first layer (50) comprising a waterproof functional layer and

a second textile layer (30) laminated to said first layer (50) and comprising at least a first component and a second component,

the first component being stable to a first temperature and the second component melting at a second temperature, wherein the first temperature is higher than the second temperature,

wherein the seam (80) is formed by the melted second component and the non-melted first component of the textile layers of each laminate, and the first edge (60a) is oriented to the second edge (60b) in a substantially edge-to-edge butted orientation.

18. The combination of claim 17, wherein each of the laminates (1a, 1b) has a laminate-thickness and the welded seam (80) has a seam-thickness wherein said seam-thickness is substantially equal to than the laminate-thickness.

19. The combination of claim 17, wherein the welded seam (80) is substantially non-linear.

20. The combination of claim 17, wherein the welded seam (80) is in the form of at least one curvature to form a three-dimensional combination.

21. The combination of claim 17, wherein the welded seam (80) is reinforced by at least one reinforcement.

22. The combination of claim 21, wherein the reinforcement is selected from the group of materials comprising tapes, threads, textile laminates.

23. The combination of claim 22, wherein the reinforcement is selected from the group of threads having at least one component melting at a temperature in the range of from 160°

C. to 230°

C.

24. The combination of claim 17, wherein the second component is meltable at a temperature in the range of from 160°

C. to 230°

C.

25. The combination of claim 17, wherein the first component is stable to a temperature of at least 180°

C.

26. The combination of claim 17, wherein the difference between the first temperature and the second temperature is at least 20°

C.

27. The combination of claim 17, wherein the seam (80) withstands a water entry pressure of at least 0.07 bar.

28. The combination of claim 17, wherein the seam (80) withstands a water entry pressure of at least 0.13 bar.

29. The combination of claim 17, wherein the seam (80) has a width less than 0.25 cm.

30. The combination of claim 17, wherein the second textile layer (30) is composed of a plurality of yarns in the form of strands, filaments, threads or fibers.

31. The combination of claim 30, wherein at least one yarn has a bi-component structure comprising the first component and the second component.

32. The combination of claim 31, wherein the yarn has a sheath-core structure, with the second component forming the cover.

33. The combination of claim 31, wherein the yarn has a “

side-by-side”

structure.

34. The combination of claim 17, wherein the second layer (30) is a knitted, woven or non-woven textile layer.

35. The combination of claim 17, wherein the first component is selected from the group of polymers comprising polyester, polyamide, cellulose or protein fibers.

36. The combination of claim 17, wherein the first component is polyamide 6.6.

37. The combination of claim 17, wherein the second component is a thermoplastic.

38. The combination of claim 17, wherein the second component is selected from the group of thermoplastics comprising co-polyester, polyamide, co-polyamide and polyolefin.

39. The combination of claim 17, wherein the second component is a polypropylene.

40. The combination of claim 17, wherein the second component is a polyamide 6.

41. The combination of claim 17, wherein the second component is melted using ultrasonic energy.

42. The combination of claim 17, wherein the seam (80) is formed continuously.

43. The combination of claim 17, wherein the functional layer (50) is a membrane or a film.

44. The combination of claim 17, wherein the functional layer (50) is selected from the group of materials consisting of polyesters, polyamides, polyolefins, polyvinylchloride, polyketones, polysulfones, polycarbonates, fluoropolymers, polyacrylates, polyurethanes, co-polyetheresters, and co-polyetheramides.

45. The combination of claim 17, wherein the functional layer (50) is made from expanded polytetrafluoroethylene (PTFE).

46. Articles of clothing made from the combination of claim 17.

47. The combination of claim 21, wherein said at least one reinforcement comprises a seam tape comprising an adhesive tape.

48. The combination of claim 21, wherein said at least one reinforcement comprises a seam tape comprising a textile tape.

49. The combination of claim 21, wherein said at least one reinforcement comprises a seam tape comprising a laminate tape.

50. The combination of claim 21, wherein said at least one reinforcement comprises a seam tape comprising a waterproof tape.

51. The combination of claim 21, wherein said at least one reinforcement comprises a seam tape comprising a thermoplastic film.

52. The combination of claim 21, wherein said at least one reinforcement comprises a seam tape having a width of 10 mm or less.

53. The combination of claim 21, wherein the at least one reinforcement comprises a seam tape comprising a laminate of a woven bi-component textile layer, a functional layer and a knitted bi-component textile backer layer.

54. The combination of claim 21, wherein said reinforcement comprises a seam tape comprising a knit band.

55. An article comprising at least a first laminate and a second laminate joined together at a welded seam, each of said laminates comprising a first layer comprising a waterproof functional layer and a second textile layer laminated to said first layer, and

wherein the welded seam is reinforced by at least one reinforcement comprising a seam tape oriented over the welded seam and contacts a position of said first laminate and said second laminate.

56. The article of claim 55, wherein the welded seam has a width of 0.25 mm or less.

57. The article of claim 55, wherein the seam tape comprises an adhesive tape.

58. The article of claim 55, wherein the seam tape comprises a textile tape.

76. The article of claim 55, wherein the seam tape comprises a laminate tape.

77. The article of claim 55, wherein the seam tape comprises a waterproof tape.

61. The article of claim 55, wherein the seam tape comprises a thermoplastic film.

62. The article of claim 55, wherein the seam tape has a width of about 10 mm or less.

63. The article of claim 55, wherein the at least one reinforcement comprises a seam tape comprising a laminate of a woven bi-component textile layer, a functional layer and a knitted bi-component textile backer layer.

64. The article of claim 55, wherein the seam tape has a width of about 8 mm.

65. The article of claim 55, wherein the seam tape has a width of about 6 mm.

66. The article of claim 55, wherein said reinforcement comprises a seam tape comprising a knit band.

67. The article of claim 55, wherein said article has a water entry pressure of 0.007 bar or greater.

68. The article of claim 55, wherein said article has a water entry pressure of 0.13 bar or greater.

69. The article of claim 55, wherein said article has a water entry pressure of 0.2 bar or greater.