FABRIC HAVING A THERMOPLASTIC FUSIBLE YARN, PROCESS OF MAKING A FABRIC CONTAINING A THERMOPLASTIC FUSIBLE YARN, AND FABRIC ARTICLE FORMED WITH A FABRIC CONTAINING A THERMOPLASTIC FUSIBLE YARN

• US 20090068908A1
• Filed: 09/11/2008
• Published: 03/12/2009
• Est. Priority Date: 09/12/2007
• Status: Abandoned Application

• Current Assignee: Maidenform Incorporated (Hanesbrands Incorporated)
• Original Assignee: Maidenform Incorporated (Hanesbrands Incorporated)
• Inventors: HINCHCLIFF, MARIA
• Application Number:
  US12/208,481
• Publication Number:
  US 20090068908A1
• Time in Patent Office: Days
• US Class Current: 442/181
• 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 65/02 by heating, with or without pressure
• 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 66/43 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 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/729 Textile or other fibrous material made from plastics
• CPC Class Codes: B29K 2023/00 Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2067/00 Use of polyesters 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 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2313/00 Use of textile products or fabrics as reinforcement B29K2105/06 takes precedence
• CPC Class Codes: B29K 2995/0046 Elastic
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/4871 Underwear
• CPC Class Codes: B29L 2031/4885 Brassieres
• CPC Class Codes: B32B 2038/008 Sewing, stitching
• CPC Class Codes: B32B 2262/0215 : Thermoplastic elastomer fibers
• CPC Class Codes: B32B 2437/00 : Clothing
• CPC Class Codes: B32B 2459/00 : Nets, e.g. camouflage nets
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D03D 15/283 : synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/56 : elastic
• CPC Class Codes: D03D 15/587 : adhesive; fusible
• CPC Class Codes: D04B 1/16 : synthetic threads
• CPC Class Codes: D04B 21/16 : incorporating synthetic threads
• CPC Class Codes: D10B 2321/021 : polyethylene
• CPC Class Codes: D10B 2321/022 : polypropylene
• CPC Class Codes: D10B 2321/04 : polymers of halogenated hydrocarbons
• CPC Class Codes: D10B 2331/02 : polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 : polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2331/10 : polyurethanes
• CPC Class Codes: D10B 2401/041 : thermoplastic; thermosetting
• CPC Class Codes: D10B 2401/061 : elastic
• CPC Class Codes: D10B 2401/14 : Dyeability
• CPC Class Codes: D10B 2501/00 : Wearing apparel
• CPC Class Codes: D10B 2501/02 : Underwear
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/40 : Knit fabric [i.e., knit strand or strip material]

Abstract

A fabric that contains a thermoplastic fusible yarn and a process of making a fabric containing a thermoplastic fusible yarn are provided. A fabric article is formed with the fabric containing a thermoplastic fusible yarn.

Claims

1. A method of making a fabric article having a first fabric containing thermoplastic fusible yarn and a second fabric, the method comprising:

(a) knitting, weaving or otherwise inserting one or more thermoplastic fusible yarns with one or more non-thermoplastic yarns to form the first fabric; and

(b) affixing the first fabric to the second fabric by;

(1) contacting a portion of the first fabric having thermoplastic fusible yarns with a region of the second fabric to which the first fabric is to he affixed;

(2) applying, to at least the contacting portion, heat sufficient to melt and/or fuse the thermoplastic fusible yarns in the first fabric, so as to affix the first fabric with the second fabric to form the fabric article.

2. The method of claim 1, wherein in step (a), the thermoplastic fusible yarns are distributed substantially uniformly throughout the first fabric.

3. The method of claim 1, wherein in step (a), the thermoplastic fusible yarns are isolated to one or more particular regions of the first fabric.

4. The method of claim 3, wherein the one or more particular regions include at least one edge region of the first fabric.

5. The method of claim 4, wherein step (b)(1) comprises contacting the at least one edge region of the first fabric with the region of the second fabric to which the first fabric is to be affixed.

6. The method of claim 1, further comprising, before step (b), processing the first fabric at a temperature below the melting temperature of the thermoplastic fusible yarns.

7. The method of claim 6, wherein the processing comprises at least one of bleaching, dyeing, and drying the first fabric.

8. The method of claim 1, wherein the second fabric also contains thermoplastic fusible yarns.

9. The method of claim 1, wherein the thermoplastic fusible yarns are oriented transverse to the direction of the non-thermoplastic yarns of the first fabric.

10. The method of claim 1, wherein the thermoplastic fusible yarns comprise Elastane yarn.

11. A fabric article formed with a first fabric containing thermoplastic fusible yarn and a second fabric, comprising:

a first fabric inter-knit or interwoven with one or more thermoplastic fusible yarns together with one or more non-thermoplastic yarns;

a second fabric,

the first fabric and the second fabric being affixed to one another without a stitched seam, by a contact between a melted portion of the first fabric having thermoplastic fusible yarns and the second fabric to form the fabric article.

12. The fabric article of claim 11, wherein the thermoplastic fusible yarns are distributed substantially uniformly throughout the first fabric.

13. The fabric article of claim 11, wherein the thermoplastic fusible yarns are isolated to one or more particular regions of the first fabric.

14. The fabric article of claim 13, wherein the one or more particular regions include at least one edge region of the first fabric, wherein the first fabric is affixed to the second fabric at the at least one edge region.

15. The fabric article of claim 11, wherein the second fabric also contains thermoplastic fusible yarns.

16. The fabric article of claim 11, wherein the thermoplastic fusible yarns are oriented transverse to the direction of the non-thermoplastic yarns of the first fabric.

17. The fabric article of claim 11, wherein the thermoplastic fusible yarns comprise Elastane yarn.

18. A fabric containing a thermoplastic fusible yarn, comprising:

one or more thermoplastic fusible yarns interknit, interwoven or otherwise inserted with one or more non-thermoplastic yarns to form the fabric.

19. The fabric according to claim 18, wherein the thermoplastic fusible yarns are distributed substantially uniformly throughout the fabric.

20. The fabric according to claim 18, wherein the thermoplastic fusible yarns are isolated to one or more particular regions of the fabric.

21. The fabric according to claim 20, wherein the one or more particular regions include at least one edge region of the first fabric.

22. The fabric according to claim 20, wherein the one or more particular regions are affixable to a second fabric, or a portion of said fabric other than said one or more particular regions, by application of heat sufficient to melt and/or fuse the thermoplastic fusible yarns.

23. The fabric according to claim 22, wherein the second fabric also contains thermoplastic fusible yarns.

24. The fabric according to claim 18, wherein the thermoplastic fusible yarns are oriented transverse to the direction of the non-thermoplastic yarns of the fabric.

25. The fabric according to claim 18, wherein the thermoplastic fusible yarns comprise Elastane yarn.