Method of manufacture of inflatable applique

• US 5,251,337 A
• Filed: 01/09/1992
• Issued: 10/12/1993
• Est. Priority Date: 06/25/1990
• Status: Expired due to Fees

• Current Assignee: Printmark Industries, Inc.
• Original Assignee: Printmark Industries, Inc.
• Inventors: Sloot, Alexander
• Primary Examiner(s): Crowder, Clifford D.
• Assistant Examiner(s): Chapman, Jeanette E.
• Application Number:
  US07/818,795
• Time in Patent Office: 642 Days
• Field of Search: 2/46, 2/49 R, 2/69, 2/75, 2/79, 2/85, 2/86, 2/87, 2/93, 2/94, 2/115, 2/105, 2/244, 2/243 R, 2/243 A, 2/243 B, 446/26, 446/27, 446/28, 446/220, 446/226, 5/419, 5/449, 5/644, 5/932, 428/79
• US Class Current: 2/243.1
• CPC Class Codes: A41D 27/08 Trimmings; Ornaments
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/04 Dielectric heating, e.g. high-frequency welding , i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/7441 for making welds and cuts of other than simple rectilinear form
• 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 66/232 said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
• CPC Class Codes: B29C 66/242 said joint lines being closed, i.e. forming closed contours
• CPC Class Codes: B29C 66/244 said joint lines being non-straight, e.g. forming non-closed contours
• CPC Class Codes: B29C 66/246 said joint lines forming figures, e.g. animals, flowers, hearts
• CPC Class Codes: B29C 66/4724 said single elements being appliques, e.g. in the form of a text or drawing
• CPC Class Codes: B29C 66/474 said single elements being substantially non-flat
• 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: B29C 66/81419 and flat
• CPC Class Codes: B29C 66/81427 comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• CPC Class Codes: B29C 66/81431 comprising a single cavity, e.g. a groove
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29K 2021/00 Use of unspecified rubbers 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 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/48 : Wearing apparel
• CPC Class Codes: Y10S 5/932 : Seals and sealing methods, for plastics

Abstract

An inflatable applique for an fabric article comprises a valved, substantially airtight enclosure having a top layer and a backing layer with complementary peripheral outlines. In the method of manufacture, the top and backing layers are welded together preferably simultaneously with the attachment of the enclosure to a clothing article. Various decorative elements may be given to the top layer, such as printing and embossing. The top layer may also be welded to the backing layer within the peripheral outlines to create inflatable subenclosures to give the applique a sculpted appearance.

Claims

1. A method of manufacturing an inflatable applique for a fabric article, comprising the steps of:

affixing a valve having a valve flange to an air impervious valve layer of a polymeric material, said affixing step including

cutting an aperture sized to be contained within the valve flange in said valve layer,

welding said valve flange to said valve layer with said flange surrounding and containing said aperture;

affixing a backing layer to a fabric article;

sealingly affixing a top layer to said backing layer at least around a peripheral zone of said top layer to form a substantially airtight inflatable enclosure that defines a three dimensional object;

one of said backing and top layers comprising said valve layer;

cutting said top and backing layers to provide said top and backing layers with complementary peripheral outlines; and

separating excess top and backing layers from around the perimeter of said enclosure.

2. A method of manufacturing in accordance with claim 1, wherein said step of affixing said top layer to said backing layer comprises a welding step using a welding die.

3. A method of manufacturing in accordance with claim 2, wherein said step of cutting said top and backing layers occurs at substantially the same time as said welding step, said cutting step being performed by an outline cutting edge provided in the welding die.

4. A method of manufacturing in accordance with claim 3, wherein said step of affixing said backing layer to said clothing article occurs substantially at the same time as said steps of welding said top layer to said backing layer and cutting said said top and backing layers, said step of affixing said backing layer to said clothing comprising applying sufficient energy and pressure by said welding die to at least a peripheral portion of said backing layer to soften said peripheral portion sufficiently to cause said peripheral portion of said backing layer to penetrate interstices in said clothing article.

5. A method of manufacturing in accordance with claim 2, further comprising the step of:

welding selected portions of said top layer to said backing layer at locations within the peripheral outline of said top and backing layers to provide said enclosure with at least one inflatable subenclosure of a desired outline operably connected with said enclosure and inflatable therewith.

6. A method of manufacturing in accordance with claim 4, further comprising the steps of:

welding an additional layer of a soft flexible flexible polymer material to said backing layer with said clothing therebetween, simultaneously with the welding of said top layer to said backing layer and said backing layer to said clothing.

7. A method of manufacturing in accordance with claim 1, wherein said step of affixing a valve to said valve layer comprises:

cutting an aperture sized to be contained within the valve flange in said fabric article;

cutting an aperture sized to be contained within the valve flange in said backing layer;

locating said backing layer against said fabric article with said apertures in said fabric article and backing layer in alignment;

locating said valve flange on an outer surface of said backing layer with a body of said valve extending through said apertures and through said fabric article;

welding said valve flange to said backing layer and causing said backing layer to soften and penetrate interstices in said fabric article;

whereby said valve is affixed to said backing layer and said fabric article.

8. A method of manufacturing in accordance with claim 1, wherein said valve comprises a valve stem and base with a flange and a valve backing fittable together, both formed of a polymeric material, and wherein said step of affixing a valve to said valve layer comprises:

cutting an aperture sized to be contained within the valve flange in said fabric article;

cutting an aperture sized to be contained within the valve flange in said backing layer;

locating said backing layer against said fabric article with said apertures in alignment;

locating said valve backing adjacent said backing layer with said valve backing surrounding and containing said backing layer aperture;

locating said valve flange adjacent said fabric article with said valve flange surrounding and containing said fabric article aperture;

fitting said valve stem and base together with said valve backing to sandwich portions of said backing layer and said fabric article between said valve flange and valve backing;

welding said valve flange to said backing layer and to said valve backing with a tubular die;

whereby said valve is affixed to said backing layer and said fabric article.

9. A method of manufacturing in accordance with claim 1, wherein said fabric article comprises a towel.

10. A method of manufacturing in accordance with claim 1, wherein said fabric article comprises a blanket.

11. A method of manufacturing in accordance with claim 1, wherein said enclosure is located on an outer surface of said fabric article and projects outwardly therefrom.

12. A method of manufacturing in accordance with claim 11, wherein said enclosure is an inflatable cushion.