Textile products constructed using curable adhesive threadless sewing and processes for producing same

• US 20010001300A1
• Filed: 12/21/2000
• Published: 05/17/2001
• Est. Priority Date: 08/30/1996
• Status: Active Grant

• Current Assignee: Springs Global US Incorporated (JOSÉ Alencar Gomes Da Silva Comércio Participações E Empreendimentos S/A)
• Original Assignee: Springs Industries Incorporated
• Inventors: Waite, Carmen Lee, Tolbert, Thomas Warren
• Granted Patent: US 6,579,403 B2
• Time in Patent Office: Days
• US Class Current: 442/60
• 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 53/36 Bending and joining, e.g. for making hollow articles B29C53/56 takes precedence
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• CPC Class Codes: B29C 65/484 Moisture curing adhesives
• 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 66/71 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 66/7294 Non woven mats, e.g. felt
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/9534 of the atmosphere, i.e. taking the ambient humidity into account
• CPC Class Codes: B29K 2001/08 Cellulose derivatives
• 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 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2033/08 Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
• CPC Class Codes: B29K 2033/12 Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• 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: B29K 2077/10 : Aromatic polyamides [polyaramides] or derivatives thereof
• CPC Class Codes: D05B 35/02 : for facilitating seaming; Hem-turning elements; Hemmers D05B35/062 takes precedence
• CPC Class Codes: D06M 17/10 : Polyurethanes polyurea
• CPC Class Codes: D06M 23/16 : Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
• CPC Class Codes: Y10T 156/1089 : of discrete laminae to single face of additional lamina
• CPC Class Codes: Y10T 428/2813 : Heat or solvent activated or sealable
• CPC Class Codes: Y10T 428/2848 : Three or more layers
• CPC Class Codes: Y10T 442/2008 : Fabric composed of a fiber or strand which is of specific structural definition
• CPC Class Codes: Y10T 442/2033 : Coating or impregnation formed in situ [e.g., by interfacial condensation, coagulation, precipitation, etc.]
• CPC Class Codes: Y10T 442/2738 : Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
• CPC Class Codes: Y10T 442/2746 : Heat-activatable adhesive

Abstract

Processes for constructing textile articles using curable hot melt adhesives is disclosed. In the process, a molten curable hot melt adhesive is applied to a fabric surface along a simulated sewing path and contacted to another fabric surface so that the adhesive is disposed between the fabric surfaces. The adhesive bonds the fabric surfaces so that the article can withstand subsequent fabric processing. The adhesive cures over time, causing an irreversible increase in the initial softening point of the adhesive. The resultant textile articles exhibit good seam strengths, durability and desirable aesthetics.

Claims

1. A process for simulated sewing of textile articles, comprising:

applying molten curable hot melt adhesive to a surface of a textile substrate along a simulated sewing path;

applying pressure to the textile substrate to cause adhesive to penetrate into the fibrous structure of the textile substrate; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

2. The process of

claim 1

, wherein said process further comprises directing first and second textile substrates into opposing face-to-face relationship prior to said adhesive applying step;

and

wherein said adhesive applying step comprises applying molten curable hot melt adhesive between the overlying substrates.

3. The process of

claim 1

, wherein said process further comprises contacting molten adhesive with an opposing textile substrate surface so that adhesive is disposed between textile substrate surfaces prior to said pressure applying step.

4. The process of

claim 1

, wherein said process further comprises folding a longitudinal edge portion of a textile substrate upon itself into overlying substrate layers to define a longitudinal hem along the longitudinal edge of the textile substrate prior to said adhesive applying step;

and

wherein said adhesive applying step comprises applying molten curable hot melt adhesive between the overlying substrate layers.

5. The process of

claim 1

, wherein said adhesive applying step comprises applying molten curable hot melt adhesive along a longitudinal edge portion of a surface of a textile substrate.

6. The process of

claim 1

, wherein the curable hot melt adhesive comprises an initial softening point, and wherein said subjecting step comprises subjecting the adhesive to conditions sufficient to irreversibly increase the initial softening point of the curable hot melt adhesive.

7. The process of

claim 1

, wherein the curable hot melt adhesive is a moisture curable hot melt adhesive.

8. The process of

claim 7

, wherein the curable hot melt adhesive is a moisture curable polyurethane hot melt adhesive.

9. The process of

claim 7

, wherein said subjecting step comprises exposing the adhesive to atmospheric moisture.

10. The process of

claim 7

, wherein said subjecting step comprises increasing the atmospheric moisture in a region proximate the curable adhesive.

11. The process of

claim 10

, wherein said atmospheric moisture increasing step comprises introducing steam or mist into a region proximate the adhesive.

12. A process for hemming a fabric, comprising:

directing a fabric along a predetermined path of travel while directing one longitudinal edge portion of the fabric into and through a folding guide and folding the longitudinal edge portion upon itself into overlying fabric layers to define a longitudinal hem along the longitudinal edge of the fabric;

applying molten curable hot melt adhesive between the overlying fabric layers along a simulated sewing path;

applying pressure to said longitudinal hem to cause molten adhesive to penetrate into the fibrous structure of the fabric layers and to adhere the fabric layers to one another; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

13. The process of

claim 12

, further comprising reheating the curable hot melt adhesive and realigning the overlying fabric layers prior to said subjecting step.

14. The process of

claim 12

, wherein said adhesive applying step comprises extruding the adhesive.

15. The process of

claim 14

, wherein said adhesive applying step comprises extruding a continuous bead of adhesive along the simulated sewing path.

16. The process of

claim 12

, wherein the curable hot melt adhesive comprises an initial softening point, and wherein said subjecting step comprises subjecting the adhesive to conditions sufficient to irreversibly increase the initial softening point of the curable hot melt adhesive.

17. The process of

claim 16

, wherein the curable hot melt adhesive is a moisture curable hot melt adhesive.

18. The process of

claim 17

, wherein the curable hot melt adhesive is a moisture curable polyurethane hot melt adhesive.

19. The process of

claim 17

, wherein said subjecting step comprises exposing the adhesive to atmospheric moisture.

20. The process of

claim 17

, wherein said subjecting step comprises increasing the atmospheric moisture in a region proximate the curable adhesive.

21. The process of

claim 20

, wherein said atmospheric moisture increasing step comprises introducing steam or mist to a region proximate the curable hot melt adhesive.

22. A process for forming a selvage, comprising:

applying molten curable hot melt adhesive to an edge portion of a surface of a textile substrate along a simulated sewing path; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

23. The process of

claim 22

, further comprising applying pressure to the substrate to cause adhesive to penetrate into the fibrous structure of the textile substrate after said adhesive applying step.

24. The process of

claim 22

, wherein the curable hot melt adhesive comprises an initial softening point, and wherein said subjecting step comprises subjecting the adhesive to conditions sufficient to irreversibly increase the initial softening point of the curable hot melt adhesive.

25. The process of

claim 24

, wherein the curable hot melt adhesive is a moisture curable hot melt adhesive.

26. The process of

claim 25

, wherein the curable hot melt adhesive is a moisture curable polyurethane hot melt adhesive.

27. The process of

claim 25

, wherein said subjecting step comprises exposing the adhesive to atmospheric moisture.

28. The process of

claim 25

, wherein said subjecting step comprises increasing the atmospheric moisture in a region proximate the curable hot melt adhesive.

29. The process of

claim 28

, wherein said atmospheric moisture increasing step comprises introducing steam or mist to a region proximate the curable hot melt adhesive.

30. A process for making textile articles, comprising:

directing first and second textile substrates into opposing face-to-face relationship;

applying molten curable hot melt adhesive between the overlying substrates along a simulated sewing path so that adhesive is disposed between the substrates;

applying pressure to the textile substrates to cause adhesive to penetrate into the fibrous structure of the textile substrate; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

31. A process for making textile articles, comprising:

applying molten curable hot melt adhesive along a simulated sewing path on a surface of a textile substrate;

contacting the molten adhesive with an opposing textile substrate surface so that adhesive is disposed between textile substrate surfaces;

applying pressure to the textile article to cause adhesive to penetrate into the fibrous structure of the textile substrate; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

32. A process for making textile articles, comprising:

applying molten curable hot melt adhesive along a simulated sewing path on a surface of a textile substrate;

thermally quenching the molten curable hot melt adhesive to its initial non-tacky, solid phase;

configuring the textile substrate prior to substantial cure of said adhesive so that the non-tacky adhesive is disposed between opposed surfaces of the textile substrate;

heating said curable hot melt adhesive and applying pressure to the textile substrate surface to cause adhesive to penetrate into the fibrous structure of the opposed surfaces of the substrate; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

33. The process of

claim 32

, wherein said configuring step comprises positioning the substrate to form a textile article comprising multiple points of juxtaposed contacting surfaces with non-tacky adhesive disposed therebetween.

34. A process for providing decorative patterns to textile articles, comprising:

applying a pattern of molten curable hot melt adhesive on a surface of a textile substrate along a simulated sewing path; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

35. The process of

claim 34

, further comprising contacting at least a portion of the curable hot melt adhesive with another substrate prior to applying the adhesive.

36. The process of

claim 35

, wherein said another substrate is selected from the group consisting of ribbons, beads, and braiding.

37. A process for providing a decorative edge affect to textile articles, comprising:

applying a shaped deposit of curable hot melt adhesive to an edge of a textile substrate; and

subjecting the adhesive to conditions sufficient for curing the adhesive.

38. A textile article comprising curable hot melt adhesive along a simulated sewing path of a surface of a textile substrate.

39. The textile article of

claim 38

, wherein said article comprises first and second textile substrates in opposing face-to-face relationship;

and

curable hot melt adhesive disposed between and bonding the overlying substrates.

40. The textile article of

claim 38

, wherein said article comprises a longitudinal edge portion of a textile substrate folded upon itself into overlying substrate layers to define a longitudinal hem along the longitudinal edge of the textile substrate;

and curable hot melt adhesive disposed between and bonding the overlying substrate layers.

41. The textile article of

claim 38

, wherein said article comprises curable hot melt adhesive on an edge portion of a surface of a textile substrate.

42. The textile article of

claim 38

, wherein said article comprises a pattern of curable hot melt adhesive on a surface of a textile substrate.

43. The textile article of

claim 38

, wherein said article comprises a shaped deposit of curable hot melt adhesive to an edge of a textile substrate.

44. The textile article of

claim 38

, wherein said curable hot melt adhesive has an initial softening point prior to curing and an irreversibly increased softening point relative to said initial softening point after curing.

45. The textile article of

claim 44

, wherein said curable hot melt adhesive is cured.

46. The textile article of

claim 45

, wherein said cured hot melt adhesive is cured to a substantially thermoset state.

47. The textile article of

claim 44

, wherein said curable hot melt adhesive comprises a moisture curable hot melt adhesive.

48. The textile article of

claim 47

, wherein said moisture cured hot melt adhesive comprises a moisture curable hot melt polyurethane adhesive.

49. The textile article of

claim 40

, wherein said hem exhibits a tensile strength of at least about 15 pounds.

50. The textile article of

claim 49

, wherein said hem exhibits a tensile strength of at least about 15 pounds after five launderings.

51. The textile article of

claim 40

, wherein said hem has, a flexural rigidity of at least about 7,000 milligrams centimeter in the long dimension of the simulated sewing path.

52. The textile article of

claim 38

, wherein said adhesive in its cured state is resistant to substantial degradation upon exposure to laundering chemicals.

53. The textile article of

claim 38

, wherein said adhesive in its cured state is substantially heat resistant at temperatures ranging from at least about 10°

F. to about 100°

F. higher than the softening point of said adhesive in its uncured state.

54. The textile article of

claim 53

, wherein said adhesive is substantially heat resistant in its cured state at temperatures of at least about 40°

F. higher than the softening point of said adhesive in its uncured state.

55. The textile article of

claim 38

, wherein said textile article is selected from the group consisting of apparel, window treatments, bedding, floor coverings, shower curtains, towels and napery.

56. The textile article of

claim 55

, wherein said bedding is selected from the group consisting of sheets, comforters, bedspreads, blankets, quilts, pillowcases, pillow shams and dust ruffles.

57. A fabric having a selvage comprising curable hot melt adhesive.