WO2013016405A1 - Tissu composite stratifié souple et son procédé de réalisation - Google Patents

Tissu composite stratifié souple et son procédé de réalisation Download PDF

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Publication number
WO2013016405A1
WO2013016405A1 PCT/US2012/048100 US2012048100W WO2013016405A1 WO 2013016405 A1 WO2013016405 A1 WO 2013016405A1 US 2012048100 W US2012048100 W US 2012048100W WO 2013016405 A1 WO2013016405 A1 WO 2013016405A1
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WIPO (PCT)
Prior art keywords
fibers
layer
biaxially
lightweight
composite fabric
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2012/048100
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English (en)
Inventor
Thomas W. Fields
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Starensier Inc
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Starensier Inc
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Publication of WO2013016405A1 publication Critical patent/WO2013016405A1/fr
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing
    • B32B2437/02—Gloves, shoes

Definitions

  • the present invention relates generally to composite fabric and more particularly to a durable lightweight, flexible, breathable fabric that does not stretch or tear under load conditions, and that comprises sufficient surface area for secured bonding to other fabrics for use in products repeatedly subjected to acute forces.
  • Composite laminate fabrics especially those used in footwear as an intermediate support layer, typically lack strength and breathability, and therefore lack structural support and comfort.
  • a thin intermediate support layer called the "doubler" provides structural support for the outer materials and the inner lining materials.
  • Producing a shoe that is comfortable and durable requires that the doubler be breathable, strong and lightweight.
  • Doubler layers having excellent breathability characteristics such as fiber meshes, typically lack strength and sufficient surface area for effective attachment to the upper layer and inner lining layer. Strengthening a fiber mesh requires incorporation of large diameter fibers arranged densely. This adds weight and reduces breathability. Incorporating smaller diameter, high performance fibers increases cost.
  • Meshes also present a unique mode of mechanical failure, namely fiber movement under force from a foot, specifically the toes of a foot.
  • the little toe or the first knuckle of the big toe typically force their way through a fiber mesh by pushing the parallel and perpendicular (horizontal axial and vertical axial) yarns out of the way, resulting in a hole or expanded open area in the mesh, and thereby defeating the purpose of the mesh reinforcement.
  • the present invention solves the problems associated with reinforcing a multilayered article of manufacture, particularly a footwear article requiring a particular combination of strength, durability and weigh characteristics without a substantial increase in cost.
  • the composite of the present invention has a lightweight, strong, durable mesh fiber affixed between two lightweight, flexible, strong laminate layers having perforations therethrough for facilitating evaporation of moisture.
  • One embodiment of the lightweight, breathable reinforcing flexible laminate composite of the present invention comprises a top layer of biaxially-oriented film and a bottom layer of biaxially-oriented film affixed to the top layer of biaxially-oriented film.
  • Fixedly disposed between the top layer of biaxially-oriented film and a bottom layer of biaxially-oriented film is a mesh layer of fibers aligned in parallel and interwoven rows and columns in a grid formation.
  • the mesh layer of fibers is immobilized between the top layer and bottom layer of biaxially-oriented film.
  • the top layer and bottom layer of biaxially-oriented film form an airtight seal around the mesh layer of fibers.
  • the lightweight, breathable reinforcing flexible laminate composite of the present invention comprises a plurality of perforations extending through the top layer of biaxially-oriented film and bottom layer of biaxially-oriented film and disposed in between the fibers of the immobilized mesh layer of fibers.
  • the perforations therefore are formed through top and bottom layer of biaxially-oriented film at the interstices between the fibers laid out in grid formation to form the mesh grid.
  • the present invention also comprises a method of making a lightweight, breathable reinforcing flexible laminate composite fabric.
  • the method comprises providing a first layer of biaxially-oriented film, providing a second layer of biaxially-oriented film for affixation to the first layer of biaxially-oriented film.
  • the method also comprises applying an adhesive to at least the first layer of biaxially-oriented film and laminating onto the adhesive of the first layer of biaxially-oriented film a mesh layer of fibers fixedly disposed in a grid formation.
  • the method further comprises applying the second layer of biaxially-oriented film onto the mesh layer of fibers and first layer of biaxially-oriented film such that the mesh layer of fibers is immobilized between the first layer and second layer of biaxially-oriented film form an airtight seal around the mesh layer of fibers.
  • the lightweight breathable reinforcing flexible laminate composite fabric is completed by forming a plurality of perforations extending through the first layer of biaxially-oriented film and second layer of biaxially-oriented film without severing any of the fibers of the mesh layer of fibers.
  • FIG. 1 is a cross-sectional side view of one embodiment of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention prior to affixation of the composite layers.
  • FIG. 2 is a top view of one embodiment of the mesh fiber layer of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention.
  • FIG. 3 is a top view of one embodiment of a biaxially-oriented film of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention.
  • FIG. 4A is a cross-sectional side view of one embodiment of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention following affixation of the composite layers.
  • FIG. 4B is a top view of one embodiment of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention following affixation of the composite layers.
  • FIG. 5 is a partial top view of a non-reinforced composite fabric subjected to the application of force.
  • FIG. 6A is a top view of one embodiment of a biaxially-oriented film of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention.
  • FIG. 6B is a top view of one embodiment of a biaxially-oriented film of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention.
  • FIG. 7 is a top view of one embodiment of a biaxially-oriented film of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention.
  • FIG. 8 is a top view of one embodiment of a biaxially-oriented film of the lightweight, breathable reinforcing flexible laminate composite fabric of the present invention.
  • the present invention solves the problems associated with standard footwear support layers, i.e. doublers.
  • the present invention provides a breathable, lightweight, sturdy, durable, cost effective reinforcing flexible laminate composite fabric (having sufficient surface area for permanent attachment to both the upper layer and inner lining of a shoe.
  • the present invention thus provides numerous benefits to the user, as described more fully below with reference to the drawings.
  • the present invention is a breathable, lightweight, sturdy, durable, cost effective reinforcing flexible laminate composite fabric (hereafter, "composite fabric”) 100 comprising a top layer of film 105a, a bottom layer of film 105b and a mesh layer of fibers (hereafter “mesh layer”) 200 fixedly disposed in a grid formation therebetween.
  • composite fabric a breathable, lightweight, sturdy, durable, cost effective reinforcing flexible laminate composite fabric
  • mesh layer a mesh layer of fibers
  • the composite fabric 100 of the present invention depicts a portion of one embodiment of the composite fabric 100 of the present invention during the application of force in a targeted area 500, such as application of force by a toe abutting the composite fabric installed in an athletic shoe.
  • Immobilizing the fibers 205, 210 of the mesh layer 200 prevents migration from the position indicated by A to the position indicated by B, which would result in a zone of weakness in the composite fabric 100 and potentially lead to catastrophic tearing or rupture.
  • the composite fabric weighs 3oz or less per square yard and exhibits double the strength characteristic at same weight of a standard doubler layer or the same strength characteristic at two thirds the weight of standard doubler fabric.
  • one embodiment of the present invention further comprises an adhesive 110 applied between the top layer of film 105a and bottom layer of film 105b.
  • the adhesive 100 is applied fully and uniformly across all of one or both of the top layer of film 105a and bottom layer of film 105b and in another embodiment, the adhesive 110 may be applied sporadically and/or as a supplement to other affixation techniques, such as but not limited to thermal bonding, of the top layer of film 105a to the bottom layer of film 105b.
  • the adhesive 1 10 is applied fully and uniformly such the mesh layer 200 is affixed and immobilized across the entire composite fabric 100.
  • a layer of film 105 which could become either the top layer of film 105a or the bottom layer of film 105b, comprises a plurality of perforations 300 therethrough.
  • the top layer of film 105a and the bottom layer of film 105b are of identical dimensions with the plurality of perforations 300 positioned at identical locations so that they align during lamination of the composite fabric 100 without leaving any tacky adhesive exposed.
  • Pre-manufacturing the plurality of perforations 300 in a layer of film 105 prevents accidentally puncturing and weakening the mesh layer 200.
  • the plurality of perforations 300 may be formed in the completed composite fabric 100 following lamination of the top layer of film 105a, mesh layer 200 and bottom layer of film 105b.
  • the plurality of perforations 300 are formed carefully and without severing the fibers 205, 210 forming the mesh layer 200.
  • FIGS. 4A and 4B depict a plurality of perforations 300 formed through the top layer of film 105a and bottom layer of film 105b such that the completed assembly of the composite fabric 100 comprises a plurality of perforations 300 extending through the top layer of film 105a and bottom layer of film 105b and disposed in between the fibers 205, 210 in the grid formation of the mesh layer 200.
  • the plurality of perforations 300 are aligned so as not to overlap or expose the mesh layer 200, which remains immobilized between the top layer of film 105a and bottom layer of film 105b and protected from wear and tear, thereby reliably adding strength to the composite fabric 100.
  • the mesh layer 200 comprises interwoven horizontal axial fibers 205 and vertical axial fibers 210 crossing over one another at a 90 degree angle.
  • the vertical axial fibers 210 and horizontal axial fibers 205 are not horizontal and vertical and instead cross over one another at a 45 degree angle.
  • the angles between the horizontal axial fibers 205 and vertical axial fibers 210 are not horizontal and vertical and instead cross over one another at an angle between 30-85 degree.
  • the mesh layer 200 comprises horizontal and vertical rows of fibers laid atop one another without interweaving the same.
  • the mesh layer of fibers 200 is interwoven and the fibers 205, 210 are bonded at their nodes 215, the locations of intersection.
  • the mesh layer of fibers is not interwoven, but are laid across one another and the fibers are bonded together at their nodes 215.
  • the fibers 205, 210 are interwoven such that they are firmly secured relative to one another and restricted from movement.
  • Bonding the nodes 215 enables the fibers 205, 210 also to maintain stability and withstand localized movement of fibers 205, 210 under acute and often repeated applications of force.
  • the nodes 215 may be secured by any number of means, such as, for example, mechanical ties (such as, but not limited to, those applied by a stitch bonding machine), binder fibers, ultrasonic welds, adhesive bond, or thermal bond.
  • the nodes 215 are mechanically bonded by tying them with separate piece of fiber without adding thickness to the mesh layer 200 and preventing a tightly formed seal of the top layer of film 105 a and bottom layer of film 105b around the mesh layer 200.
  • protrusions at the nodes 215 would prevent formation of a compressed composition fabric 100 with a securely retrained mesh layer 200 that resists movement under applications of force.
  • Thermal bonding techniques for example, cause degradation in the strength of fibers and weakens a mesh formed thereof.
  • the horizontal axial fibers and/or vertical axial fibers are bi-component fibers.
  • the horizontal axial fibers and vertical axial fibers may be the same material, different material, or combinations of the same and different materials.
  • the horizontal axial fibers 205 and vertical axial fibers 210 may be the same material and dimensioned to the same thickness, or diameter, except that the vertical axial fibers 210 further comprise sporadically spaced alternate fibers 212 of material having superior tensile strength than that of the horizontal axial fibers 205 and vertical axial fibers 210.
  • the alternate fibers 212 run vertically and/or horizontally. In another embodiment, the alternate fibers are biaxially-oriented (i.e. 45 degree angle) relative to the horizontal axial fibers 205 and vertical axial fibers 210 In one embodiment, the alternate fibers 212 may be of a different thickness or diameter, but preferably, the alternate fibers 210 are of similar or identical dimensions to those of the vertical axial fibers 210 such that the mesh layer 200 is of uniform overall thickness.
  • Producing a mesh of uniform overall thickness further improves the production of a composite fabric 100 having a tightly secured mesh fabric 200 immobilized therein without any points of incongruity that could lead to delamination of the composite fabric 100 and/or movement of the fibers 205, 210, 212 of the mesh layer 200.
  • some or all of the horizontal axial fibers 205, vertical axial fibers 210 and/or alternate fibers 212 may be a lightweight, high tensile strength, low elongation reinforcing fiber.
  • the alternate fibers 212 are manufactured from a lightweight, high tensile strength, low elongation reinforcing fiber.
  • such fiber materials produce excellent performance characteristics, but are more costly than other types of fibers. Therefore, interspersing such material between the other fiber materials in the mesh layer 200 increases overall performance exponentially with out adding significant cost to a final product.
  • the alternate fibers 212 may be manufactured from materials such as, but not limited to, high tenacity yarn, ultra high molecular weight polyethylene (UHMWPE), polyethylene naphthalate (PEN), aramid polymer, carbon fiber or fiberglass.
  • UHMWPE ultra high molecular weight polyethylene
  • PEN polyethylene naphthalate
  • aramid polymer carbon fiber or fiberglass.
  • the alternate fibers are manufactured from a UHMWPE material, such as Spectra® manufactured by Honeywell®.
  • the horizontal axial fibers 205, vertical axial fibers 210 and/or alternate fibers 212 have a denier ranging from 100 to 3800 and an ultimate tensile strength ranging between 5 and 50 grams per denier.
  • the horizontal axial fibers 205, vertical axial fibers 210 and/or alternate fibers 212 are Spectra® have an ultimate tensile strength ranging between 30 and 39 grams per denier. In one embodiment, the horizontal axial fibers 205, vertical axial fibers 210 and/or alternate fibers 212 are made of high tenacity yarn having an ultimate tensile strength equal to or greater than 6 grams per denier. In one embodiment, the horizontal axial fibers 205, vertical axial fibers 210 and/or alternate fibers 212 have a tensile modulus of at least 900 grams per denier. In one embodiment, the horizontal axial fibers 205, vertical axial fibers 210 and/or alternate fibers 212 have an elongation at break of less than 5 percent.
  • the alternate fibers 212 interspersed within the horizontal axial fibers 205 and/or vertical axial fibers 210 provide all of these performance characteristics.
  • the alternate fibers 212 have a denier between 100-4800, an ultimate tensile strength of greater than 6 grams per denier for the horizontal axial fibers 205 and vertical axial fibers 210, an ultimate tensile strength between 30 to 39 for Spectra® fibers comprising the alternate fibers 212, a tensile modulus of at least 900 grams per denier for the alternate fiber 212 and an elongation at break of less than 5 percent for the alternate fiber 212.
  • At least the alternate fibers 212 have a high flex fatigue and high breaking strength, for example, 9 pounds for a denier of 100. Additionally, in a preferred embodiment, at least the alternate fibers, and preferably the horizontal axial fibers 204 and vertical axial fibers 210 as well, have a low moisture absorption percentage, for example, less than 1% and more preferably, less than 0.5%. Preventing moisture regain and providing a strong, flexible composite fabric 100 that does not stretch or yield catastrophically under acute, repetitive applications of force, such as those associated with a high performance athletic shoe, enables the creation of a sturdy, flexible comfortable final product with a long usage lifespan. In the example of athletic footwear, this could reduce the number of returns for catastrophic, untimely failure and thereby increase revenue and marketing appeal for a manufacturer.
  • Creating a composite fabric 100 having superior strength, comfort and flexibility characteristics requires not only selecting, arranging and affixing the fibers 205, 210, 212 of the mesh layer 200, but also combining the performance characteristics of the mesh layer 200 with a particularly dimensioned and strengthened film layer 105 comprising the top layer of film 105 a and bottom layer of film 105b.
  • the film layer 105 is manufactured from an inelastic, flexible plastic film having high tensile strength and high burst strength resistance as measured by a Mullen burst test, or any burst test designed to ensure that film layer 105 remains intact and that the fibers 205, 210, 212 of the mesh layer 200 remain in the designed mesh configuration under severe, focused load imparted on the composite fabric 100.
  • the fiber film 105 is a biaxially-oriented film 105, wherein a film has been drawn in the machine direction to stretch the fibers comprising the film, reducing their diameters and aligning the fibers to form covalent bonds. Such a biaxially-oriented film 105 therefore is stronger than an extruded plastic film and relatively very thin, such the strength to weight ratio increases greatly as compared to standard plastic films.
  • the top layer of film 105 a and bottom layer of film 105b are manufactured from the same material and in another embodiment, the top layer of film 105a and bottom layer of film 105b are manufactured from different materials having similar performance characteristics. Preferably, the top layer of film 105a and bottom layer of film 105b are manufactured from the same material to ensure a reliable composite fabric 100 reliably exhibiting desired performance characteristics.
  • the biaxially- oriented film 105 comprising the top layer of film 105a and bottom layer of film 105b is biaxially-oriented polyethylene terephthalate (BOPET).
  • the biaxially-oriented film 105 comprising the top layer of film 105a and bottom layer of film 105b is biaxially-oriented polypropylene (BOPP).
  • the biaxially-oriented film 105 comprising the top layer of film 105 a and bottom layer of film 105b is biaxially-oriented polyamid (BOPA).
  • the top layer of film 105a and bottom layer of film 105b are manufactured from BOPET and have a tensile strength in the machine direction of 5 to 50,00 pounds, and preferably at least 40,500 pounds, and a tensile strength of 5 to 50,000 pounds, and preferably at least 36,250, pounds in the cross machine direction.
  • the thickness of each of the top layer of film 105a and bottom layer of film 105b ranges from 3 microns to 15 microns. In a preferred embodiment, the thickness of each of the top layer of film 105a and bottom layer of film 105b is no greater than 9 microns. In this embodiment, combined with the preferred embodiment of the mesh layer, the composite fabric 100 has a burst strength of greater than 1000 pounds.
  • Each of the top layer of film 105a and bottom layer of film 105b further comprises a plurality of perforations 300 therethrough, which can be any shape, but preferably is a rounded shape having no sharp corners at which tearing would propagate under application of force.
  • the plurality of perforations 300 may be evenly spaced round perforations 300 as shown in FIGS. 3 through 5, elliptical perforations 315, 320 as shown in FIGS. 6A and 6B, or star shaped perforations 330, as shown in FIG. 7.
  • the plurality of perforations 300 are pre-formed through each of the top layer of film 105a and bottom layer of film 105b.
  • pre-forming the plurality of perforations 300 eliminates any adhesive buildup on cutting implements used to form the plurality of perforations 300, thereby increasing production efficiency by decreasing time associated with continuously cleaning cutting surfaces to maintain accuracy and precision of cuts.
  • the plurality of perforations 300 formed through the top layer of film 105 a are positioned such that their center 302 points align with the center points 302 of the plurality of perforations 300 formed through the bottom layer of film 105b.
  • the plurality of elliptical perforations 315 formed in a top layer of film 105b are oriented with vertical longitudinal axes 312 and the plurality of elliptical perforations 320 formed in a bottom layer of film 105b are oriented with horizontal longitudinal axes 322 such that when laminated to form the composite fabric 100, a percentage of overlap occurs such that the composite fabric 100 comprises at least 10% perforation therethrough.
  • Similar embodiments comprise offset or randomly placed perforations, such as the offset star shaped perforations 330 of FIG. 7 and randomly formed circular perforations 340 of FIG. 8. Offset and random placement of the plurality of perforations 300, 310, 320, 330, 340 may facilitate manufacturing processes, thereby improving process efficiency and reducing production costs.
  • the plurality perforations 300 are formed in the composite fabric 100 after the lamination of the top layer of film 105a, mesh layer 200 and bottom layer of film 105b.
  • Forming the plurality of perforations after laminating the top layer of film 105a, mesh layer 200 and bottom layer of film 105b prevents exposure of the mesh layer and/or adhesive 1 10.
  • Preventing exposure of the mesh layer 200 prevents snagging, cutting, and general wear and tear of the mesh layer 200 and keeping the adhesive unexposed prevents creating a tacky composite fabric 100 that is difficult to handle during the manufacturing process.
  • Forming a plurality of perforations 300 following assembly of the composite fabric 100 requires precisely aligning the formation tool, a punch or laser for example, and placing each of the plurality of perforations 300 through only the top layer of film 105 a and bottom layer of film 105b without piercing the mesh layer 200.
  • Another major consideration in forming the plurality of perforations 300 involves selecting size and quantity such that a certain percentage of film surface area 305 remains available for permanent attachment to one or more articles of manufacture, such as an "upper" element and inner lining element of a shoe.
  • the fibers 205, 210, 212 of the mesh layer 200 are spaced apart between one thirty-second (1/32) to one half (1/2) of an inch in both the horizontal and vertical directions of the grid formation and each of the plurality of perforations 300 is between one sixty-fourth (1/64) of an inch and one eighth (1/8) of an inch at its largest dimension.
  • the fibers 205, 210, 212 of the mesh layer 200 are spaced apart at least an eighth (1/8) of an inch in both the horizontal and vertical directions of the grid formation and each of the plurality of perforations 300 is one sixteenth (1/16) of an inch at its largest dimension.
  • the fibers 205, 210, 212 of the mesh layer 200 are spaced apart at least a quarter (1/4) of an inch in both the horizontal and vertical directions of the grid formation and each of the plurality of perforations 300 is three sixteenths (3/16) of an inch at its largest dimension (e.g. a diameter of a circular perforation).
  • the spacing between axial fibers 205, 210, 212 determines not only the strength characteristics of the fibers selected for incorporation into the mesh layer 200, but also the largest dimension of the plurality of perforations 300.
  • the ratio of A1/A2 is determined by the amount of bonding distance D required to prevent a fiber 205, 210, 212 from sliding out of place, wherein Al represents the area removed by the perforation 300 within one square of the grid of the mesh layer 200 and A2 represents the area of remaining biaxially-oriented film situated between a perforation 300 and the fibers 205, 210, 212 boxing in that particular perforation 300.
  • Changing the spacing between axial fibers 205, 210, 212 in the mesh layer 200 therefore changes amount of remaining biaxially-oriented film required to prevent the fibers from moving under load. Accordingly the spacing between axial fibers 205, 210, 212 in the mesh layer 200 determines the allowable size of the plurality of perforations 300 punched through the bonded top and bottom layers of biaxially-oriented film 105 a, 105b.
  • the plurality of perforations 300 eliminate between 25 and 75 percent of the film surface area 305, and in a preferred embodiment the plurality of perforations 300 remove 40 to 50 percent of the film surface area 305. In yet another embodiment, the plurality of perforations remove 45 percent of the film surface area 305, leaving 55 percent of the film surface area 305 intact and available for attachment to another element, such as a shoe upper. Removing approximately half of the top layer of film 105a and half of the bottom layer of film 105b to create the plurality of perforations 300 through the composite fabric 100 significantly increases breathability and vapor disposition, making the composite fabric 100 comfortable to the wearer, especially in footwear applications in which an active foot heats up and perspires.
  • the strong, flexible composite fabric 100 retains all of the strength and performance characteristics of the combined, laminated constituent materials while having a reduced weight and still presenting sufficient surface area 305 for permanent, secure attachment to other product components from which the composite fabric 100 will not delaminate under repeated applications of force.
  • an adhesive applied across the composite fabric 100 permanently affixes the composite fabric 100 to a shoe upper without impeding permeability through the plurality of perforations. Such adhesive affixation ensures that the composite fabric does not delaminate from the shoe upper, which maybe manufactured from a material such as leather, from which fibers typically delaminate.
  • the present invention further comprises a method of making the lightweight, breathable reinforcing flexible laminate composite fabric.
  • the method comprises providing a first layer of biaxially-oriented film 105a, providing a second layer of biaxially-oriented film 105b for affixation to the first layer of biaxially-oriented film 105a and applying an adhesive 1 10 to at least the first layer of biaxially-oriented film 105a.
  • the adhesive 1 10 is applied uniformly across all of one surface of the first layer of biaxially-oriented film 105a.
  • adhesive may be applied to the first layer of biaxially-oriented film 105 a and second layer of biaxially-oriented film 105b.
  • the method further comprises laminating onto the adhesive 1 10 of the first layer of biaxially-oriented film 105a a mesh layer of fibers 200 fixedly disposed in a grid formation and then applying the second layer of biaxially-oriented film 105b onto the mesh layer of fibers 200 and first layer of biaxially-oriented film 105a such that the mesh layer of fibers 200 is immobilized between the first layer of biaxially- oriented film 105a and second layer of biaxially-oriented film 105b form an airtight seal around the mesh layer of fibers. Formation of this airtight seal prevents the fibers of the mesh layer of fibers 200 from moving under application of force.
  • the method further comprises forming a plurality of perforations extending through the first layer of biaxially-oriented film affixed to the second layer of biaxially-oriented film without severing any of the fibers of the mesh layer of fibers.
  • the assembled composite fabric 100 may be, for example, placed on a tenter frame having pins that hold the composite fabric 100 taught such that an automated optical system locates the mesh layer 200 and enables high torque microcontrollers to punch the plurality of perforations 300 accurately therebetween without severing any portion of the mesh layer 200.
  • the plurality of perforations 300 may be pre-formed in the top layer of biaxially-oriented film 105a and bottom layer of biaxially-oriented film 105b and an optical system may be used to align the centers of the plurality of perforations 300 in the top layer of biaxially-oriented film 105a and with the plurality of perforations 300 in the bottom layer of biaxially-oriented film 105b such that the assembled composite fabric 100 has a plurality of perforations 300 therethrough without leaving exposed any adhesive 1 10.
  • the method comprises affixing the top layer of biaxially-oriented film 105a and bottom layer of biaxially-oriented film 105b using a thermal means, such as melting, reflow or heat pressing, such that the mesh layer 200 is immobilized therebetween.
  • a thermal means such as melting, reflow or heat pressing
  • the mesh layer 200 is immobilized such that none of the fibers 205, 210, 212 therein spread apart under the application of force, such as the pointed and acute repetitive application of force by one or more toes in a footwear application of the present invention.

Landscapes

  • Laminated Bodies (AREA)

Abstract

La présente invention vise à résoudre les problèmes associés au renforcement d'un article de fabrication multicouche, en particulier une chaussure nécessitant une combinaison particulière de caractéristiques de robustesse, de durée de vie et de poids sans augmentation substantielle du coût. A cet effet, la présente invention porte sur un composite, qui a une fibre à mailles de faible poids, résistante et durable fixée entre deux couches de stratifié de faible poids, souples et résistantes ayant des perforations à travers celles-ci pour faciliter l'évaporation d'humidité qui communique une fatigue de flexion élevée à l'article de fabrication.
PCT/US2012/048100 2011-07-26 2012-07-25 Tissu composite stratifié souple et son procédé de réalisation Ceased WO2013016405A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161511716P 2011-07-26 2011-07-26
US61/511,716 2011-07-26

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WO2013016405A1 true WO2013016405A1 (fr) 2013-01-31

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Cited By (1)

* Cited by examiner, † Cited by third party
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WO2019006542A1 (fr) * 2017-07-06 2019-01-10 Epic Ventures Inc. Matériau de polyéthylène à poids moléculaire ultra-élevé (uhmwpe) composite et son procédé de fabrication

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US4248938A (en) * 1977-11-15 1981-02-03 Teijin Limited Process for preparing polyester fiber composite materials useful for reinforcing rubber articles
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US4317792A (en) * 1979-08-23 1982-03-02 Ethyl Corporation Process for producing perforated film
US4552795A (en) * 1983-12-27 1985-11-12 Minnesota Mining And Manufacturing Co. Inelastic, heat-elasticizable sheet material
US4653640A (en) * 1984-09-07 1987-03-31 Fuji Photo Film Co., Ltd. Packaging materials for photosensitive materials and process for producing same
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Publication number Priority date Publication date Assignee Title
WO2019006542A1 (fr) * 2017-07-06 2019-01-10 Epic Ventures Inc. Matériau de polyéthylène à poids moléculaire ultra-élevé (uhmwpe) composite et son procédé de fabrication
EP3649282A4 (fr) * 2017-07-06 2021-03-03 Aluula Composites Inc. Matériau de polyéthylène à poids moléculaire ultra-élevé (uhmwpe) composite et son procédé de fabrication
US11590729B2 (en) 2017-07-06 2023-02-28 Aluula Composites Inc. Composite ultra-high molecular weight polyethylene (UHMWPE) material and method of manufacture of the same

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