Method for preparing formed polyurethane foam materials and formed polyurethane foam materials therefrom

a technology foam material, which is applied in the field of preparation of formed polyurethane foam material, can solve the problems of poor shape stability after laundering and machine washing, sewing, and inability to meet current fashion requirements for seamless brassiere cups, and achieve excellent color fastness and porosity. excellent

Inactive Publication Date: 2006-07-13
JUNG SHUN
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0008] The above-discussed problems of the prior art are overcome by the present invention with which molded brassiere cup with sufficient porosity an

Problems solved by technology

Prior art processes have suffered from thinning at the apex and consequently resulted in poor shape stability after laundering and machine washing.
The sewing, however, cannot meet current fashion requirement for a seamless brassiere cup.
This process, however, requires homogeneous distribution of the thermoplastic resin within the fibrous material and, thus, production of brassiere cups with even softness and resilience using this process is difficult.
Another drawback of this invention is the requirement for a precise resin contain.
A brassiere cup with an insufficient amount of resin binding tends to be affected by laundering and results in poor shape stability.
Such thermal treatment causes dissociation of chemical bond in the polyurethane, which results in loss in physical properties and accelerated yellowing in the service life of the polyurethane foam.
A signific

Method used

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Examples

Experimental program
Comparison scheme
Effect test

examples 1 to 4

[0033] Foams 1 to 4, as described in Table 1: Foams produced according to this invention, below, are prepared. Specimens of 3 inches in thickness and 10 inches X 10 inches in width and length were rolled and placed in a 3 liter autoclave reactor in separate experiments. In every experiment, the content in the autoclave was vacuumed to about 1 torr for 5 minutes, and then stop the vacuum and inject oxygen into the autoclave to about 250 torr. After the oxygen injection, hydrogen is then injected till the inner pressure reaches about 650 torr. The explosive gaseous content is then ignited with a spark device placed inside the autoclave. After the procedure, foam specimen was checked. Repeat the procedure until all the celled membranes are completely burn-away. Foam specimen from each experiment was named as Foam 5 to 8 accordingly, as shown in Table I. Resulted Foams 5 to 8 were then immersed in distilled methylene chloride to remove possible dissociation products from the reticulatio...

examples 5 to 12

[0035] Foams 1 to 8 were placed between aluminum plates, which were already heated to desire temperature, and pressed with hydraulic cylinder. The foams were thermally formed to desired thickness (Foams 9-16).

[0036] Mold parts equipped with built-in electric heaters are installed on a hydraulic press device built by Shen-Lin Industries Co. Ltd., Hong Kong. The device is capable of providing pressure of approximately 60 psi on the mold area. Mold surface temperature is measure and recorded by using a “K” type thermo-coupler and a digital thermal recorder made by Shimatsu, Japan. A foam sheet of 3 inches thickness is thermally formed by a pair of aluminum plates, which was preheated by build-in electrical heater plate to 180 degree Celsius, for 100 seconds. The gap between these two mold parts is 1 inch. Final thickness of resulted foam is measured after 30 minutes while the foam is cooled down. Molding condition and final foam thickness were recorded.

TABLE IIMolding conditions of ...

examples 13 to 20

[0038] Breathability of the thermally formed foam specimens 9 to 16 was measured, according to the procedures described below. Foam specimens were placed on the top of the beaker and then sealed in the humid controlled jar. The whole assembly was stored in an oven of 38 degree Celsius in temperature in order to ensure temperature control. The weight of the beaker assembly was measured at the end of every hour, for continuously 24 hours.

[0039] Water-vapor permeability is measured to illustrate the breathability of the produced polyurethane foam. Thermally formed polyurethane foam materials are tested according to ISO 1663. A desiccant, calcium chloride, is placed in the bottom of a glass beaker. The foam specimen is sealed into the top of a beaker using a circular template to ensure that a reproducible area of the foam surface is exposed to the controlled humidity, which is set at 38 degree Celsius under 88.5% humidity. The assembly is exposed to the controlled atmosphere for a succ...

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Abstract

This invention relates to a novel method for the preparation of polyurethane foam materials suited for seamless breast pads, cups, fronts and the like for use in brassieres and other garments. Polyurethane foam is produced from aliphatic isocyanates and polyols. The aliphatic polyurethane foam is reticulated to remove all celled membranes and sliced into sheet with a thickness greater than the thicker wall of the finished brassiere cup. The sliced aliphatic polyurethane foam sheet is then pressed between mold parts of a female mold part and a male mold part. The mold parts are closed and pressed whereby the aliphatic polyurethane foam material is molded into the exact shape of the mold cavity. The molded aliphatic polyurethane foam material can be used as seamless breast pads, cups, fronts and the like in brassieres and other garments and expresses superior non-yellowing properties over previous aromatic polyurethane brassiere pads and improved breathability and porosity.

Description

FIELD OF THE INVENTION [0001] This invention relates to a novel method for the preparation of formed polyurethane foam materials, especially to method for preparation of formed polyurethane foam materials for breast pads, cups, fronts and the like for use in brassieres and other garments, and the breast pads, cups fronts and the like prepared according to the invented method. This method is especially useful in the preparation of a molded seamless brassiere cup from soft polyurethane foam materials that were produced from the polymerization of aliphatic isocyanates and polyols. BACKGROUND OF THE INVENTION [0002] In the manufacture of brassieres and other garments that include formed breast pads, cups, fronts and the like, there is a need for resilient materials that can adapt themselves to the various positions and motions of the wearer, while always retaining their original shape. Further, their shape and resilience should not be affected by laundering and machine washing. Still fu...

Claims

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Application Information

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IPC IPC(8): A41C3/00
CPCA41C3/144A41C5/005B29C44/5636B29C44/5654
Inventor JUNG-SHUN, OU
Owner JUNG SHUN
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