Multilayer assembly for textile applications

Abstract

A multi-layer assembly (1a, 1b, 1c) for textile applications (e.g., a part of a garment or a medical support strap) comprises a first layer (2) made of an elastic fabric and an adhesive layer (6) made of a polymeric elastic material. The bonding layer (6) is of a three-dimensional grid structure, and the three-dimensional grid structure is provided with orderly and continuous rhombic openings (8).

Description

[0001] The present invention relates to the field of the manufacture of garments or medical support belts, in particular to the field of solutions for bonding fabric layers, preferably by hot-melt bonding.

[0002] To optimally perform the functions they are designed for, certain parts of certain garments or medical support belts require a structure that maintains the desired shape during use. To achieve this property, these parts are made by coupling multiple layers of fabric, because a single layer will not be able to maintain the desired shape, no matter how rigid the material itself is.

[0003] To this end, a generally continuous and uniform thermal adhesive tape is typically inserted between the fabric layers to hold the two fabric layers together. For example, the applicant has produced and sold a variety of thermal adhesive tapes for many years, including series of thermal adhesive tapes, which have satisfied its customers.

[0004] However, the solutions known to date have some disadvantages, for example in cases where parts of the garment must have considerable elasticity, lightness and breathability, such as the waistband of tights, the underband of a bra or the entire bra, abdominal binders or medical braces (e.g. knee braces, elbow braces etc.).

[0005] In this case, the thermal adhesive tape often exerts too strong an action, which prevents the multi-layer assembly from achieving the elastic elongation required to achieve the specific function of the garment.

[0006] Other known solutions are described, for example, in US2015 / 351474, US4977011, US2004 / 166756, DE2746146 and WO2021 / 181160.

[0007] The object of the present invention is to provide a multilayer assembly that overcomes the above mentioned drawbacks and meets the needs in the field.

[0008] This object is achieved by a multilayer component as claimed in claim 1. The dependent claims describe additional advantageous embodiments.

[0009] The characteristics and advantages of the multilayer assembly according to the invention will become apparent from the following description given by way of non-limiting example with reference to the figures of the accompanying drawings, in which:

[0010] Figure 1 is a schematic diagram of a multi-layer assembly according to an embodiment of the present invention;

[0011] Figure 2 is a schematic diagram of an adhesive layer of a multi-layer assembly according to an exemplary embodiment;

[0012] Figure 3a , 3band 3c show other examples of adhesive layers for multi-layer assemblies;

[0013] Figure 4 is a schematic diagram of a multi-layer assembly according to another embodiment of the present invention;

[0014] Figure 5 is a schematic diagram of a multi-layer assembly according to yet another embodiment of the present invention; and

[0015] Figure 6 The adhesive layer of the multilayer assembly according to the invention is schematically represented.

[0016] According to the first embodiment ( Figure 1 ), a multilayer assembly 1a for making a part of or the whole of a garment comprises: a first layer 2 made of a textile material, which has an inner surface 2a and an outer surface 2b; a second layer 4 made of a textile material, which has an inner surface 4a and an outer surface 4b; and an adhesive layer 6 interposed between the first layer 2 and the second layer 4 and tightly coupled to the inner surface 2a of the first layer 2 and the inner surface 4a of the second layer 4. In other words, the first layer 2 is coupled to the second layer 4 via the adhesive layer 6.

[0017] According to the international standard ISO 13934, a fabric is defined as "elastic" if the elongation under maximum force in the selvedge direction (eg, weft direction) and / or transverse to the selvedge (eg, warp direction) is greater than or equal to 8%.

[0018] Preferably, the first layer 2 is a synthetic, natural or blended elastic fabric.

[0019] For example, the first layer 2 is a polyester-based fabric (ie having a composition in which polyester constitutes a relatively large portion by weight), a polyamide-based fabric, a cotton-based fabric or a polyurethane-based fabric, such as elastane.

[0020] Preferably, the second layer 4 is a synthetic, natural or blended elastic fabric.

[0021] For example, the second layer 4 is a polyester-based fabric, a polyamide-based fabric, a cotton-based fabric or a polyurethane-based fabric, such as elastane.

[0022] The adhesive layer 6 consists of a single sheet forming a perforated layer of a polymer material which activates adhesive properties to the first layer 2 and the second layer 4 at a predetermined temperature, thereby keeping them coupled even after cooling.

[0023] The adhesive layer 6 is perforated in the sense of having a grid structure having a plurality of openings 8 arranged in an orderly and continuous manner and in a predetermined shape.

[0024] For example, according to the preferred embodiment ( Figure 2 ), the adhesive layer 6 has a grid structure, in which the openings 8 are in a rhombus shape with a main diagonal Dmax and a secondary diagonal Dmin perpendicular to each other, wherein the main diagonal is greater than the secondary diagonal. In other words, in such an embodiment, the adhesive layer 6 is composed of a plurality of substantially straight, parallel and spaced first branches 10 and a plurality of substantially straight, parallel and spaced second branches 12; the first branches 10 intersect with the second branches 12 to form a grid with rhombus-shaped openings 8.

[0025] For example, the bonding layer 6 is a three-dimensional grid, wherein:

[0026] a first aspect ratio (R1) between the length of the main diagonal and the length of the secondary diagonal (R1=Dmax / Dmin) between 0.5 and 4 (0.5≤R1≤4), for example equal to 1.5;

[0027] - a second aspect ratio (R2) between the length of the main diagonal (Dmax) and the thickness (S) of the branches 10, 12 (R2

[0028] =Dmax / S) is between 2 and 8 (2≤R2≤8), for example, equal to 4;

[0029] - A third aspect ratio (R3) between the length of the main diagonal (Dmax) and the height (H) of the bonding layer (R3 = Dmax / H)

[0030] Between 10 and 30 (10≤R3≤30), for example equal to 18;

[0031] a fourth aspect ratio (R4) between the thickness of the branches (S) and the height of the adhesive layer (H) (R4=S / H) between 2 and 7 (2≤R4≤7), for example equal to 4.5.

[0032] For example, the bonding layer 6 is a three-dimensional grid, wherein:

[0033] - the length of the main diagonal (Dmax) of the rhombus opening is preferably between 2 and 4 mm (2≤Dmax≤4), for example equal to 3 mm;

[0034] - the length of the minor diagonal (Dmin) of the rhombus opening is preferably between 1 and 3 mm (1≤Dmin≤3), for example equal to 2 mm;

[0035] - the thickness (S) of the branches 10, 12 defining the rhombus opening is preferably between 0.50 and 1 mm (0.50 ≤ S ≤ 1),

[0036] For example, it is equal to 0.75 mm;

[0037] The height (H) of the adhesive layer 6 is uniform, preferably between 150 and 180 micrometers (150≤H≤180), for example equal to 165 micrometers, with a tolerance of 3% (ie 165 micrometers±5 micrometers).

[0038] The Applicant has found that the above-mentioned specific dimensional ratios and / or specific dimensions allow obtaining a garment or a medical support belt having excellent elasticity, breathability and comfort properties.

[0039] Having defined a deformation direction X of the garment or medical support belt, along which it is desired that the garment or support belt exhibits significant deformation, the first branch 10 and the second branch 12 are inclined relative to the deformation direction X. For example, preferably, for a multi-layer assembly, an imaginary diagonal line of the side-by-side openings defines a diagonal direction Y that is substantially parallel to the deformation direction X.

[0040] In the context of the present specification, the terms "substantially straight" and "substantially parallel" are to be understood relative to standard tolerances associated with the technology used to manufacture the bonding layer.

[0041] According to other exemplary embodiments, the adhesive layer has circular or pseudo-circular openings ( Figure 3a ), or a triangular opening with a common side ( Figure 3b ) or a mix of triangle and diamond openings ( Figure 3c ).

[0042] Preferably, the adhesive layer 6 is made of a thermoplastic elastic material.

[0043] For example, the adhesive layer is made of thermoplastic polyurethane (TPU), for example, having a hardness of about 55 ShA, an elongation at break of about 860% and a softening temperature between 130°-140°C.

[0044] According to another embodiment, the adhesive layer is made of styrene-ethylene-butylene-styrene (SEBS), for example, having a hardness of about 15 ShA and a melting point of about 90°C.

[0045] Preferably, the first layer 2, the adhesive layer 6 and the second layer 4 are coupled by thermal lamination, typically activated between 120° - 150°C.

[0046] According to another embodiment ( Figure 4 ), the multilayer component 1b is composed of the above-mentioned first layer 2 and the above-mentioned adhesive layer 6, and the adhesive layer 6 is tightly coupled to the first layer 2 on the surface.

[0047] According to yet another embodiment ( Figure 5), the multilayer component 1c is composed of the above-mentioned first layer 2, the above-mentioned adhesive layer 6 and the auxiliary layer 20, the adhesive layer 6 is tightly coupled to one side of the first layer 2 on the surface, the auxiliary layer 20 is composed of a polymer material, such as polyethylene (PE), and the auxiliary layer 20 is tightly coupled to the first layer 2 on the side surface opposite to the adhesive layer 6. This component is particularly suitable for making clothing labels.

[0048] Preferably, the multilayer assembly 1a, 1b, 1c is provided in the form of a roll consisting of a continuous strip having a predetermined length wound to form the roll.

[0049] The above-mentioned multi-layer components are particularly suitable for making waistbands of leggings, underbands of sports bras, bra cups, sports bras, men's underwear, abdominal girdles, parts of jeans (for example, to create a lifting effect), or making medical support belts (for example, knee support belts, elbow support belts, ankle support belts, etc.).

[0050] According to an exemplary embodiment of the invention, to manufacture a garment or a support belt, the first layer 2 of the multilayer assembly 1a is coupled to the adhesive layer 6 by hot melt bonding, and the adhesive layer 6 is coupled to the second layer 4, preferably simultaneously.

[0051] According to another example, the first layer 2 of the multilayer assembly 1b is preferably coupled to the adhesive layer 6 by hot melt bonding, thereby forming a tape, for example in a first factory; subsequently, for example in a second factory, the tape is coupled to the second layer 4 via the adhesive tape 6.

[0052] According to yet another example, in order to create, for example, a label, the first layer 2 of the multilayer assembly 1c is coupled to the adhesive layer 6 by hot melt bonding, thereby forming a tape, for example in a first factory; subsequently, typically in the same first factory, the tape is coupled to the auxiliary layer 20 via the first layer 2.

[0053] Innovatively, the multi-layer assembly described above overcomes the aforementioned shortcomings of the prior art as it enables the creation of garment portions having significant elasticity.

[0054] Furthermore, advantageously, these portions exhibit considerable comfort, provide a feeling of lightness, and exhibit high breathability.

[0055] Obviously, those skilled in the art may make changes to the multi-layer assembly described above to meet additional requirements, and these changes fall within the scope of protection defined in the following claims.

Claims

1. A multilayer assembly (1a, 1b, 1c) for use in textile applications, such as a portion of a garment or a medical support belt, comprising: A first layer (2) made of synthetic, natural or mixed elastic fabric, the first layer (2) having an elongation at maximum force greater than or equal to 8% in the selvedge direction (e.g. weft direction) and / or transverse to the selvedge (e.g. warp direction), the first layer (2) having an inner surface (2a) and an opposite outer surface (2b), and an adhesive layer (6) made of a polymeric elastic material, the adhesive layer (6) being coupled to the inner surface (2a) of the first layer (2) on the surface, wherein the adhesive layer (6) is composed of monomers forming a layer having a grid structure, the grid structure having a plurality of orderly continuous and rhombus-shaped openings. An opening (8), the opening (8) being defined by a first branch (10) and a second branch (12) intersecting each other, the opening (8) having a main diagonal (Dmax) and a secondary diagonal (Dmin) perpendicular to each other, the main diagonal being greater than the secondary diagonal, and wherein the first layer (2) is a polyester-based fabric, a polyamide-based fabric, a cotton-based fabric or a polyurethane-based fabric, and wherein the elastic polymer material of the adhesive layer (6) is a thermoplastic elastic material, which activates its adhesive properties to the first layer (2) above a predetermined temperature, thereby maintaining coupling with the first layer (2).

2. The multilayer assembly according to claim 1, wherein The adhesive layer (6) is a three-dimensional grid, wherein: A first aspect ratio (R1) between the length of the main diagonal and the length of the secondary diagonal is between 0.5 and 4 (R1=Dmax / Dmin, 0.5≤R1≤4), for example equal to 1.5; A second aspect ratio (R2) between the length (Dmax) of the main diagonal and the thickness (S) of the branches (10, 12) is between 2 and 8 (R2=Dmax / S, 2≤R2≤8), for example equal to 4; a third aspect ratio (R3) between the length of the main diagonal (Dmax) and the height (H) of the adhesive layer, between 10 and 30 (R3=Dmax / H, 10≤R3≤30), for example equal to 18; A fourth aspect ratio (R4) between the thickness (S) of the branches (10, 12) and the height (H) of the adhesive layer is between 2 and 7 (R4=S / H, 2≤R4≤7), for example equal to 4.

5.

3. The multilayer assembly according to claim 1 or 2, wherein: The adhesive layer (6) is a three-dimensional grid, wherein: The length of the main diagonal (Dmax) of the rhombus opening is between 2 and 4 mm (2≤Dmax≤4), for example, equal to 3 mm; The length of the secondary diagonal (Dmin) of the rhombus opening is between 1 and 3 mm (1≤Dmin≤3), for example, equal to 2 mm; The thickness (S) of the branches (10, 12) is between 0.50 and 1 mm (0.50≤S≤1), for example equal to 0.75 mm; The height (H) of the adhesive layer 6 is uniform and between 150 and 180 micrometers (150≤H≤180), for example equal to 165 micrometers, with a tolerance within 3% (ie, 165 micrometers±5 micrometers).

4. The multilayer assembly according to any one of the preceding claims, wherein The thermoplastic elastic material is thermoplastic polyurethane TPU or styrene-ethylene-butylene-styrene SEBS.

5. The multilayer assembly (1a) according to any one of the preceding claims, comprising a second layer (4) of synthetic, natural or blended elastic fabric, the second layer (4) having an inner surface (4a) and an opposite outer surface (4b), wherein The adhesive layer (6) is superficially coupled to the inner surface (4a) of the second layer (4).

6. The multilayer assembly according to claim 5, wherein The second layer (4) is a polyester-based fabric, a polyamide-based fabric, a cotton-based fabric or a polyurethane-based fabric.

7. The multilayer assembly according to claim 5 or 6, wherein: The polymer elastic material of the adhesive layer (6) activates adhesive properties to the second layer (2) above a predetermined temperature, thereby maintaining coupling with the second layer (2).

8. The multilayer component (1c) according to any one of claims 1 to 4, comprises an auxiliary layer (20), which is composed of a polymer material, such as polyethylene PE, which is superficially coupled to the outer surface (2b) of the first layer (2).

9. A continuous belt consisting of a multilayer assembly (1b) according to any one of claims 1 to 4 having a predetermined length.

10. A roll consisting of a strip wound according to claim 9.

11. A continuous belt consisting of a multilayer assembly (1a) according to any one of claims 5 to 7 having a predetermined length.

12. A roll consisting of a strip wound according to claim 11.

13. A continuous belt consisting of the multilayer assembly (1c) according to claim 8 having a predetermined length.

14. A roll consisting of a strip wound according to claim 13.

15. A garment or a medical support belt comprising the multi-layer assembly (1a, 1b, 1c) according to any one of claims 1 to 8.

16. The garment or medical support belt of claim 15, comprising: The part that defines the deformation direction X; Wherein, the first branch (10) and the second branch (12) are inclined relative to the deformation direction (X).

17. The garment or medical support belt of claim 16, wherein: The diagonal lines of the side-by-side openings (8) define a diagonal direction (Y) that is substantially parallel to the deformation direction (X).

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