U.S. patent application number 12/354030 was filed with the patent office on 2009-07-16 for garment with altered stress profile.
This patent application is currently assigned to INVISTA NORTH AMERICA S.A R.L.. Invention is credited to Carmen A. Covelli, Douglas K. Farmer.
Application Number | 20090181599 12/354030 |
Document ID | / |
Family ID | 40851053 |
Filed Date | 2009-07-16 |
United States Patent
Application |
20090181599 |
Kind Code |
A1 |
Farmer; Douglas K. ; et
al. |
July 16, 2009 |
GARMENT WITH ALTERED STRESS PROFILE
Abstract
Included are articles such as garments including polymer film
compositions to alter the stress profile of the garment which is
exhibited during wear of the garment. The polymer film may be
bonded to the fabric to provide a fabric/film laminate.
Inventors: |
Farmer; Douglas K.;
(Wilmington, DE) ; Covelli; Carmen A.;
(Wilmington, DE) |
Correspondence
Address: |
INVISTA NORTH AMERICA S.A.R.L.
THREE LITTLE FALLS CENTRE/1052, 2801 CENTERVILLE ROAD
WILMINGTON
DE
19808
US
|
Assignee: |
INVISTA NORTH AMERICA S.A
R.L.
Wilmington
DE
|
Family ID: |
40851053 |
Appl. No.: |
12/354030 |
Filed: |
January 15, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61021241 |
Jan 15, 2008 |
|
|
|
Current U.S.
Class: |
450/39 ; 2/69;
450/85; 450/86; 450/93 |
Current CPC
Class: |
A41C 3/0014 20130101;
A41D 13/04 20130101; B32B 2437/00 20130101; A41D 1/04 20130101;
A41D 1/18 20130101; A41B 1/08 20130101; A41B 9/06 20130101; B32B
5/18 20130101; A41C 3/10 20130101; A41D 3/04 20130101; A41D 13/1209
20130101; A41D 27/02 20130101; A42B 1/00 20130101; B32B 5/02
20130101; A41D 1/14 20130101; A41D 10/00 20130101; A61F 13/00038
20130101; A41B 11/14 20130101; A41D 13/012 20130101; A61F 5/3715
20130101; A41B 9/04 20130101; A41D 1/22 20130101; A41D 1/00
20130101; A41D 13/002 20130101; A41C 1/00 20130101; A41C 3/00
20130101; A41D 3/02 20130101; A42B 5/00 20130101; A41B 11/003
20130101; A41D 31/00 20130101; A41B 17/00 20130101; A41B 2500/50
20130101; A41D 17/00 20130101; A41F 9/00 20130101; A41D 29/00
20130101; A41D 3/08 20130101; A41D 7/00 20130101; A41D 13/0002
20130101; A41D 20/00 20130101; A41B 9/001 20130101; A41B 2400/38
20130101; B32B 27/06 20130101; A41D 1/06 20130101; A41D 25/00
20130101 |
Class at
Publication: |
450/39 ; 450/85;
450/86; 450/93; 2/69 |
International
Class: |
A41C 3/00 20060101
A41C003/00; A41D 1/00 20060101 A41D001/00 |
Claims
1. An article comprising a garment comprising: (a) one or more
sections of fabric; wherein each section of fabric has a stress
profile; and (b) one or more polymeric films attached to one or
more sections of fabric to form a fabric laminate; wherein the
fabric laminate has an altered stress profile.
2. The article of claim 1, wherein the garment is a body-shaping
garment or a performance-enhancing garment.
3. The article of claim 1, wherein said altered stress profile
includes a uniform distribution of stress and/or pressure.
4. The article of claim 1, wherein said altered stress profile
provides a stress and/or pressure gradient to provide support at
one or more areas within said fabric laminate.
5. The article of claim 4, wherein the altered stress profile
provides a performance enhancing property.
6. The article of claim 1, wherein said fabric has a construction
selected from the group consisting of single and multiple
layers.
7. The article of claim 6, wherein said fabric has a multiple layer
construction including one or more layers of fabric and optionally
one or more layers of foam.
8. The article of claim 1, wherein said fabric laminate includes
one or more layers of fabric, one or more layers of foam, and one
or more layers of a polymeric film.
9. The article of claim 1, wherein said polymeric film is selected
from the group consisting of polyurethaneurea films, polyurethane
films, polyolefin films, and combinations thereof.
10. The article of claim 1, wherein said polymeric film is a
polyurethaneurea cast and dried from a polyurethaneurea
dispersion.
11. The article of claim 1, wherein said polymeric film includes
one or more layers of film.
12. The article of claim 1, wherein said polymeric film has the
same shape as said fabric section and is geometrically
inverted.
13. The article of claim 1, wherein said fabric section comprises a
trapezoid having a wide end and a shorter end; said polymeric film
also has a wide end and a shorter end; and said shorter end of said
polymeric film is placed corresponding to said wide end of said
fabric section and said wide end of said polymeric film is placed
corresponding to said shorter end of said fabric section.
14. The article of claim 1, wherein said polymeric film comprises a
narrow strip; said fabric section has a top portion, an
intermediate portion and a bottom portion; and said polymeric film
is oriented adjacent to two or more portions of said fabric
section.
15. The article of claim 14, wherein said polymeric film comprises
a narrow strip; said fabric section has a top, a middle and a
bottom; and said polymeric film is oriented on said fabric section
along a diagonal from the top of the fabric section to the bottom
of the fabric section.
16. The article of claim 14, wherein said polymeric film is
oriented along a diagonal or is perpendicular to the top portion or
the bottom portion.
17. The article of claim 14, wherein said polymeric film comprises
a non-linear strip.
18. A garment comprising a brassiere having a wing portion, said
wing portion including a polymeric film in the form of a narrow
strip or geometrically inverted to said wing portion.
19. The garment according to claim 18, wherein said narrow strip is
oriented along a diagonal within or to edges of said wing
portion.
20. A brassiere which comprises an assembly of layers of material
defining a pair of breast cups with a bridge between said cups,
said assembly comprising at least a first and a second layer of
material molded to define the shape of the breast cups, each of
said breast cups including a lower periphery which extends from
said bridge and toward a side periphery that extends from said
lower periphery to a top portion of each of said breast cups where
a strap is optionally attached; wherein adjacent to either or both
each of said lower and side peripheries of said breast cups, there
is embedded in or adhered to said layers of material of said
assembly a polymeric film including a polyurethaneurea cast and
dried from a polyurethaneurea dispersion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Application No.
61/021,241 filed on Jan. 15, 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to articles such as garments
including body shaping garments and performance enhancing garments
that include an altered stress profile. The article or garment
includes one or more layers of material such as fabric and/or
polyurethane foam in combination with a polyurethaneurea
composition.
[0004] 2. Summary of Related Technology
[0005] Garments provide a variety of different functions including,
but not limited to, warmth, fashion, and comfort. Two goals of body
shaping garments include support and comfort either of which can be
compromised due to the other. One reason for reduction in comfort
is that garments designed for body-shaping or support frequently
have areas where increased pressure is exerted on the wearer of the
garment. For example, if one imagines a band of material wrapped
around a person where the band has a wide section and a narrow
section, the force within the band length of the band is the same,
however, this force is distributed more evenly across the wide
portion of the band compared to thin portion. The result is an
increased pressure at the point where the narrow portion is in
contact with the body.
[0006] The areas of increased pressure can result in discomfort to
the wearer. Therefore, there is a need for garments that overcome
these deficiencies by redistributing the pressure by altering the
stress profile of the garment, including providing additional
support where desired, and providing greater comfort to the
wearer.
[0007] Another issue experience by body-shaping garments, such as
laminated foam garments, is fabric growth. This is particularly an
issue with one-piece laminated foam brassieres. There is a need to
provide a method of redistributing or controlling stress within the
garment to prevent fabric growth.
SUMMARY OF THE INVENTION
[0008] In some embodiments are an article including a garment
including:
[0009] (a) one or more sections of fabric;
[0010] wherein each section of fabric has a stress profile; and
[0011] (b) one or more polymeric films attached to one or more
sections of fabric to form a fabric laminate;
wherein the fabric laminate has an altered stress profile. These
garments can be designed to prevent greater comfort to the wearer
in addition to reducing fabric growth.
[0012] A garment including a brassiere having a wing portion, the
wing portion including a polymeric film in the shape or form of a
narrow strip, a triangular shape, or the shape of the wing portion
geometrically inverted to the wing portion.
[0013] A brassiere which includes an assembly of layers of material
defining a pair of breast cups with a bridge between said cups,
said assembly comprising at least a first and a second layer of
material molded to define the shape of the breast cups, each of
said breast cups including a lower periphery which extends from
said bridge and toward a side periphery that extends from said
lower periphery to a top portion of each of said breast cups where
a strap is optionally attached;
[0014] wherein adjacent to either or both each of said lower and
side peripheries of said breast cups, there is embedded in or
adhered to said layers of material of said assembly a polymeric
film including a polyurethaneurea cast and dried from a
polyurethaneurea dispersion.
[0015] Methods of preparing garments including an altered stress
profile are also included.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a portion of fabric including a geometrically
inverted polymer film.
[0017] FIG. 2 shows a portion of fabric including a geometrically
inverted polymer film.
[0018] FIG. 3 shows a portion of fabric including a narrow strip of
polymer film.
[0019] FIG. 4 shows a brassiere including polymer film regions
along a lower and side periphery.
[0020] FIG. 5 shows a brassiere including polymer film regions.
[0021] FIG. 6 shows a brassiere including polymer film regions.
[0022] FIG. 7 shows a brassiere including polymer film regions.
[0023] FIG. 8 shows a portion of fabric including a triangular
shaped polymer film region.
[0024] FIG. 9 shows a portion of fabric including a triangular
shaped polymer film region.
[0025] FIG. 10 shows a panty including polymer film regions.
[0026] FIG. 11 shows a panty including polymer film regions.
[0027] FIG. 12 shows a polymer film on a substrate.
[0028] FIG. 13 shows a polymer film between two substrates.
[0029] FIG. 14 shows a portion of fabric including a polymer film
region.
[0030] FIG. 14A shows a multiple layer portion of fabric including
a polymer film region.
[0031] FIG. 15 shows a portion of fabric including a polymer film
region.
[0032] FIG. 15A shows a multiple layer portion of fabric including
a polymer film region.
[0033] FIG. 16 shows a cross-section of the multiple layer fabric
of FIG. 14A along line X-X.
[0034] FIG. 17 is a graphic representation of the set % of garments
laminated with polymer compositions.
[0035] FIG. 18 is a graphic representation of a control fabric
compared to a polymer film.
[0036] FIG. 19 is a graphic representation of a stress/strain
analysis.
[0037] FIG. 20 is a graphic representation of a stress/strain
analysis
DETAILED DESCRIPTION OF THE INVENTION
[0038] For the purposes of this invention, the term "stress
profile" of a fabric is defined as a physical pressure, pull, or
other force that is exerted on a fabric accounting for various
different forces that can be measured at various points throughout
the garment. The stress profile can be observed in any fabric such
as a fabric used in a garment. One example of a stress profile of a
fabric is noted for body shaping garments where the stress or
pressure exerted on the garment will vary as the garment is being
worn due to wearer movement. Another example is for a support
garment such as a brassiere where the stress on the bottom of the
cup portions may be greater than that on the top of the cup
portions.
[0039] For the purposes of this invention, the term "geometrically
inverted" is meant to include embodiments where a film of the same
geometric shape as the fabric with which it will be laminated has
been rotated with respect to the fabric. The film may be larger,
smaller, or the same size as the fabric section. This also
includes, but is not limited to, where film and fabric of size and
dimension are designed inversely proportionate to the modulus of
the film and fabric, respectively.
[0040] As used herein, the term "non-linear" includes shapes other
than a straight line. This includes, but is not limited to, curved
shapes, arc shapes, and wavy shapes.
[0041] As used herein, the term "narrow strip" refers to a shape
having a length and a width where the length is at least twice the
width. The length may vary and depends on the size of the garment
to which it is applied.
[0042] As used herein, the term "porous" refers to a substrate that
includes voids or holes in the surface or at any point within or
through the thickness of the substrate or to any material of which
the articles of the present invention may come into contact.
[0043] As used herein, the term "pressing" or "pressed" refers to
an article that has been subjected to heat and/or pressure to
provide a substantially planar structure.
[0044] As used herein, the term "foam" refers to any suitable foam
that may be used in fabric construction such as polyurethane
foam.
[0045] As used herein, the term "dispersion" refers to a system in
which the disperse phase consists of finely divided particles, and
the continuous phase can be a liquid, solid or gas.
[0046] As used herein, the term "aqueous polyurethane dispersion"
refers to a composition containing at least a polyurethane or
polyurethane urea polymer or prepolymer (such as the polyurethane
prepolymer described herein), optionally including a solvent, that
has been dispersed in an aqueous medium, such as water, including
de-ionized water.
[0047] As used herein, the term "solvent," unless otherwise
indicated, refers to a non-aqueous medium, wherein the non-aqueous
medium includes organic solvents, including volatile organic
solvents (such as acetone) and somewhat less volatile organic
solvents (such as MEK, or NMP).
[0048] As used herein, the term "solvent-free" or "solvent-free
system" refers to a composition or dispersion wherein the bulk of
the composition or dispersed components has not been dissolved or
dispersed in a solvent.
[0049] As used herein, the term "article" refers to an article
which comprises a dispersion or shaped article and a substrate, for
example a textile fabric, which may or may not have at least one
elastic property, in part, due to the application of a dispersion
or shaped article as described herein. The article may be in any
suitable configuration such as one-dimensional, two-dimensional
and/or three-dimensional.
[0050] As used herein, the term "fabric" refers to a knitted, woven
or nonwoven material. The knitted fabric may be flat knit, circular
knit, warp knit, narrow elastic, and lace. The woven fabric may be
of any construction, for example sateen, twill, plain weave, oxford
weave, basket weave, and narrow elastic. The nonwoven material may
be meltblown, spun bonded, wet-laid, carded fiber-based staple
webs, and the like.
[0051] As used herein, the term "hard yarn" refers to a yarn which
is substantially non-elastic.
[0052] As used herein, the term "molded" article refers to a result
by which the shape of an article or shaped article is changed in
response to application of heat and/or pressure.
[0053] As used herein, the term "derived from" refers to forming a
substance out of another object. For example, a film may be derived
from a dispersion which can be dried.
[0054] As used herein, the term "modulus" refers to a ratio of the
stress on an item expressed in force per unit linear density or
area.
[0055] As used herein, the term "fabric growth" is meant to include
the natural tendency of fabrics to stretch over time or during wear
that is not recovered (i.e., not elastic).
[0056] For the purposes of this invention, the terms "polymer
film," "polymer solution," and "polymer dispersion" are used
interchangeably to describe a substantially two-dimensional or
relatively flat layer of polymer, optionally in water or solvent,
that may or may not require application to a substrate for
support.
[0057] As used herein, the term "fabric laminate" refers to a
multiple layer article including at least one fabric layer and at
least one polymer layer that have been attached or bonded together.
The methods of attachment include, but are not limited to, gluing,
heating, application of pressure, and combinations thereof.
[0058] As used herein, the term "performance-enhancing" in
reference to a garment refers to a garment that reduces fatigue or
maintains performance-ability of the wearer of the garment. For
example, an athlete may wear a performance-enhancing garment during
competition to reduce fatigue and/or maintain competitive
performance.
[0059] In some embodiments are garments including a polymer film
that alters the stress profile of the garment. This includes
equally distributing stress throughout the garment as well as
providing a "stress gradient" where additional support is desired.
The stress gradient provides areas of preselected stress to
redistribute the stress such as from an area of lower stress to an
area of greater stress within the fabric of the garment. One
example of a stress gradient is useful for a brassiere. The polymer
film may be included in a bra cup to provide a stress gradient that
provides greater stress for support at the bottom of the cup and
lower stress at the top of the cup.
[0060] The articles of some embodiments include at least one layer
of a polymer film such as a polyurethaneurea composition in the
form of a film or dispersion. These articles have at least two
layers including the polymer film. The polymer film may be placed
adjacent to or between the layers of material such as fabric or
foam and also may provide stretch and recovery, increased elastic
modulus, adhesion, moldability, shape retention, and flexibility
properties for the article. These articles may be formed into
fabrics and/or garments.
[0061] A variety of polymers are useful with the articles of some
embodiments and more than one layer of film may be included. These
include polymer films of polyurethane, polyurethaneurea,
polyolefin, and combinations thereof. Examples of useful polyolefin
resins are commercially available under the brand name VISTAMAXX by
ExxonMobil, such as VISTAMAXX.RTM. 1100 and VISTAMAXX.RTM. 2100
which may be melted and shaped into a film or prepared as a
nonwoven.
[0062] A variety of different polyurethaneurea compositions are
useful with the films and dispersions of some embodiments. For
example, the films of the some embodiments may be cast from a
solution, an aqueous dispersion, or a substantially solvent free
aqueous dispersion. Many such solutions or dispersions are known in
the art. For example, a polyurethaneurea solution such as a
spinning solution from a commercial spandex production line may be
used to cast a film, according to some embodiments of the present
invention. Specific examples of aqueous dispersions and films cast
from them which are useful with the present invention are described
hereinbelow.
[0063] In an embodiment where the article includes a multiple layer
article including three or more layers where one layer is a film,
the film may be an intermediate layer between two fabric layers,
between two foam layers, between a fabric layer and a foam layer,
or adjacent to a foam layer which is adjacent to a fabric layer.
Combinations of these fabric/foam/film arrangements are also
contemplated. For example, the article may include, in order, a
fabric layer, a foam layer, a film layer, a foam layer, and a
fabric layer. This article includes two separate fabric layers, two
separate foam layers and a film layer. In any of these embodiments,
the polymer film may be replaced with a polymer solution or
dispersion. Therefore, the article may include one or more polymer
film and one or more polymer dispersion layers.
[0064] In another embodiment, a single layer of a fabric or foam
may be folded to form two or more layers of the multiple layer
article with a polymer film, solution, or dispersion as an
intermediate layer (where the film may be considered `embedded`
within the article). In this embodiment, the article may then also
be molded or pressed to a desired shape, such as for a body shaping
garment. Where a polymer film is placed at the point of folding,
the tape may provide additional stretch recovery power, such as at
a hem or for a body shaping garment, to provide additional support.
This is also useful in a garment such as an underbust bra where the
film/tape placement may provide increased wall strength or rigidity
and may keep the garment from rolling at the edge. The polymer film
may also be placed at the point where the edges of the single layer
meet which form the double layer fabric as shown in FIG. 16 which
is described hereinbelow in more detail. Additional fabric or foam
layers may also be included within the folded over layer as
desired. For example, a fabric layer may be folded over to form two
layers where a polymer film and a foam are included within the
folded area.
[0065] In an embodiment that includes two or more layers, the
polyurethaneurea composition may form an external layer. Including
the polyurethaneurea composition on an external surface forms many
advantageous functions. For example, the polyurethaneurea
composition may provide an anchor or area of increased friction to
reduce the relative movement between the article including the
polyurethaneurea composition and an external substrate. This is
particularly useful when the article is an undergarment including a
skin-contacting surface (where the wearer's skin is the substrate).
Alternatively, the substrate may be outer clothing which is in
contact with the polyurethaneurea composition of the inventive
article. Where the substrate is outer clothing of a wearer and the
article is worn as an undergarment, the article prevents or reduces
the relative movement of the outer garment. In addition, an outer
garment (e.g. a dress) may include a polyurethaneurea composition
to maintain the relative placement of an inner garment (e.g. a
slip).
[0066] After the layers of fabric, foam, and the film have been
selected, they may subsequently be adhered through pressing or
molding to form flat or shaped articles (including articles having
three-dimensions such as a molded brassiere cup). The processes to
prepare the pressed and molded articles of some embodiments include
the use of pressure and heat as necessary. For example, heat may be
applied at about 150.degree. C. to about 200.degree. C. or about
180.degree. C. to about 190.degree. C., including about 185.degree.
C. for a sufficient time to achieve a molded article. Suitable
times for application of heat include, but are not limited to, from
about 30 sec to about 360 sec including from about 45 sec to about
120 sec. Bonding may be effected by any known method, including but
not limited to, microwave, infrared, conduction, ultrasonic,
pressure application over time (i.e. clamping) and combinations
thereof.
[0067] Due the application of heat and pressure to the articles
including polyurethaneurea films or dispersion and given that films
and fabrics are themselves porous materials, it is recognized that
the film or dispersion may partially or completely impregnate the
fabric or foam of the article. For example, the polyurethaneurea
composition may form a layer which is partially separate from the
surrounding layers, or may be completely transferred to the
surrounding layer or layers to form an integrated article without a
distinguishably separate polyurethaneurea composition layer.
[0068] One application of the multi-layer articles of the present
invention is body-shaping garments such as brassieres (especially
in cups or wings) other women's undergarments and men's
undergarments. These articles can provide the desirable features of
body shaping and support while still providing comfort,
breathability, air permeability, moisture/vapor transport, wicking,
and combinations thereof. In the articles of some embodiments of
the present invention, the layers may take on predetermined shapes
and may be arranged in predetermined orientations relative to each
other in the design of a molded or shaped article such as the cups
of a brassiere construction. The layers of these fabrics may be
used either alone or in combination with other materials that are
sewn, glued or otherwise applied to the fabrics.
[0069] In some embodiments there is a system for the construction
of a garment with integrated shaping ability provided by the
fabric. This system of construction may be used in a variety of
different garment constructions such as activewear, sportswear,
men's and women's intimate apparel such as bras, underwear,
panties, shaping garments, legwear and hosiery such as pantyhose,
ready-to-wear garments such as denim jeans, camisoles, tailored
shirts, and pants among others. This construction may be applied to
any formable body area. While many advantages of the fabric
constructions are included, it is further recognized that the
utility is not limited to garments, but also finds applicability
with any shapeable or formable medium, including cushions for
furniture which are also subject to movement and potential slipping
of a fabric in contact with the shapeable area.
[0070] In order to add additional support and other features, the
polymer film composition may be added to different areas of the
article. For example, it may either extend through the entire area
of the article or to a selected portion to provide different
benefits. For example, a brassiere may include a layered fabric of
some embodiments in the cup portion. In the brassiere cup, it can
be useful to use a portion of film in the lower portion of the cup
for support, in a central portion of the cup for modesty, in the
side portion for shaping, or in specific areas for embellishment or
decoration.
[0071] In each of the figures, the polymer films are shown as a
separate layer for clarity only. The polymer film on attachment may
partially or completely fill the pores of the fabric or foam
substrate.
[0072] In FIGS. 1-3, 8-9, and 14-15, a portion of fabric is shown
having a substantially trapezoidal shape. Such a shape is useful as
a bra wing portion, as discussed. However, although referred to a a
bra wing portion, the fabric portion may be useful in other areas
of a garment and is shown to demonstrate an example of how a
polymer film may be oriented with respect to the shape of the
fabric to alter the stress-profile of the fabric. A variety of
geometric shapes for both the fabric portion and the polymer film
portion are contemplated and can be chosen based on the desired
alteration of stress-profile. The alteration may be to provide
comfort by distributing stress throughout the garment or to
increase stress in portions of the garment to provide additional
control or support.
[0073] As shown in FIG. 1, a polymer film composition 2 may be
geometrically inverted onto a portion of a garment such as a bra
wing portion 1, which is a substantially trapezoid shape, and is
shown as a trapezoid. The corners 4 that overlap extend beyond the
edges of the wing portion may be folded over or cut to shape of the
polymer film.
[0074] As an alternative, FIG. 2 also shows a polymer film
composition 2 that has been geometrically inverted onto a wing
portion 1, however, while the film has substantially the same shape
as the wing portion, it is reduced in size to avoid the overlapping
corners 4 of FIG. 1, while still providing a altered stress
profile.
[0075] In either FIG. 1 or FIG. 2, the fabric section 1 may be a
wing including a trapezoid having a wide end and a shorter end. The
polymeric film 2 also has a wide and a shorter end. The shorter end
of the polymeric film is placed corresponding to the wide end of
the fabric section and the wide end of the polymeric film is placed
corresponding to the shorter end of the fabric section.
[0076] FIG. 8 and FIG. 9 also show fabric portions 1 having a
polymer film region 2 bonded to the fabric portion 1. In each of
FIG. 8 and FIG. 9, the polymer film region has a triangular
shape.
[0077] As shown in FIG. 3, another method of altering the stress
profile of a garment, such as a wing 1 is to include a narrow strip
of a polymer film 2. Although this polymer film shown appears
substantially linear, it is understood that this may be modified to
a non-linear shape depending on the manner of altering the stress
profile that is selected. The film 2 may extend to the edges of the
wing 1 as shown or may alternatively begin and end at intermediate
portions of the wing 1. The film 2, may be oriented along a
diagonal (as it appears in FIG. 3) or may be perpendicular to the
wing edge.
[0078] In other words, the fabric section may have a top portion an
intermediate portion and a bottom portion where the polymeric film
is oriented adjacent to two or more portions of the fabric section.
The polymer film may be oriented along a diagonal from the top of
the fabric section to the bottom of the fabric section, along a
diagonal at other portions within the fabric or perpendicular to
the fabric section.
[0079] FIG. 4 shows a brassiere as an example of a garment that can
include the polymer film to alter the garment's stress profile. The
brassiere includes a wing portion 1 and two cup portions 6 and 10.
The cup portion 6 includes a polymer film 8 located along the
bottom periphery of the cup 6. The other cup portion 10 includes a
polymer film that is located along the side periphery 12. The side
periphery film 12 and the bottom periphery film 8 can be used
together or separately to adjust the stress profile of the garment
to provide shaping and support. Although a brassiere is shown as
the example, it is understood that this could apply to other
formable areas of the body, such as the derriere.
[0080] FIG. 5 also shows a brassiere including an underwire portion
18. The underwire portion is also a potential cause of a pressure
point in a brassiere. The addition of polymer films 14 and 16 can
provide one or both of additional comfort and support by altering
the stress profile to which the underwire portion 18
contributes.
[0081] Although the brassieres of FIGS. 4-7 appear to be back
closure brassieres that include straps, it is understood that
straps are optional and that a front closure (not shown) may be
included in the area between the cups at 14.
[0082] The brassiere of FIG. 6 includes two cup portions 20 each
having a polymer film portion 22 at the inner part of the cup. The
stress profile of the cup portions 20 are altered by including the
film portions 22 which may vary in width from the top part of the
cup 24 which is wider as shown as the film portion 22 extends to
the inner part of the cup 26. The opposite configuration is shown
in FIG. 7, where the cup portions 20 include film portions 28 that
vary in width from a narrow part at the top of the cup 30 extending
to the bottom inner part of the cup 32. Altering the stress profile
of this area of the brassiere can avoid pinch points while provide
support or enhancement as desired. In order to achieve the desired
effect, other geometries or configurations of the film portions 22
and 28 are contemplated.
[0083] FIG. 10 and FIG. 11 each show a panty 34 including different
film portions 36, 37, 38 and 40. The film region 36 can be located
at the waistband as shown in FIG. 10 to provide the garment with a
reduced stress profile to reduce the appearance of the waistband
through clothing. The width of the polymer film 36 can vary in the
front or back of the garment to reduce pressure providing a pinch
point or alter the stress profile to increase support (such as by
providing tummy control). Similarly, the film portions at the leg
bands 36 and 37 can vary in width to provide distribution of stress
along the back portion decreasing a pinch point that can show as a
panty line under clothing, such as by increasing the width of the
film along the back portion 37. FIG. 11 includes a polymer film
region 40 of a different geometry that can provide additional
control, such as tummy control, or by providing support useful for
maternity panties.
[0084] Any of the polymer film regions 1 may be included on a
single surface 2 as shown in FIG. 12 where the surface 2 may be
either a fabric, foam or other substrate suitable for a garment.
Alternatively, the polymer film 2 may be included between two
surfaces such as a fabric, foam, etc. as in FIG. 13 where a top
surface layer 1 and bottom surface layer 3 are included.
[0085] FIG. 14 and FIG. 15 show two possibilities for using a
folded over fabric that provides a top surface layer 1 and a bottom
surface layer 2 after folding along a preselected folding lines 42.
Arrows show the direction of folding in FIG. 14 and FIG. 15. The
edges of the bottom surface layers 3 meet to form a butt seam 5 as
shown in FIG. 14A and FIG. 15A. The edges 5 may be attached or
bonded to the film region 2 at that point.
[0086] FIG. 16 is a cross-section of a butt seam at line X-X as
indicated in FIG. 14A. The seam 5 indicates the edges of the fabric
or other substrate that is folded over and bonded or attached. The
polymer film region 2 may be bonded to the top surface 1, the
bottom surface 3 or two both the top and bottom surfaces. The
folded portion 42 is indicated to demonstrate the orientation of
layer prior to bonding, however, where the fabric is sufficiently
thin, the cross-section will appear substantially linear. Also, a
space 44 is shown to demonstrate that the bonded film 2 may not
extend to the folded portion 42 of the fabric, however, this space
44 may be absent depending on the bonding technique because the
film may melt and fill this available space.
[0087] Depending on the desired effect of the polyurethaneurea
composition when applied as a film or dispersion from the aqueous
dispersion described herein, the weight average molecular weight of
the polymer in the film may vary from about 40,000 to about
150,000, including from about 100,000 to about 150,000 and about
120,000 to about 140,000.
[0088] In some embodiments, the polymer film may act as an adhesive
to attach two or more layers of fabric or foam, or to attach a
layer of fabric to foam. One suitable method for accomplishing this
is to apply a dispersion to a layer by any suitable method. Methods
for applying the dispersions of some embodiments include spraying,
kissing, printing, brushing, dipping, padding, dispensing,
metering, painting, and combinations thereof. This may be followed
by application of heat and/or pressure.
[0089] The same methods for applying polyurethaneurea dispersion
can be used for application of adhesive to attach a film to a
fabric or foam layer. Examples of adhesives include thermoset or
thermoplastic adhesives, pressure sensitive adhesives, hot melt
adhesives, and combinations thereof. The adhesive may be used to
adhere the different layers and may be applied to any of the
fabric, foam or polyurethaneurea films or dispersion. Moreover, the
polyurethaneurea aqueous dispersions may also be used as an
adhesive to adhere more than one layer of any fabric, foam or
polyurethaneurea film as described in some embodiments.
Alternatively, the polymer film may be sewn into the garment.
[0090] As described above, there are a variety of fabric
constructions that are useful for the articles of the present
invention. Furthermore, the polyurethane composition may be either
a film or a dispersion in any of these embodiments. In addition,
the polyurethaneurea composition may provide structural properties,
flexibility, adhesion, or any combination of these. The order of
layer arrangement may be (1) fabric layer, foam layer,
polyurethaneurea composition layer; (2) fabric layer, foam layer,
polyurethaneurea composition layer, foam layer, fabric layer; (3)
fabric layer, polyurethaneurea composition layer, fabric layer; (4)
foam layer, polyurethaneurea layer, foam layer; (5) foam layer,
polyurethaneurea composition layer; (6) fabric layer,
polyurethaneurea layer; or any combination of these which may be
combined to achieve more layers in the fabric construction. An
adhesive may be included to adhere any of the layers, including
wherein the polyurethaneurea composition is the adhesive.
[0091] A variety of different fibers and yarns may be used with the
fabrics of some embodiments. These include cotton, wool, acrylic,
polyamide (nylon), polyester, spandex, regenerated cellulose,
rubber (natural or synthetic), bamboo, silk, soy or combinations
thereof.
[0092] Aqueous polyurethane dispersions useful in some embodiments
of the invention are provided from particular urethane prepolymers,
which are described below in more detail.
[0093] Urethane prepolymers, or capped glycols, can generally be
conceptualized as the reaction product of a polyol, a
polyisocyanate, and a compound capable of salt-forming upon
neutralization, before the prepolymer is dispersed in water and is
chain-extended. Such prepolymers can typically be made in one or
more steps, with or without solvents. Depending on whether the
prepolymer is dissolved in a less volatile solvent (such as MEK, or
NMP) which will remain in the dispersion; dissolved in a volatile
solvent such as acetone, which can be later removed; or is
dispersed in water without any solvent; the dispersion process can
be classified in practice as the solvent process, acetone process,
or prepolymer mixing process. The prepolymer mixing process has
environmental and economical advantages, and therefore is also
useful as the basic process for making the aqueous dispersions in
the present invention.
[0094] In the prepolymer mixing process, it is important that the
viscosity of the prepolymer is adequately low enough, without
dilution by a solvent, to be transported and dispersed in water.
The present invention in one embodiment, relates to polyurethane
dispersions derived from such a prepolymer, which meet this
viscosity requirement and do not have any organic solvent in the
prepolymer or in the dispersion. In accordance with the invention,
the prepolymer is the reaction product of a polyol (a), a
diisocyanate (b) and a diol compound (c). However, prepolymers
including an organic solvent are also contemplated.
[0095] The present invention can provide stable, aqueous
polyurethane dispersions, which can be processed and applied
directly as adhesive materials (i.e., without the need of any
additional adhesive materials) for coating, bonding, and lamination
to substrates by conventional techniques. Aqueous polyurethane
dispersions falling within the scope of the present invention may
be provided with or without the use of volatile organic materials;
with acceptable curing time in production; and with good adhesion
strength, heat resistance, and stretch/recovery properties in
finished products and in practical applications.
[0096] Polyurethaneurea polymer films which may or may not be
adhesive can be coated on a release paper, whereby aqueous
dispersions of the can be used for bonding and lamination to
substrates including textile fabrics. The adhesion can be activated
by applying heat and/or pressure onto a substrate and the adhesive
film with a residence time of less than one minute, for example,
from about 15 seconds to about 60 seconds. The thus bonded articles
have good stretch/recovery properties and are expected to be
durable in normal wear and wash cycles.
[0097] Polyol components suitable as a starting material for
preparing urethane prepolymers, according to the invention, are
polyether glycols, polycarbonate glycols, and polyester glycols of
number average molecular weight of about 600 to about 3,500.
[0098] Examples of polyether polyols that can be used include those
glycols with two or more hydroxy groups, from ring-opening
polymerization and/or copolymerization of ethylene oxide, propylene
oxide, trimethylene oxide, tetrahydrofuran, and
3-methyltetrahydrofuran, or from condensation polymerization of a
polyhydric alcohol, preferably a diol or diol mixtures, with less
than 12 carbon atoms in each molecule, such as ethylene glycol,
1,3-propanediol, 1,4-butanediol, 1,5-pentanediol 1,6-hexanediol,
neopentyl glycol, 3-methyl-1,5-pentanediol, 1,7-heptanediol,
1,8-octanediol, 1,9-nonanediol, 1,10-decanediol and
1,12-dodecanediol. A linear, bifunctional polyether polyol is
preferred, and a poly(tetramethylene ether) glycol of molecular
weight of about 1,700 to about 2,100, such as Terathane.RTM. 1800
(Invista) with a functionality of 2, is particularly preferred in
the present invention.
[0099] Examples of polyester polyols that can be used include those
ester glycols with two or more hydroxy groups, produced by
condensation polymerization of aliphatic polycarboxylic acids and
polyols, or their mixtures, of low molecular weights with no more
than 12 carbon atoms in each molecule. Examples of suitable
polycarboxylic acids are malonic acid, succinic acid, glutaric
acid, adipic acid, pimelic acid, suberic acid, azelaic acid,
sebacic acid, undecanedicarboxylic acid, and dodecanedicarboxylic
acid. Examples of suitable polyols for preparing the polyester
polyols are ethylene glycol, 1,3-propanediol, 1,4-butanediol,
1,5-pentanediol 1,6-hexanediol, neopentyl glycol,
3-methyl-1,5-pentanediol, 1,7-heptanediol, 1,8-octanediol,
1,9-nonanediol, 1,10-decanediol and 1,12-dodecanediol. A linear
bifunctional polyester polyol with a melting temperature of about
5.degree. C. to about 50.degree. C. is preferred.
[0100] Examples of polycarbonate polyols that can be used include
those carbonate glycols with two or more hydroxy groups, produced
by condensation polymerization of phosgene, chloroformic acid
ester, dialkyl carbonate or diallyl carbonate and aliphatic
polyols, or their mixtures, of low molecular weights with no more
than 12 carbon atoms in each molecule. Examples of suitable polyols
for preparing the polycarbonate polyols are diethylene glycol,
1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol,
neopentyl glycol, 3-methyl-1,5-pentanediol, 1,7-heptanediol,
1,8-octanediol, 1,9-nonanediol, 1,10-decanediol and
1,12-dodecanediol. A linear, bifunctional polycarbonate polyol with
a melting temperature of about 5.degree. C. to about 50.degree. C.
is preferred.
[0101] The polyisocyanate component (b), suitable as another
starting material for making urethane prepolymers according to the
invention, can be an isomer mixture of diphenylmethane diisocyanate
(MDI) containing 4,4'-methylene bis(phenyl isocyanate) and
2,4'-methylene bis(phenyl isocyanate) in the range of 4,4'-MDI to
2,4'-MDI isomer ratios of between about 65:35 to about 35:65,
preferably in the range of about 55:45 to about 45:55 and more
preferably at about 50:50. Examples of suitable polyisocyanate
components include Mondur.RTM. ML (Bayer), Lupranate.RTM. MI
(BASF), and Isonate.RTM. 50 O,P' (Dow Chemical).
[0102] Diol compounds (c), suitable as further starting materials
for preparing urethane prepolymers according to the invention,
include at least one diol compound with: (i) two hydroxy groups
capable of reacting with the polyisocyanates b); and (ii) at least
one carboxylic acid group capable of forming salt upon
neutralization and incapable of reacting with the polyisocyanates
(b). Typical examples of diol compounds (c) having a carboxylic
acid group, include 2,2-dimethylopropionic acid (DMPA),
2,2-dimethylobutanoic acid, 2,2-dimethylovaleric acid, and DMPA
initiated caprolactones such as CAPA.RTM. HC 1060 (Solvay). DMPA is
preferred in the present invention.
[0103] The prepolymer can be prepared by mixing starting materials
(a), (b), and (c) together in one step and by reacting at
temperatures of about 50.degree. C. to about 100.degree. C. for
adequate time until all hydroxy groups are essentially consumed and
a desired % NCO of the isocyanate group is achieved. Alternatively,
this prepolymer can be made in two steps by first reacting starting
material (a) with excess (b), followed by reacting with component
(c) until a final desired % NCO of the prepolymer is achieved. For
example, the % NCO may range from about 1.3 to about 6.5, such as
from about 1.8 to about 2.6. Significantly, no organic solvent is
added to or mixed with the starting materials before, during or
after the reaction. Optionally, a catalyst may be used to
facilitate the prepolymer formation.
[0104] In an embodiment of the present invention, the prepolymer
comprises components (a), (b), and (c), which are combined together
and provided in the following ranges of weight percentages, based
on the total weight of the prepolymer:
about 34% to about 89% of component (a); about 59% to about 10% of
component (b); and about 7.0% to about 1.0% of component (c).
[0105] In another embodiment of present invention, the prepolymer
comprises Terathane.RTM. 1800 polyether glycol as component (a),
Mondur.RTM. ML diisocyanate as component (b), and
2,2-dimethylopropionic acid (DMPA) as component (c). Within such
embodiments, these components may, for example, be present in the
following ranges of weight percentages, based on the total weight
of the prepolymer:
TABLE-US-00001 a) Terathane .RTM. 1800 polyether glycol: about 61%
to about 80%; b) Mondur .RTM. ML diisocyanate: about 35% to about
18%; and c) 2,2-dimethylopropionic acid (DMPA): about 4.0% to about
2.0%.
[0106] The prepolymer prepared from components (a), (b) and (c) may
have a bulk viscosity (without any solvent present) below about
6,000 poises, such as below about 4,500 poises, measured by the
falling ball method at 40.degree. C. This prepolymer, containing
carboxylic acid groups along the polymer chains, can be dispersed
with a high-speed disperser into a de-ionized water medium that
comprises: at least one neutralizing agent (d), to form an ionic
salt with the acid; at least one surface active agent (ionic and/or
non-ionic dispersant or surfactant); and, optionally, at least one
diamine chain extension component (f). Alternatively, the
neutralizing agent can be mixed with the prepolymer before being
dispersed into the water medium. At least one antifoam and/or
defoam agent and preferably at least one rheological modifier can
be added to the water medium before, during, or after the
prepolymer is dispersed.
[0107] Examples of suitable neutralizing agents (d) to convert the
acid groups to salt groups include: tertiary amines (such as
triethylamine, N,N-diethylmethylamine, N-methylmorpholine,
N,N-diisopropylethylamine, and triethanolamine) and alkali metal
hydroxides (such as lithium, sodium and potassium hydroxides).
Primary and/or secondary amines may be also used as the
neutralizing agent for the acid groups. The degrees of
neutralization are generally between about 60% to about 140%, for
example, in the range of about 80% to about 120% of the acid
groups.
[0108] Examples of suitable diamine chain extenders (f) include:
1,2-ethylenediamine, 1,4-butanediamine, 1,6-hexamethylenediamine,
1,12-dodecanediamine, 1,2-propanediamine,
2-methyl-1,5-pentanediamine, 1,2-cyclohexanediamine,
1,4-cyclohexanediamine, 4,4'-methylene-bis(cyclohexylamine),
isophorone diamine, 2,2-dimethyl-1,3-propanediamine,
meta-tetramethylxylenediamine, and Jeffamine.RTM. (Texaco) of
molecular weight less than 500.
[0109] Examples of suitable surface active agents include: anionic,
cationic, or nonionic dispersants or surfactants, such as sodium
dodecyl sulfate, sodium dodecylbenzenesulfonate, ethoxylated
nonylphenols, and lauryl pyridinium bromide.
[0110] Examples of suitable antifoaming or deforming or foam
controlling agents include: Additive 65 and Additive 62 (silicone
based additives from Dow Corning), FoamStar.RTM. 1300 (a mineral
oil based, silicone free defoamer from Cognis) and Surfynol.TM. DF
110 L (a high molecular weight acetylenic glycol non-ionic
surfactant from Air Products & Chemicals).
[0111] Examples of suitable rheological modifiers include:
hydrophobically-modified ethoxylate urethanes (HEUR),
hydrophobically-modified alkali swellable emulsions (HASE), and
hydrophobically-modified hydroxy-ethyl cellulose (HMHEC).
[0112] At least one monofunctional dialkyl amine compound or
monofunctional alcohol, as the blocking agent (e) for isocyanate
groups, may be added to the water medium during or after the
prepolymer is dispersed to control the weight average molecular
weight of the polyurethaneurea polymer. For example, the blocking
agent can be added to the water mixture immediately after the
prepolymer is dispersed. Optionally at least one polymeric
component (g) (MW>about 500), with at least three or more
primary and/or secondary amino groups per mole of the polymer, is
added to the water medium after the prepolymer is dispersed and the
blocking agent is added.
[0113] Examples of suitable mono-functional dialkylamine blocking
agents (e) include: N,N-diethylamine, N-ethyl-N-propylamine,
N,N-diisopropylamine, N-tert-butyl-N-methylamine,
N-tert-butyl-N-benzylamine, N,N-dicyclohexylamine,
N-ethyl-N-isopropylamine, N-tert-butyl-N-isopropylamine,
N-isopropyl-N-cyclohexylamine, N-ethyl-N-cyclohexylamine,
N,N-diethanolamine, and 2,2,6,6-tetramethylpiperidine. The molar
ratio of the amine blocking agent to the isocyanate groups of the
prepolymer prior to dispersion in water generally should range from
about 0.05 to about 0.50, for example from about 0.20 to about
0.40. Catalysts may be used for the de-blocking reactions.
[0114] Examples of monofunctional alcohol blocking agents (e)
include: aliphatic and cycloaliphatic primary and secondary
alcohols with 1 to 18 carbons, phenol, substituted phenols,
ethoxylated alkyl phenols and ethoxylated fatty alcohols with
molecular weight less than about 750, including molecular weight
less than 500, hydroxyamines, hydroxymethyl and hydroxyethyl
substituted tertiary amines, hydroxymethyl and hydroxyethyl
substituted heterocyclic compounds, and combinations thereof,
including furfuryl alcohol, tetrahydrofurfuryl alcohol,
N-(2-hydroxyethyl)succinimide, 4-(2-hydroxyethyl)morpholine,
methanol, ethanol, butanol, neopentyl alcohol, hexanol,
cyclohexanol, cyclohexanemethanol, benzyl alcohol, octanol,
octadecanol, N,N-diethylhydroxylamine, 2-(diethylamino)ethanol,
2-dimethylaminoethanol, and 4-piperidineethanol, and combinations
thereof.
[0115] Examples of the suitable polymeric component (g) include:
polyethylenimine, poly(vinylamine), poly(allylamine), and
poly(amidoamine) dendrimers.
[0116] An anti-yellowing compound useful in some polyurethaneurea
dispersions includes an aliphatic or aromatic isocyanate
(mono-functional), an aliphatic diisocyanate, or a combination
thereof.
[0117] Examples of anti-yellowing monoisocyanates include aliphatic
monoisocyanates, cycloaliphatic isocyanates. Specifically included
are compounds of the formula R--N.dbd.C.dbd.O, where are is
aliphatic or cylcoaliphatic such as ethyl-, propyl-, butyl-,
pentyl-, hexyl, cyclohexyl-, etc. as well as aromatic
monoisocyanates. Aliphatic polyisocyanates have been used in
polyurethane applications to reduce yellowing due to the absence of
an aromatic group. In the present invention, a monoisocyanate is
added to a polyurethaneurea dispersion prepared with an aromatic
polyisocyanate and surprisingly results in a composition that has a
significant reduction in yellowing of films cast and dried from the
dispersion. Yellowing can result from exposure to environmental or
process conditions such as heat, NO2, and UV, among others.
[0118] A non-limiting list of suitable monoisocyanates include:
1-methyl-decyl isocyanate, 2-chloroethyl isocyanate, 2-ethylhexyl
isocyanate, 2-methylcyclohexyl isocyanate, 3-(triethoxysilyl)propyl
isocyanate, 3-chloropropyl isocyanate,
3-isopropenyl-a,a-dimethylbenzyl isocyanate, 3-methylcyclohexyl
isocyanate, 4-methycyclohexyl isocyanate, 6-chlorohexyl isocyanate,
benzyl isocyanate, cycloheptyl isocyanate, cycloheptyl isocyanate,
cyclohexyl isocyanate, cyclohexanemethyl isocyanate, cyclooctyl
isocyanate, decyl isocyanate, dodecyl isocyanate, isocyanatoacetic
acid n-butyl ester, isopropyl isocyanate, n-hepyl isocyanate,
n-hexyl isocyanate, nonyl isocyanate, octadecyl isocyanate, octyl
isocyanate, pentyl isocyanate, phenethyl isocyanate,
trans-4-methycyclohexyl isocyanate, .alpha.-methylbenzyl
isocyanate, (3-isocyanatopropyl)triethoxysilane, ethyl
6-isocyanatohexanoate, ethyl 3-isocyanatopropionate, 1-tetradecyl
isocyanate, and combinations thereof. An example of a suitable
aromatic monoisocyanate includes phenyl isocyanate, which may be
used alone or in combination with other aromatic or aliphatic
isocyanates.
[0119] A variety of different aliphatic diisocyanates are also
useful as anti-yellowing compounds and may be used alone, or in
combinations with other aliphatic diisocyanates or a
monoisocyanate.
[0120] Other additives that may be optionally included in the
aqueous dispersion or in the prepolymer include: anti-oxidants, UV
stabilizers, colorants, pigments, crosslinking agents, phase change
materials (i.e., Outlast.RTM., commercially available from Outlast
Technologies, Boulder, Colo.), antimicrobials, minerals (i.e.,
copper), microencapsulated well-being additives (i.e., aloe vera,
vitamin E gel, aloe vera, sea kelp, nicotine, caffeine, scents or
aromas), nanoparticles (i.e., silica or carbon), calcium carbonate,
flame retardants, antitack additives, chlorine degradation
resistant additives, vitamins, medicines, fragrances, electrically
conductive additives, and/or dye-assist agents (i.e.,
Methacrol.RTM., commercially available from E.I. DuPont de Nemours,
Wilmington, Del.). Other additives which may be added to the
prepolymer or the aqueous dispersion comprise adhesion promoters,
anti-static agents, anti-cratering agents, anti-crawling agents,
optical brighteners, coalescing agents, electroconductive
additives, luminescent additives, flow and leveling agents,
freeze-thaw stabilizers, lubricants, organic and inorganic fillers,
preservatives, texturizing agents, thermochromic additives, insect
repellants, and wetting agents.
[0121] Such optional additives may be added to the aqueous
dispersion before, during, or after the prepolymer is dispersed, as
the process allows. No organic solvent is added to the aqueous
dispersion at any time.
[0122] Polyurethane aqueous dispersions falling within the scope of
the present invention should be expected to have a solids content
of from about 10% to about 50% by weight, for example from about
30% to about 45% by weight. The viscosity of polyurethane aqueous
dispersions falling within the scope of the present invention may
be varied in a broad range from about 10 centipoises to about
100,000 centipoises depending on the processing and application
requirements. For example, in one embodiment, the viscosity is in
the range of about 500 centipoises to about 30,000 centipoises. The
viscosity may be varied by using an appropriate amount of
thickening agent, such as from about 0 to about 2.0 wt %, based on
the total weight of the aqueous dispersion.
[0123] An organic solvent may also be used in the preparation of
films and dispersions of some embodiments. The organic solvent may
be used to lower the prepolymer viscosity through dissolution and
dilution and/or to assist the dispersion of solid particles of the
diol compound having a carboxylic acid group such as
2,2-dimethylopropionic acid (DMPA) to enhance the dispersion
quality. It may also serve for the purposes to improve the film
uniformity such as reducing streaks and cracks in the coating
process.
[0124] The solvents selected for these purposes are substantially
or completely non-reactive to isocyanate groups, stable in water,
and have a good solubilizing ability for DMPA, the formed salt of
DMPA and triethylamine, and the prepolymer. Examples of suitable
solvents include N-methylpyrrolidone, N-ethylpyrrolidone,
dipropylene glycol dimethyl ether, propylene glycol n-butyl ether
acetate, N,N-dimethylacetamide, N,N-dimethylformamide, 2-propanone
(acetone) and 2-butanone (methylethylketone or MEK).
[0125] The amount of solvent added to the films/dispersion of some
embodiments may vary. When a solvent is include, suitable ranges of
solvent include amounts of less than 50% by weight of the
dispersion. Smaller amounts may also be used such as less than 20%
by weight of the dispersion, less than 10% by weight of the
dispersion, less than 5% by weight of the dispersion and less than
3% by weight of the dispersion.
[0126] There are many ways to incorporate the organic solvent into
the dispersion at different stages of the manufacturing process,
for example, [0127] 1) The solvent can be added to and mixed with
the prepolymer after the polymerization is completed prior to
transferring and dispersing the prepolymer, the diluted prepolymer
containing the carboxylic acid groups in the backbone and
isocyanate groups at the chain ends is neutralized and chain
extended while it is dispersed in water. [0128] 2) The solvent can
be added and mixed with other ingredients such as Terathane.RTM.
1800, DMPA and Lupranate.RTM. MI to make a prepolymer in the
solution, and then this prepolymer containing the carboxylic acid
groups in the backbone and isocyanate groups at the chain ends in
the solution is dispersed in water and at the same time it is
neutralized and chain extended. [0129] 3) The solvent can be added
with the neutralized salt of DMPA and Triethylamine (TEA), and
mixed with Terathane.RTM. 1800 and Lupranate.RTM. MI to make the
prepolymer prior to dispersion. [0130] 4) The solvent can be mixed
with TEA, and then added to the formed prepolymer prior to
dispersion. [0131] 5) The solvent can be added and mixed with the
glycol, followed by the addition of DMPA, TEA and then
Lupranate.RTM. MI in sequence to a neutralized prepolymer in
solution prior to dispersion.
[0132] The aqueous polyurethane dispersions of the some embodiments
are particularly suitable for adhesive polymer films, which can be
used for fabric bonding, lamination, and adhesion purposes when
applied with heat and pressure for a relatively short period of
time. Pressures, can for example, range from about atmospheric
pressure to about 60 psi and times can range from less than about
one second to about 30 minutes in accordance with the bonding
method used.
[0133] Such polymer films may be made by coating the dispersion
onto a release paper and drying to remove water at temperatures
below about 100.degree. C. through commercially available processes
to form a film on the paper. The formed film sheets can be slit
into strips of desired width and wound-up into spools for later use
in applications to form stretch articles, for example textile
fabrics. Examples of such applications include: stitch-less or
seamless garment constructions; seam seal and reinforcement; labels
and patches bonding to garments; and localized stretch/recovery
enhancement. The adhesion bonding can be developed in the
temperature range of from about 100.degree. C. to about 200.degree.
C., such as from about 130.degree. C. to about 200.degree. C., for
example, from about 140.degree. C. to about 180.degree. C., in a
period of 0.1 seconds to several minutes, for example, less than
about one minute. Typical bonding machines are Sew Free
(commercially available from SewSystems in Leicester, England),
Macpi hemming machine (commercially available from the Macpi Group
in Brescia, Italy), Framis hot air welding machine (commercially
available from Framis Italy, s p.a. in Milano, Italy). This bonding
is expected to be strong and durable when exposed to repeated wear,
wash, and stretch in a textile fabric garment.
[0134] The coating, dispersion, or shaped article may be pigmented
or colored and also may be used as a design element in that
regard.
[0135] In addition, articles with laminated films or dispersions
can be molded. For example, fabric can be molded under conditions
appropriate for the hard yarn in the fabric. Also, molding may be
possible at temperature which will mold the shaped article or
dispersion, but below temperatures suitable for molding the hard
yarn.
[0136] One suitable method of attaching a layer of polymer film to
a substrate is lamination using any method wherein heat or energy
is applied to the laminate surface. Methods of heat application
include, for example, ultrasonic, direct heat, indirect heat, and
microwave. Such direct lamination may provide an advantage in view
of other methods used in the art in that the shaped article may not
only bond to the a substrate via a mechanical interaction but also
via a chemical bond. For example, if the substrate has any reactive
hydrogen functional groups, such groups may react with the
isocyanate and hydroxyl groups on the dispersion or shaped article,
thereby providing a chemical bond between the substrate and the
dispersion or shaped article. Such chemical bonding of the
dispersion or shaped article to the substrate can give a much
stronger bond. Such bonding may occur in dry polymer films that are
cured onto a substrate or in wet dispersions that are dried and
cured in one step. Materials without an active hydrogen include
polypropylene fabrics and anything with a fluoropolymer or a
silicone based surface. Materials with an active hydrogen include,
for example, nylon, cotton, polyester, wool, silk, cellulosics,
acetates, metals, and acrylics. Additionally, articles treated with
acid, plasma, or another form of etching may have active hydrogens
for adhesion. Dye molecules also may have active hydrogens for
bonding.
[0137] Methods and means for applying the polymer films of some
embodiments include, but are not limited to: roll coating
(including reverse roll coating); use of a metal tool or knife
blade (for example, pouring a dispersion onto a substrate and then
casting the dispersion into uniform thickness by spreading it
across the substrate using a metal tool, such as a knife blade);
spraying (for example, using a pump spray bottle); dipping;
painting; printing; stamping; and impregnating the article. These
methods can be used to apply dispersion directly onto a substrate
without the need of further adhesive materials and can be repeated
if additional/heavier layers are required. The dispersions can be
applied to any fabrics of knits, wovens or nonwovens made from
synthetic, natural, or synthetic/natural blended materials for
coating, bonding, lamination and adhesion purposes. The water in
the dispersion can be eliminated with drying during the processing
(for example, via air drying or use of an oven), leaving the
precipitated and coalesced polyurethane layer on the fabrics to
form an adhesive bond.
[0138] At least one coagulant may optionally be used to control or
to minimize penetration of dispersions according to the invention
into a fabric or other article. Examples of coagulants that may be
used include calcium nitrate (including calcium nitrate
tetrahydrate), calcium chloride, aluminum sulfate (hydrated),
magnesium acetate, zinc chloride (hydrated) and zinc nitrate.
[0139] An example of a tool that can be used for applying
dispersions is a knife blade. The knife blade can be made of metal
or any other suitable material. The knife blade can have a gap of a
predetermined width and thickness. The gap may range in thickness,
for example, from 0.2 mils to 50 mils, such as a thickness of 5
mils, 10 mils, 15 mils, 25 mils, 30 mils, or 45 mils.
[0140] The thickness of the films, solutions, and dispersions may
vary depending on the application. In the case of dry polymer
films, the final thickness may, for example, range from about 0.1
mil to about 250 mil, such as from about 0.5 mil to about 25 mil,
including from about 1 to about 6 mil (one mil=one thousandth of an
inch).
[0141] Suitable thicknesses include about 0.5 mil to about 12 mil,
about 0.5 to about 10 mil, and about 1.5 mil to about 9 mil. For
aqueous dispersions, the amount used may, for example, range from
about 2.5 g/m.sup.2 to about 6.40 kg/m.sup.2, such as from about
12.7 to about 635 g/m.sup.2, including from about 25.4 to about
152.4 g/m.sup.2.
[0142] Types of planar sheets and tapes that can be coated with
dispersions and polymer films falling within the scope of the
present invention include, but are not limited to: textile fabrics,
including wovens and knits; nonwovens; leather (real or synthetic);
paper; metal; plastic; and scrim.
[0143] End articles that can be produced using the dispersions and
polymer films falling within the scope of the present invention
include, but are not limited to: apparel, which includes any type
of garment or article of clothing; knitted gloves; upholstery; hair
accessories; bed sheets; carpet and carpet backing; conveyor belts;
medical applications, such as stretch bandages; personal care
items, including incontinence and feminine hygiene products; and
footwear. Articles coated with dispersion or covered with film or
tape may be used as sound suppression articles.
[0144] Non-elastic fabrics laminated to polymer films can have
improved stretch and recovery and improved molding properties.
[0145] Articles including polymer films, film, tape, or aqueous
polyurethane dispersion may be molded. The articles may be made
with multiple layers of substrate and shaped article, film, tape,
or dispersion. The multi-layered articles also may be molded.
Molded and non-molded articles may have different levels of stretch
and recovery. The molded articles may comprise a body shaping or
body supporting garment, such as a brassiere.
[0146] Examples of apparel or garments that can be produced using
dispersions and polymer films, include but are not limited to:
undergarments, brassieres, panties, lingerie, swimwear, shapers,
camisoles, hosiery, sleepwear, aprons, wetsuits, ties, scrubs,
space suits, uniforms, hats, garters, sweatbands, belts,
activewear, outerwear, rainwear, cold-weather jackets, pants,
shirtings, dresses, blouses, mens and womens tops, sweaters,
corsets, vests, knickers, socks, knee highs, dresses, blouses,
aprons, tuxedos, bisht, abaya, hijab, jilbab, thoub, burka, cape,
costumes, diving suit, kilt, kimono, jerseys, gowns, protective
clothing, sari, sarong, skirts, spats, stola, suits, straitjacket,
toga, tights, towel, uniform, veils, wetsuit, medical compression
garments, bandages, suit interlinings, waistbands, and all
components therein.
[0147] The following examples are meant to be exemplary and not
limiting of the embodiments described herein.
[0148] Included below are examples of polymer films that are useful
in the articles of some embodiments. Testing including inventive
and comparative examples are also included.
EXAMPLES
[0149] Terathane.RTM. 1800 is a linear polytetramethylene ether
glycol (PTMEG), with a number average molecular weight of 1,800
(commercially available from INVISTA S.a.r.L., of Wichita,
Kans.);
[0150] Pluracol.RTM. HP 4000D is a linear, primary hydroxyl
terminated polypropylene ether glycol, with a number average
molecular weight of 400 (commercially available from BASF,
Bruxelles, Belgium);
[0151] Mondur.RTM. ML is an isomer mixture of diphenylmethane
diisocyanate (MDI) containing 50-60% 2,4'-MDI isomer and 50-40%
4,4'-MDI isomer (commercially available from Bayer, Baytown,
Tex.);
[0152] Lupranate.RTM. MI is an isomer mixture of diphenylmethane
diisocyanate (MDI) containing 45-55% 2,4'-MDI isomer and 55-45%
4,4'-MDI isomer (commercially available from BASF, Wyandotte,
Mich.);
[0153] Isonate.RTM. 125MDR is a pure mixture of diphenylmethane
diisocyanate (MDI) containing 98% 4,4'-MDI isomer and 2% 2,4'-MDI
isomer (commercially available from the Dow Company, Midland,
Mich.); and
[0154] DMPA is 2,2-dimethylopropionic acid.
[0155] The following prepolymer samples were prepared with MDI
isomer mixtures, such as Lupranate.RTM. MI and Mondur.RTM. ML,
containing a high level of 2,4'-MDI.
Example 1
[0156] The preparation of the prepolymers was conducted in a glove
box with nitrogen atmosphere. A 2000 ml Pyrex.RTM. glass reaction
kettle, which was equipped with an air pressure driven stirrer, a
heating mantle, and a thermocouple temperature measurement, was
charged with about 382.5 grams of Terathane.RTM. 1800 glycol and
about 12.5 grams of DMPA. This mixture was heated to about
50.degree. C. with stirring, followed by the addition of about 105
grams of Lupranate.RTM. MI diisocyanate. The reaction mixture was
then heated to about 90.degree. C. with continuous stirring and
held at about 90.degree. C. for about 120 minutes, after which time
the reaction was completed, as the % NCO of the mixture declined to
a stable value, matching the calculated value (% NCO aim of 1.914)
of the prepolymer with isocyanate end groups. The viscosity of the
prepolymer was determined in accordance with the general method of
ASTM D1343-69 using a Model DV-8 Falling Ball Viscometer (sold by
Duratech Corp., Waynesboro, Va.) operated at about 40.degree. C.
The total isocyanate moiety content, in terms of the weight percent
of NCO groups, of the capped glycol prepolymer was measured by the
method of S. Siggia, "Quantitative Organic Analysis via Functional
Group", 3rd Edition, Wiley & Sons, New York, pp. 559-561
(1963), the entire disclosure of which is incorporated herein by
reference.
Example 2
[0157] The solvent-free prepolymer, as prepared according to the
procedures and composition described in Example 1, was used to make
a polyurethaneurea aqueous dispersion.
[0158] A 2,000 ml stainless steel beaker was charged with about 700
grams of de-ionized water, about 15 grams of sodium
dodecylbenzenesulfonate (SDBS), and about 10 grams of triethylamine
(TEA). This mixture was then cooled with ice/water to about
5.degree. C. and mixed with a high shear laboratory mixer with
rotor/stator mix head (Ross, Model 100LC) at about 5,000 rpm for
about 30 seconds. The viscous prepolymer, prepared in the manner as
Example 1 and contained in a metal tubular cylinder, was added to
the bottom of the mix head in the aqueous solution through flexible
tubing with applied air pressure. The temperature of the prepolymer
was maintained between about 50.degree. C. and about 70.degree. C.
The extruded prepolymer stream was dispersed and chain-extended
with water under the continuous mixing of about 5,000 rpm. In a
period of about 50 minutes, a total amount of about 540 grams of
prepolymer was introduced and dispersed in water. Immediately after
the prepolymer was added and dispersed, the dispersed mixture was
charged with about 2 grams of Additive 65 (commercially available
from Dow Corning.RTM., Midland Mich.) and about 6 grams of
diethylamine (DEA). The reaction mixture was then mixed for about
another 30 minutes. The resulting solvent-free aqueous dispersion
was milky white and stable. The viscosity of the dispersion was
adjusted with the addition and mixing of Hauthane HA thickening
agent 900 (commercially available from Hauthway, Lynn, Mass.) at a
level of about 2.0 wt % of the aqueous dispersion. The viscous
dispersion was then filtered through a 40 micron Bendix metal mesh
filter and stored at room temperatures for film casting or
lamination uses. The dispersion had solids level of 43% and a
viscosity of about 25,000 centipoises. The cast film from this
dispersion was soft, tacky, and elastomeric.
Example 3
[0159] The preparation procedures were the same as Example 2,
except that DEA was not added into the dispersion after the
prepolymer was mixed. Initially, the dispersion appeared to be no
different from Example 2.
Example 4
[0160] Fabric including various laminated films were subjected to
stress/strain testing.
[0161] Elongation and tenacity properties were measured on films
using a dynamic tensile tester Instron. The sample size was as
indicated below. The sample was placed in clamps and extended at a
strain rate of 200% elongation per minute until a maximum
elongation was reached. The tenacity and elongation were measured
just prior to the film break. Similarly, the set % was measured by
extending a laminated sample from 0 to 50% elongation for five
cycles at a strain rate of 200% per minute. The set % was measured
after the fourth cycle.
[0162] The films of Samples A and B are polyurethaneurea films cast
from the dispersion of Example 3. The films of Samples D, K, L, and
M were polyurethaneurea films cast from the dispersion of Example
2. The films of Samples C, G, H, I, and J were three-layered
polyurethaneurea "sandwich" films cast from the dispersion of
Example 3, with a film from the dispersion of Example 2 on each
side. The film of Sample E and nonwoven of Sample F were prepared
from a polypropylene based polymer commercially available from
ExxonMobil under the trade name VISTAMAXX. Sample N was a
comparative example using a hot melt glue in a dot matrix
configuration.
[0163] Using Pacific Fabric a range of tape (narrow strip) and film
variants were bonded to fabric. The conditions for preparation of
Samples are described in Table 1 below. Each fabric/polymer
composition sample had a width of 63.5 mm.
TABLE-US-00002 TABLE 1 Sample Preparation Description Polymer
Composition Press Press Time Press Pressure Sample Description Temp
.degree. C. (sec) (bar) A Film 3 mil thick 200 30 5 B Film 1.5 mil
thick 200 30 5 C Film 7 mil thick 170 45 5 D 2 Films 2 mil thick
170 45 5 E Film 3 mil thick 170 45 5 F Nonwoven 170 45 5 60
oz/yd.sup.2 G Film 7 mil thick 170 45 5 H Film 7 mil thick 170 45 5
including 11 side- by side pieces of approximately equal width I
Film 7 mil thick 170 45 5 J Film 7 mil thick 170 45 5 K Film 4 mil
thick 170 45 5 L Film 4 mil thick 170 45 5 M Film 4 mil thick 170
45 5 N Dot matrix 150 30 5
[0164] These samples were tested in Instron cycling to 120%
elongation, 3 times and measuring the elongation (set) on the
fourth load at 25 gram force (as shown in FIG. 17). The first cycle
data is shown in FIG. 19 for samples A-G and in FIG. 20 for samples
H--N as shown in FIG. 17. By evaluating this data one can see that
the stress/strain behavior of the base fabric can be enhanced by
the application of the polyurethaneurea films prepared from the
dispersions of Examples 2 and 3. The films add power, particularly
the samples include films of Example 3 (A, B, C, G, H, I, and J).
The set data suggests that when compared to a stretch narrow bra
wing the laminated wings using films including the composition of
Example 3 can give comparable recovery (set) and power
(load/unload). The laminated wings including the composition of
Example 3 can offer improved performance vs. commercial bra wings
of laminated fabrics/foam constructions.
Example 5
[0165] To demonstrate effect of altering stress profile of a
garment, a commercially available bra was retrofit with a range of
film and narrow film/tape variants as shown in Table 2. These
film/tape variants were applied to the bra wing which has a
substantially trapezoidal shape. The commercially available bra was
Victoria's Secret: Secret Embrace Style 6505, size 36C. These
garments were fit and wear tested.
[0166] The polymer composition of Test 12 was a polyurethaneurea
film cast and dried from the dispersion of Example 2. The polymer
composition of Tests 2, 3, 7, 9-11, 13 and 21 were polyurethaneurea
films cast and dried from the dispersion of Example 3. Tests 1,
4-7, 15, 18, and 19 include three-layered polyurethaneurea
"sandwich" films cast from the dispersion of Example 3, with a film
from the dispersion of Example 2 on each side. Test 8 is the
control including no retrofit polymer composition. Tests 14 and 20
include a polyurethane film commercially available from Bemis
(Bemis 3410). The film of Test 16 and the nonwoven of Test 17 were
prepared from a polypropylene based polymer commercially available
from ExxonMobil under the trade name VISTAMAXX.
TABLE-US-00003 TABLE 2 Retrofit of Commercial Bra Polymer
Composition Time Pressure Test Description of Modification
Description Temp .degree. C. (sec) (bar) 1 Tape along edge 8 mm
width, 7 mil thick 175 45 5 2 Cover entire wing 1.5 mil thick 200
30 5 3 Cover entire wing 3 mil thick 175 45 5 4 Tape along edge 6
mm width, 7 mil thick 175 45 5 5 Tape along edge 8 mm width, 7 mil
thick 175 45 5 6 Tape along edge 10 mm width, 7 mil thick 175 45 5
7 Cover entire wing 1.5 mil thick 200 30 5 8 Control None 165 45 5
9 Tape along edge 6 mm width, 6 mil thick 200 30 5 10 Trapezoid
shape according 1.5 mil thick 175 45 5 to FIG. 1 with edges 4
folded over and bonded 11 Trapezoid shape of wing 3 mil thick 175
45 5 folded in half and reversed 180.degree. 12 Two film layers
covering 4 mil thick 175 45 5 entire wing 13 Trapezoid shape
covering 1.5 mil thick 175 45 5 entire wing 14 Trapezoid shape
covering 2 mil thick 165 45 5 entire wing 15 Narrow film applied 7
mil thick 175 45 5 according to FIG. 3 16 Trapezoid shape covering
4 mil thick 165 45 5 entire wing 17 Trapezoid shape covering
Nonwoven 90 oz/yd.sup.2 165 45 5 entire wing 18 Narrow film applied
7 mil thick 150 45 5 according to FIG. 3 19 Film bonded to edges 7
mil thick 150 45 5 20 Film bonded to edges 2 mil thick 150 45 5 21
Film bonded to edges 3 mil thick 175 45 5
[0167] The film of Test 3 and Test 8 (control) were compared for
compression force measured with Gebiom Dynamic Force Sensor.
Measurements were taken in the center of the bra wing where the
film had been bonded to the garment. Results are shown in FIG. 18.
By comparing the force of the control garment versus the garment
with the film in Test 3 bonded to it, concluded that adding this
film provided about 3.times. the compressive force of garment
alone. From this, it was extrapolated that a film of similar
composition having a half the thickness would result in a
compressive force approximately equal to that of the garment alone.
While it would be expected that the film would result in a
compressive force approximately equal to that of 2.times. the
garment alone.
[0168] Using this information, the intent was to construct a
garment in which along the length of the bra wing would result an
equal compressive force on the body. The bra wing is essentially a
trapezoid shape, as shown in FIGS. 1 to 3.
[0169] Since the bra wing is wider at the front (where it is
attached to the bra) than the back (where it is attached to a hook
or eye closure), the front of the bra wing will have a higher force
when worn at equal elongation. To improve the comfort, an inverted
trapezoid of polyurethaneurea film of 1.5 mil thickness (Test 10)
was applied by bonding to the bra wing trapezoid as shown in the
FIG. 1.
[0170] Similarly, Test 11 was made using an inverted trapezoid of 3
mil thick polyurethaneurea film of Example 3 bonded to the bra wing
trapezoid, except that the trapezoid was cut in half along the
length, since the 3 mil thick film has 2.times. the compressive
force of the bra wing.
[0171] Test 18, was prepared using a tape of 10 mm wide film. This
was bonded diagonally from the bottom of the cup to the top of the
hook/eye closure, as shown in FIG. 3. This provided a means to
uplift, improve the comfort and fit of the bra by engineered design
and placement of the increased power and recovery.
[0172] The resultant bras were fit and wear tested. The improved
comfort and fit was validated by the fit model for the retrofit
bras of Tests 10, 11, and 18.
[0173] While the present invention has been described in an
illustrative manner, it should be understood that the terminology
used is intended to be in a nature of words or description rather
than of limitation. Furthermore, while the present invention has
been described in terms of several illustrative embodiments, it is
to be appreciated that those skilled in the art will readily apply
these teachings to other possible variations of the invention.
* * * * *