Fabric bonding

Abstract

A method for making a shaped object is disclosed. A mould ( 14 ) is disposed between two layers of fabric ( 10 a , 10 b ), with joining layer ( 12 ) layer therebetween. The upper fabric layer ( 10 b ) has a greater surface are a than the lower layer ( 10 a ), so that the final garment has a natural curvature. Further embodiments respectively describe how garment inserts may be joined by a vacuum draw-down process (FIG. 10 ) and by the use of adhesive cups (FIG. 12 ).

1 . A method for making a shaped object from sheets of synthetic material comprising the steps of: 
 (c) placing a first sheet of material in proximity to a second sheet of material such that the edges of the first and second sheets of material correspond; and    (d) sealing together the edges of said sheets of material;    characterised in that a mould is disposed between the first and second sheets of material, the mould having an upper surface for contact with the first sheet of material and a lower surface for contact with the second sheet of material, the mould being shaped such that the is surface areas of the upper and lower surfaces are different and also being shaped such that the first and second sheets of material are in contact where they are to be sealed together or are separated only by layers intended to be incorporated into the final seam.    
     
     
         2 . The method of  claim 1  wherein the first sheet of material is placed against the mould by laying a first edge of the first sheet of material along one side of the mould and subsequently pressing the rest of the first sheet of material against the mould progressively.  
     
     
         3 . The method as claimed in  claim 1  or  claim 2 , wherein a progressive tool is used to press said first sheet of material against the mould and the second sheet of material.  
     
     
         4 . The method as claimed in any preceding  claim 4 , wherein vacuum draw-down is used to bring a sheet of material into contact with the mould.  
     
     
         5 . The method as claimed in any preceding claim, wherein first and second sheets of material are separated where they are to be sealed together by a thermoplastic joining film.  
     
     
         6 . The method as claimed in any preceding claim wherein the shaped object is selected from the group comprising gloves, boots, jackets and trouser.  
     
     
         7 . A shaped object comprising two sheets of flexible is material, the edges of which correspond, joined around part of their perimeter by a waterproof seal, wherein one sheet of flexible material is of greater surface area than the other sheet of material.  
     
     
         8 . The shaped object as claimed in  claim 7 , wherein shape of the object is selected from the group comprising gloves, boots, jackets and trousers.  
     
     
         9 . A method of making a composite garment comprising the steps of: 
 forming a laminate of a synthetic membrane and a fabric sheet, the synthetic membrane having an adhesive layer thereon;    joining edges of two fabric sheets or two parts of the same fabric sheet to each other around part of their perimeter so as to form an insert for a garment; 
 (c) inverting said insert for a garment and placing said insert for a garment within an outer layer of a garment:  
 (d) placing a shaped inner layer of a garment within said insert, said inner layer having an adhesive layer thereon;  
 (e) lasting the inner layer and insert to the outer layer of a garment and applying heat thereto so as to melt the adhesive layers and form a composite garment.  
   
     
     
         10 . The method as claimed in  claim 9  wherein the edges of the two fabric sheets or two parts of the same fabric sheet are joined using a thermoplastic joining layer.  
     
     
         11 . A method of making a composite garment, the method comprising the steps of: 
 forming a garment shaped fibrous layer around a mould,    placing a garment liner around said glove shaped fibrous layer, the garment liner having a surface in contact with the garment shaped fibrous layer, the surface having a thermally activated adhesive thereon; and    heat activating the thermally activated adhesive, thereby joining the garment liner to the garment shaped fibrous layer.    
     
     
         12 . The method as claimed in  claim 11  wherein the garment is placed within an outer garment layer.  
     
     
         13 . The method as claimed in  claim 11  or  claim 12  wherein the garment shaped fibrous layer is formed around a mould using the method as claimed in  claim 1 .  
     
     
         14 . A method for forming a garment, the method comprising the steps of: 
 providing an outer surface of a first insert with an adhesive;    placing the first insert over a moulding, said moulding having a hollow centre and perforations formed in a surface thereof;    placing a second insert over the first insert;    reducing the pressure within the moulding, thereby drawing the second insert towards the first insert, and;    bonding the first and second inserts together.    
     
     
         15 . The method as claimed in  claim 14 , wherein the adhesive is scattercoated on the outer surface of the first insert.  
     
     
         16 . A method for forming a garment, the method comprising the steps of: 
 placing a first insert over a moulding, said moulding having a hollow centre and perforations formed in a surface thereof;    providing an inner surface of a second insert with an adhesive;    placing the second insert over the first insert;    reducing the pressure within the moulding, thereby drawing the second insert-towards the first insert, and;    bonding the first and second inserts together.    
     
     
         17 . A method as claimed in  claim 16  above wherein the adhesive may be scatter coated on the inner surface of the second insert.  
     
     
         18 . A method as claimed in any of  claims 14  to  17  wherein the adhesive is a thermoplastic.  
     
     
         19 . The method as claimed in any of  claims 14  to  17  wherein the method includes the additional step of heating the first and second inserts, subsequent to the step of drawing the inserts together.  
     
     
         20 . The method as claimed in  claim 19  wherein the heating is accomplished by applying Infra Red radiation to the inserts.  
     
     
         21 . The method as claimed in  claim 19  wherein the heat is applied to the inserts via the moulding.  
     
     
         22 . A method of forming a garment, said method comprising the steps of: 
 placing a first insert over a moulding;    providing at least one protruding portion of the first insert with one or more adhesive cups;    placing a second insert over the first insert including the one or adhesive cups, and;    bonding the first and second inserts together.    
     
     
         23 . A method as claimed in  claim 22  wherein the garment formed is a glove.  
     
     
         24 . A method as claimed in  claim 22  or  claim 23  wherein the moulding is hand-shaped and the protruding portions are digits of the glove.  
     
     
         25 . A method as claimed in any of  claims 22  to  24 , wherein the adhesive cups are thimble-shaped.  
     
     
         26 . A method as claimed in any of  claims 22  to  25  wherein the adhesive cups extend to a distance no further than the first joint from the tip of a finger.  
     
     
         27 . A method as claimed in  claim 22  wherein the garment formed is a sock or a lining for a boot.  
     
     
         28 . A method as claimed in any of claims  22  or  claim 27  wherein the mould is in the shape of a foot, and the protruding portion is the toe-cap region.  
     
     
         29 . A method as claimed in any of claims  22 ,  27 , and  28  wherein the adhesive cups extend no further than the balls of the feet.  
     
     
         30 . A method as claimed in any of claims  22  or  27  to  29  wherein adhesive cups are provided over a heel region.  
     
     
         31 . A method as claimed in any of  claims 22  to  30 , wherein the adhesive cups are manufactured from molten adhesive by a dip process.  
     
     
         32 . A method as claimed in any of  claims 22  to  30  wherein the adhesive cups are pre-formed from a sheet adhesive.  
     
     
         33 . A garment manufactured by the method of any of  claims 14  to  32 .  
     
     
         34 . A method of joining sheet materials wherein two sheet materials have join regions to be joined to each other, the method comprising the steps of: 
 forming a plurality of holes in the join regions of two material sheets;    arranging said material sheets so that the join regions are in face to face contact with a thermoplastic joining layer which separates them;    applying heat to said join regions in such a way as to cause the thermoplastic joining layer to melt and flow through holes; and    allowing the thermoplastic joining layer to cool, forming a bond between the material sheets.    
     
     
         35 . The method as claimed in  claim 34 , wherein the material sheets are siliconised materials.  
     
     
         36 . The method as claimed in  claim 34 , wherein the material sheets are PTFE-containing materials.  
     
     
         37 . The method as claimed in any of  claims 34  to  36 , wherein the plurality of holes may be formed using a pulsed laser.  
     
     
         38 . The method as claimed in any of  claims 34  to  36 , wherein the plurality of holes may be formed using a perforating member.  
     
     
         39 . The method as claimed in any of  claims 34  to  36 , wherein heat is applied to the region of material sheets which are to be joined by an RF source.  
     
     
         40 . The method as claimed in any of  claims 34  to  39 , wherein the material sheets are underlaid and overlaid with further thermoplastic joining layers.  
     
     
         41 . The method as claimed in any of  claims 34  to  40 , wherein Covering layers are situated between the regions of material which are to be joined and a source of said heat.  
     
     
         42 . A method of joining sheet materials wherein two sheet materials have join regions to be joined to each other, the method comprising the steps of: 
 (a) forming a plurality of holes in the join regions of two material sheets;    is (b) arranging said material sheets so that the join regions are in face to face contact; and    (c) applying a molten thermoplastic material to said join regions in such a way as to cause the molten thermoplastic material to melt and flow through holes; and    (d) allowing the thermoplastic material to cool, forming a bond between the material sheets.    
     
     
         43 . The method as claimed in  claim 42 , wherein the molten thermoplastic material consists of two thermoplastic sheets in face to face contact with the join regions so that the both join regions are sandwiched between the thermoplastic sheets, wherein said thermoplastic sheets are then melted.  
     
     
         44 . An article comprising two or more sheets of material joined using the method of any of  claims 34  to  43 .  
     
     
         45 . An airbag comprising two or more sheets of material joined using the method of any of  claims 34  to  43 .