Process of over-molding a thermoplastic elastomer over fabric pieces

Abstract

A method of over-molding a thermoplastic elastomer over fabric includes: precision forming a mold cavity to match the final dimensions of a finished product; cutting a piece of fabric to a correct size; fixedly securing the fabric piece in the mold cavity; and injecting a thermoplastic elastomer into the mold cavity at an appropriate temperature and pressure, on top of the fabric piece. The method may further include heating the thermoplastic elastomer to a temperature for melting a surface layer of the fabric when injected thereon, and cooling of the thermoplastic elastomer and fabric for bonding of the thermoplastic elastomer to the surface of the fabric. The method may further include adding one or more additives from the group of additives consisting of: a UV stabilizer, an anti-blocking agent, a slip agents, a plasticizer, and a flame retardant; and securing a cord member onto an exposed portion of the fabric.

Claims

1. A method of over-molding a thermoplastic elastomer over fabric, said method comprising: precision forming a cavity of a mold to match the final dimensions of a finished product; cutting a piece of fabric to a correct size; fixedly securing the piece of fabric in the cavity of the mold; heating a thermoplastic elastomer to a temperature for causing it to transform into a flowable liquid state, and be configured for melting a surface layer of the fabric; injecting the heated thermoplastic elastomer into the mold cavity at an appropriate pressure, on top of the fabric piece, causing flowing of the liquid thermoplastic elastomer into interstices of the weave of the piece of fabric; and cooling of the thermoplastic elastomer and fabric for bonding and securing of the thermoplastic elastomer to the fabric.

2. The method according to claim 1 further comprising adding a UV stabilizer to said over-molded thermoplastic elastomer and fabric after said cooling.

3. The method according to claim 1 further comprising securing a cord member onto an exposed portion of the fabric.

4. The method according to claim 1 further comprising adding an anti-blocking agent to said over-molded thermoplastic elastomer and fabric after said cooling.

5. The method according to claim 1 further comprising adding a slip agent to said over-molded thermoplastic elastomer and fabric after said cooling.

6. The method according to claim 1 further comprising adding a plasticizer to said over-molded thermoplastic elastomer and fabric after said cooling.

7. The method according to claim 1 further comprising adding a flame retardant to said over-molded thermoplastic elastomer and fabric after said cooling.

8. The method according to claim 1 wherein said thermoplastic elastomer and fabric piece are bonded together after said cooling, without the use of a bonding agent.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The description of the various example embodiments is explained in conjunction with appended drawings, in which:

(2) FIG. 1 illustrates a cross-sectional view of a part formed in accordance with the manufacturing process of the present invention, and includes a fabric piece, over-molded thermoplastic elastomer material, and additional cotton/polyester cords affixed thereto;

(3) FIG. 1A illustrates a cross-sectional view showing the fabric used for the finished part of FIG. 1, but while positioned within the specially designed mold cavity;

(4) FIG. 1B shows the mold cavity of FIG. 1A, prior to receiving the fabric therein;

(5) FIG. 2. illustrates a side view of a fabric material, a portion of which is over-molded with a thermoplastic elastomer in accordance with the process of the present invention;

(6) FIG. 3 is a cross-sectional view of a ring formed with a core of foam, a layer of rubber, and two separate pieces of fabric that are adhered to the rubber as a result of the forming process;

(7) FIG. 4 illustrates another embodiment of the process used for forming a ring in accordance with the present invention, beginning with a core of foam, having rubber overlaid thereon, with a first layer of nylon applied onto the rubber, being heat bonded thereto, and with a second layer of nylon being applied to the first layer of nylon, by being sewn thereto, and with piping being sewn onto the second layer of nylon;

(8) FIG. 5A illustrates a top portion of a disk shape formed in accordance with the process of the present invention, having been cut to expose the cross-sectional build-up of the part, and with an outer layer of nylon having been pulled back to expose a polypropylene core and a thermoplastic elastomer tip;

(9) FIG. 5B illustrates a bottom portion of the disk shape of FIG. 5A;

(10) FIG. 6A illustrates a top view of the disk of FIG. 5A;

(11) FIG. 6B is a side view of the disk of FIG. 6A; and

(12) FIG. 6C is a cross-sectional view through the disk of FIG. 6A;

(13) FIG. 6D is an enlarged detail view of the tip of the disk cross-section shown in FIG. 6C.

DETAILED DESCRIPTION OF THE INVENTION

(14) As used throughout this specification, the word may is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words include, including, and includes mean including but not limited to.

(15) The phrases at least one, one or more, and and/or are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A. B and C, one or more of A, B, and C, and A, B, and/or C mean all of the following possible combinations: A alone; or B alone; or C alone; or A and B together; or A and C together; or B and C together; or A, B and C together.

(16) Also, all references (e.g., patents, published patent applications, and non-patent literature) that are cited within this document are incorporated herein in their entirety by reference.

(17) Furthermore, the described features, advantages, and characteristics of any particular embodiment disclosed herein, may be combined in any suitable manner with any of the other embodiments disclosed herein.

(18) Additionally, any approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative or qualitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as about is not to be limited to the precise value specified, and may include values that differ from the specified value in accordance with applicable case law. Also, in at least some instances, a numerical difference provided by the approximating language may correspond to the precision of an instrument for measuring the value. A numerical difference provided by the approximating language may also correspond to a manufacturing tolerance associated with production of the aspect/feature being quantified. Furthermore, a numerical difference provided by the approximating language may also correspond to an overall tolerance for the aspect/feature that may be derived from variation resulting from a stack up (i.e., the sum) of multiple individual tolerances.

(19) In accordance with at least one embodiment of the present invention, an injection mold tool 151, as shown within FIG. 1B, may be formed to produce the part 20 shown within FIG. 1, which may be a combination of fabric 101 and plastic elastomer 102. The mold tool 151 may include a precision-formed cavity that is based upon the final dimensions of the particular finished part, and other physical and structural considerations. In particular, for the injection molding process, the thermoplastic elastomer may be over-molded onto the fabric piece on at least one side of a fabric substrate. The injection mold 151 is designed and made according to the finished product size, and its shape, and requires an accurate calculation of the fabric thickness and size, as well as the thickness of the over-molded thermoplastic elastomer that is desired, which may typically be in the range of 0.5 mm to 15 mm or more, depending upon the design. The design of the mold 151 also must include features relating to securing of the fabric within the mold cavity, and the mold may include a fixture and other accessories that may be used to precisely locate and fix the fabric piece within the mold cavity, which is also critical to forming the finished product.

(20) For this injection molding process, a piece of fabric is cut to the correct size and is fixed in the mold cavity. The thermoplastic material, which is preferably a thermoplastic elastomer, is then injected into the mold cavity at the appropriate temperature and pressure, on top of the fabric piece. The thermoplastic elastomer and fabric piece will be bonded together after cooling, without the use of a bonding agent. In one embodiment, depending on the closeness of the fabric weave the thermoplastic may be only on the surface of the fabric and bonded to the fabric. In another embodiment, the thermoplastic material may be applied at a temperature that is sufficiently high that the surface material of the fabric, if it is a thermoplastic, may undergo some melting, and the fabric may then bond to the thermoplastic being injection molded. In still another embodiment the thermoplastic may flow into the interstices of the weave of the fabric piece and secure the thermoplastic to the fabric. The molding process is conducted without any auxiliary chemicals or adhesive to combine or secure these two materials together, and is very safe, non-toxic, and fast. The thermoplastic elastomer and fabric piece are conjoined in this fashion to make the new product, which may in itself serve as a raw material for the making of a finished commercial product, and is very durable and very difficult to pull apart or crack.

(21) The finished product 20 has the elastic performance and characteristic of the thermoplastic elastomer with additional strength being provided by the fabric. Also, only a portion of the fabric piece may be over-molded with the thermoplastic elastomer, as seen in FIG. 2, and the exposed fabric it can be sewn together to make toys and cloth products. There is no limitation for the shape or size of the over-molded fabric piece formed in accordance with the present invention. The thermoplastic elastomer increases the thickness and flexibility of the product, and at the same time improves its abrasion resistance. The fabric utilized may be printed or dyed to provide the product with a better exterior appearance and diversity.

(22) As shown in FIG. 1, additional cord members 103 made of a desired material, including, but not limited to, the same material as the fabric or a different material, may be added to the part. The fabric and/or the cord material may be made of natural fibers such as cotton, linen, bamboo, jute wool, etc., or it can be made of manmade fibers including but not limited to nylons, polyolefin fibers, polyesters and blends thereof Additives, such as stabilizers such as UV stabilizers, anti-blocking agents, slip agents, plasticizers, flame retardants, biodegradable additives, etc., may be added onto the finished product to increase the product functionality. The cord members 103 may be sewed or tied onto the exposed fabric. The cord members 103 may be used to increase functionality of the final product. For example, a cord may be secured to the part to be used as a handle for tossing of the part, such as when the part may be a dog toy. A cord member 103 may also act as a decorative item, and may, for example, be secured to the fabric to serve as an appendage, such as a tail of the pet toy.

(23) FIG. 3 illustrates a cross-sectional view of a ring formed with a core of foam, a layer of rubber, and two separate pieces of fabric that are adhered to the rubber as a result of the forming process of the present invention.

(24) FIG. 4 illustrates the process of forming a ring in accordance with the present invention, beginning with a core of foam, having rubber overlaid thereon, with a first layer of nylon applied onto the rubber, being heat bonded thereto, and with a second layer of nylon being applied to the first layer of nylon, by being sewn thereto, and with piping being sewn onto the second layer of nylon.

(25) FIG. 5A illustrates a top portion of a disk shape formed in accordance with the process of the present invention, having been cut to expose the cross-sectional build-up of the part, and with an outer layer of nylon having been pulled back to expose a polypropylene core and a thermoplastic elastomer tip.

(26) FIG. 5B illustrates a bottom portion of the cut disk shape of FIG. 5A.

(27) FIG. 6A illustrates a top view of the disk of FIG. 5A.

(28) FIG. 6B is a side view of the disk of FIG. 6A.

(29) FIG. 6C is an enlarged detail view of the tip of the disk cross-section shown in FIG. 6C.

(30) While illustrative implementations of one or more embodiments of the present invention are provided hereinabove, those skilled in the art and having the benefit of the present disclosure will appreciate that further embodiments may be implemented with various changes within the scope of the present invention. Other modifications, substitutions, omissions and changes may be made in the design, size, materials used or proportions, operating conditions, assembly sequence, or arrangement or positioning of elements and members of the exemplary embodiments without departing from the spirit of this invention.

(31) Accordingly, the breadth and scope of the present disclosure should not be limited by any of the above-described example embodiments, but should be defined only in accordance with the following claims and their equivalents.