BASE FABRIC MATERIAL HAVING PAD MEMBER WITH CORE AND MANUFACTURING METHOD THEREOF

Abstract

To provide a base fabric material having a pad member with a core and a manufacturing method thereof, the pad member with the core being capable of quickly and strongly joining the pad member, on which the core such as a cushion material is disposed, with beautiful finish in a state where the core is made to sufficiently project outward. The pad member having the core is joined to a one side surface of the base fabric material via an adhesive film, with its substantially entire area in thickness projecting, by performing thermocompression bonding by using a concave mold K, a convex mold HK, or the like having a hole or a groove made to match a shape or a thickness of the core. The adhesive film is made to have a mesh-like shape, or an adhesion preventing cloth is disposed and so on so as to ensure ventilation property.

Claims

1.-12. (canceled)

13. A base fabric material having a pad member with a core, comprising: a base fabric material having elasticity and having an annular cross-section; a core disposed to project from an outer face of the base fabric material in its entire area by being adhered to the base fabric material from an inner face of the base fabric material; a pad member disposed on the inner face of the base fabric material to cover the core; and an adhesive layer for joining them.

14. The base fabric material having the pad member with the core according to claim 13, wherein the base fabric material having the pad member with the core further comprises an adhesion preventing cloth disposed at a non-adhered section of the adhesive layer, and ventilation property is ensured at a position at which the adhesion preventing cloth is disposed.

15. The base fabric material having the pad member with the core according to claim 13, wherein the base fabric material having the pad member with the core is a knee supporter or an elbow supporter.

16. A manufacturing method of a base fabric material having a pad member with a core, comprising: providing a base fabric material having elasticity and having an annular cross-section, a core such as a cushion material, a pad member disposed on the inner face of the base fabric material to cover the core, and an adhesive layer for joining them; adhering it to the base fabric material from the inner side face (an outer face when the front and back are inverted) of the base fabric material so as to join the pad member having the core to a one side surface of the base fabric material with its substantially entire area of thickness projecting; and inverting the front and back.

17. A manufacturing method of a base fabric material having a pad member with a core comprising: inserting a mold having a hole or a groove made to match a shape and a thickness of a core inside a base fabric material having elasticity and having an annular cross-section whose front and back are inverted; disposing the core and a pad member to which an adhesive layer is temporally adhered on an inner face (an outer face when the front and back are inverted) of the base fabric material; melting the adhesive layer by heating by a hot plate from a side of the pad member; making the core to project inside the hole or the groove of the mold so as to adhere the base fabric material and the pad member; and inverting the front and back.

18. The manufacturing method of the base fabric material having the pad member with the core according to claim 16, wherein the base fabric material having the pad member with the core is a knee supporter or an elbow supporter.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0039] FIG. 1 is a perspective view of a supporter of the invention.

[0040] FIG. 2 is a perspective view illustrating members used in the above supporter.

[0041] FIG. 3 is a cross-sectional view of the above supporter.

[0042] FIG. 4 is a perspective view of molds used in a manufacturing process of the invention.

[0043] FIG. 5 is a manufacturing process diagram of a first embodiment of the invention.

[0044] FIG. 6 is a manufacturing process diagram of a second embodiment of the invention.

[0045] FIG. 7 is a manufacturing process diagram of a third embodiment of the invention.

[0046] FIG. 8 is a manufacturing process diagram of a fourth embodiment of the invention.

[0047] FIG. 9 is a schematic view of a fifth embodiment of the invention.

[0048] FIG. 10 is a schematic view of a sixth embodiment of the invention.

[0049] FIG. 11 is images for comparison between the supporter of the invention and a supporter of a conventional manufacturing method.

[0050] FIG. 12 is a perspective view illustrating a pillowcase (in a state where a pillow is inserted) of the invention.

[0051] FIG. 13 is a perspective view illustrating the pillowcase (in a state where a pillow is not inserted) of the invention.

[0052] FIG. 14 is a schematic view illustrating a sock of the invention.

[0053] FIG. 15 is a schematic view illustrating a waist pad supporter of the invention.

[0054] FIG. 16 is a schematic view illustrating convex hot plates used in a manufacturing process in another embodiment of the invention.

[0055] FIG. 17 is a schematic view illustrating a method of using of a convex hot plate used in the manufacturing process in the other embodiment of the invention.

DESCRIPTION OF EMBODIMENTS

[0056] Hereinafter, specific embodiments to which the invention is applied will be described in detail with reference to the drawings.

First Embodiment

[0057] FIG. 1 is a perspective view illustrating a supporter S1 of a first embodiment of the invention, and FIG. 2 is a perspective view illustrating members to be used. FIG. 3 is an A-A cross-sectional view of the supporter S1.

[0058] The supporter S1 of the embodiment is described, assuming a case where the supporter S1 is configured as a cylindrical supporter with a cushion material which is used by being worn to protect elbow joint or knee joint of an athlete (volleyball or basketball player) from impact.

[0059] The supporter S1 is consisted of: a base fabric material 1a composed of a supporter body; a core 1b composed of a cushion material; a pad member 1d composed of a cloth having a size and a shape to just cover the cushion material; and an adhesive film 1c having the same size and the shape as those of the pad member 1d, and is manufactured by sandwiching the core 1b at a set position of the base fabric material 1a by the pad member 1d.

[0060] Although the base fabric material 1a is formed in a cylindrical shape (annular cross-section) in the example (FIG. 2), it may have an elongated shape or a rectangular shape in which its ends are not joined depending on the shape of the supporter.

[0061] As the material of the supporter, although a rubber fiber is inwoven in a fiber such as a rayon, a polyester, a nylon, and an acrylic, or pile processing is performed on the fiber , or the fiber is made to have a multi-layer structure, a chemical fiber such as rayon, polyester, and acrylic, and a member in which a rubbery chemical fiber is inwoven, a member subjected to a pile processing, or the like as an intermediate layer can be also used.

[0062] As a material of the cushion material, a urethane resin, a rubber, a foamed urethane resin, a foamed rubber, etc. are used.

[0063] As the adhesive film, a polyurethane-based thermal adhesive film is used from the standpoint of suitability with elasticity of the supporter. As the adhesive film, both films having a peelable sheet and no peelable sheet are available, and as for the film having the peelable sheet, a temporal adhesion process is preliminarily needed, but as for the film having no peelable sheet, no temporal adhesion process is needed.

[0064] The size of the pad member 1d and the adhesive film 1c is made to the size and the shape to just cover the core. However, by forming the size of the pad member 1d and the adhesive film 1c larger than the adhesive area of the core, it is possible to adhere strongly between the one side entire surface of the core and the pad member, and between the base fabric material located at a one side outer circumference of the core and the pad member.

[0065] The adhesive area between the base fabric material located at the one side outer circumference of the core and the pad member becomes larger as the size of the pad member 1d and the adhesive film 1c becomes larger than the adhesive area of the core. Therefore, it possible to form stronger adhesion, but the size is adequately selectable in consideration of adhesion method, cost, or the like.

[0066] In the example, the heat adhesive film 1c is used, but it is also possible to apply an adhesive agent to the pad member 1d for adhesion, and to use not only an adhesive agent having heat adhesive property that achieves adhesion by heating, but also various types of adhesive films and adhesive agents such as ultraviolet adhesive type that achieves adhesion within a short period by being irradiated by ultraviolet, curing agent mixed type that achieves adhesion by mixing the agent and a curing agent, and pressure sensitive type that forms adhesion by applying pressure under ordinary temperature.

[0067] As the pad member, a polyester, an arbitrary material such as a cloth made of a fabric such as cotton, or non-woven cloth may be used, but a knit material is suitable because of suitability with elasticity of the supporter.

[0068] The first embodiment of the invention is performed by the manufacturing process of FIG. 5. The adhesive film 1c having the size and the shape equivalent to those of the pad member 1d is prepared, and is temporally adhered to the pad member 1d. The base fabric 1a whose front and back are inverted, the core 1b, and the pad member 1d to which the adhesive film 1c is temporarily adhered are set on a concave mold K (FIG. 4) having a hole or a groove made to match the shape and the thickness of the core 1b, and the adhesive film 1c is melted by heating by a hot plate H from the side of the pad member 1d to form adhesion between the base fabric material 1a and the pad member 1d. After cooling, the supporter S1 is completed by being taken out from the mold K and inverting the front and back of the base fabric material 1a.

[0069] Herein, the base fabric material 1a whose front and back are inverted, the core 1b, and the pad member 1d to which the adhesive film 1c is temporarily adhered are set on the concave mold K and heating is performed by the hot plate H from the side of the pad member 1d. However, the adhesion between the base fabric material 1a and the pad member 1d may be formed by inserting the concave mold K into the base fabric material 1a whose front and back are inverted, setting the core 1b and the pad member 1d to which the adhesive film 1c is temporally adhered on the base fabric material 1a, melting the adhesive film 1c by heating by the hot plate H from the side of the pad member 1d, and making the core 1b project inside the hole or the groove of the mold K.

[0070] Strong adhesion is formed between the base fabric material 1a and the pad member 1d. Although adhesion is formed also between the core 1b and the pad member 1d, the adhesion is not so strong due to the cushioning property of the core 1b and the affinity with the adhesive agent.

[0071] In the embodiment, the example is illustrated in which the size of the adhesive film 1c and the pad member 1d is equivalent, and the adhesion is formed on the entire surface of the pad member 1d. However, the adhesion formation range is not limited thereto, and is arbitrary within the range of the pad member. For example, the adhesion may be formed only at a circumference of the pad member 1d. In doing so, it is sufficient that a film in the range in which formation of adhesion is not desired is preliminarily removed by means such as die cutting or cutting at the stage of preparation.

[0072] Furthermore, it is also possible to form an adhesive layer on the area of the base fabric material 1a on which the core 1b contacts, and on the pad member 1d, so that the adhesive layer is formed on the entire outer circumference surface of the core 1b. It becomes possible to more strongly fix the core 1b to the base fabric material 1a by the formation of the adhesive layer on the entire outer circumference surface of the core 1b.

[0073] In the embodiment, the shape of the core of the supporter S1 is rectangular, and the manufacturing process in which the mold K1 having the size and the thickness made to match the rectangular shape is used is exemplified. However, the shape of the core is optional, and when the core 1b has a circular shape, a mold K2 having a circular shape made to match the shape is used (FIG. 4). Alternatively, a plurality of separated cores 1b may be used, and in this case, a mold K3 (FIG. 4) having a plurality of separated parts is used. The thicknesses of a hole (hollow shape) Ka of the mold K and the core 1b are same. Although a concave groove Kb may be formed in the mold K, a projecting amount of the core 1b to the outer side can be made larger in the above hollow shape Ka. An underlay (underlay made of a cloth) or an iron plate may be laid below the mold to increase sticking force.

[0074] In the embodiment, the base fabric material 1a and the pad member 1d are adhered by thermocompression bonding. In the invention, however, they may be adhered to each other by heating the adhesion portion by means of laser heating, high-frequency heating, hot plate heating, vibration heating, ultrasonic heating, or heating performed by spraying thermal gas such as steam. Furthermore, any adhesion method may be employed as long as adequate adhesion can be achieved such as a short-time adhesion method by irradiating ultraviolet, an adhesion method by mixing the agent and a curing agent, and an adhesion method by applying pressure at ordinary temperature.

Second Embodiment

[0075] The second embodiment of the invention is performed by the manufacturing process of FIG. 6.

[0076] A pad 1d preliminarily equipped with a core 1b is prepared, and the pad member 1d preliminarily equipped with the core 1b is inserted into a concave mold K4 (Fig. 4) having a hole or a groove made to match the shape and the thickness of the core 1b. A base fabric 1a and an adhesive film 1c corresponding to an adhering region are set on an underlay, the mold K into which the above pad member 1d and the core 1b are fitted is placed from thereabove, the adhesive film 1c is melted by heating by a hot plate H from the side of the underlay to form adhesion between the base fabric material 1a and the pad member 1d. After cooling, a supporter S2 is completed by being taken out from the mold K.

[0077] In the embodiment, as the pad member 1d preliminarily equipped with the core 1b, the example is illustrated in which a core is inserted in the intermediate layer of the pad member. However, it is sufficient that a core is preliminarily held by a pad member like the one in which a core is hold by a cylindrical pad member, or the like, and the configuration is not limited to the configuration of the embodiment.

[0078] In the embodiment, the mold K having the groove is mounted on the underlay from upper direction so as to perform the heat adhering process, but this is not limited thereto. As for the mold structure, the mold K having a hole may be used, and the mold K may be set in the lower side and place the adhesive film 1c and the base fabric material 1a thereon to heat from the upper side.

Third Embodiment

[0079] The third embodiment of the invention is performed by the manufacturing process of FIG. 7.

[0080] An adhesive film 1c having a size and a shape equivalent to those of a pad member 1d and an adhesion preventing cloth 1e are prepared, and are temporally adhered to the pad member 1d. Herein, the adhesion preventing cloth is the cloth that is pasted at a preliminarily set non-adhered section. For example, in the case where the portion of the core 1b is not adhered, a cloth made to match the outer shape of core 1b is temporally adhered on the adhesive film 1c. The position where the adhesion preventing cloth 1e is adhered is not fixed to the core portion, and can be adhered at a free position on the adhesive film depending on a design intention and can also be adhered at a plurality of positions.

[0081] The base fabric 1a whose front and back are inverted, the core 1b, and the pad member 1d to which the adhesive film 1c and the adhesion preventing cloth 1e are temporarily adhered are set on the mold K (FIG. 4) made to match the shape and the thickness of the core 1b, and the adhesive film 1c is melted by heating by the hot plate H from the side of pad member 1d to form adhesion between the base fabric material 1a and the pad member 1d. After cooling, supporter S3 is completed by being taken out from the mold K and inverting the front and back of the base fabric material 1a.

[0082] In the embodiment, the method forms strong adhesion between the base fabric material 1a and the pad member 1d, while a portion between the core 1b and the pad member 1d is not adhered by means of the adhesion preventing cloth 1e. For example, since it is not preferable to apply an adhesive agent at the section where ensuring of ventilation property is desired, it is preferable to dispose the adhesion preventing cloth 1e at the section where ventilation property is ensured.

Fourth Embodiment

[0083] The fourth embodiment of the invention is performed by the manufacturing process of FIG. 8.

[0084] An adhesive film 1c is prepared such that its inner circumference is made smaller than the mold inner circumference to the level to be weighted down on the side face of an inside corner Kc (FIG. 4) of a mold K (FIG. 4) made to match the shape and the thickness of a core 1b and its outer circumference becomes equivalent to that of a pad member 1d. The base fabric 1a whose front and back are inverted and the above adhesive film 1c are set on the mold K (FIG. 4), the core 1b is then inserted in the mold, the pad member 1d is set, and the adhesive film 1c is melted by heating by a hot plate H from the side of the pad member 1d to form adhesion between the base fabric material 1a and the pad member 1d. After cooling, a supporter S4 is completed by being taken out from the mold and inversing the front and back of the base fabric material 1a.

[0085] Strong adhesion is formed between the base fabric material 1a and the pad member 1d. Furthermore, by the adhesive film set at the position of the side face of the above mold, adhesion is formed between the base fabric material 1a and a lower corner of the core 1b, and the pad member 1d and a side face portion of the core 1d.

[0086] By the formation of the above adhesion, a fold Sc may be generated in the base fabric material 1a and the pad member 1d near the lower corner of the core 1b of the supporter S3 (FIG. 7). Thereby, the core 1b in the supporter S4 manufactured in the fourth embodiment remarkably projects on the surface side as compared with that of the supporters S1 and S3 respectively manufactured in the first and third embodiments, and its shape keeping ability is improved, making it possible to prevent shapeless of the core 1b and the pad member 1d.

Fifth Embodiment

[0087] The fifth embodiment of the invention is schematically illustrated in FIG. 9.

[0088] FIG. 9 schematically illustrates a microstructure of the adhesion portion of the supporter S1 manufactured in the above first embodiment when the pad member 1d is a pile woven fabric or a spinning cloth in which loops are formed on the side of the adhesive film. The adhesive agent of the adhesive film 1c is infiltrated and cured in the loops of the pad member 1d to achieve strong adhesion. Thereby, the strength equivalent to or not less than that provided by the conventional sewing, and thus, peeling off does not occur by the force that is applied during strenuous exercise by a supporter wearer.

Sixth Embodiment

[0089] The sixth embodiment of the invention is schematically illustrated in FIG. 10.

[0090] FIG. 10 schematically illustrates a microstructure of the adhesion portion of the supporter S1 manufactured in the above first embodiment when the adhesive film 1c has a mesh-like shape. In the adhesion portion, gaps are formed according to a predetermined interval in the mesh to ensure ventilation routes V. This enables to ensure ventilation property, water-absorbing property, elasticity, and sweating property, which are original property of the member.

[0091] According to the invention, it becomes possible to design adhesion depending on a design intention, for example, a sheet-like adhesive film is used in the area in which adhesive strength is prioritized, while a mesh-like adhesive film is used in the area in which original property of the member are prioritized, exerting superiority of increase in the degree of freedom in product designing of the supporter or the like.

Comparison between the Supporter of the Invention and the Supporter by Conventional Manufacturing Method

[0092] FIG. 10 shows images of a supporter according to the invention and a supporter by a conventional manufacturing method. S1 is a supporter manufactured by the above first embodiment, and So is a supporter manufactured by sewing a supporter body and a pad member, which is a conventional manufacturing method. The supporter S1 of the invention is remarkable in projection of the cushion material on the surface side as compared with conventional supporter So, and it is apparent that its elasticity can be sufficiently exerted, and improvement of performance of protecting knee, elbow, waist, or the like can be expected. Therefore, it is apparent that the effect of the invention largely contributes to improvement of the performance of the supporter or the like with the cushion material.

[0093] Furthermore, in the supporter S1 of the invention, since no needless stress is applied to the joint between the supporter body and the pad member, the joint is flat, but in the conventional supporter So, a stress due to sewing remains, resulting in appearance of the shape that does not contribute to the original functions of the supporter such as wrinkles and creases (w in FIG. 11) around the sewing portion. Therefore, it is apparent that the invention also makes it possible to manufacture a supporter finished more beautifully in appearance.

Seventh Embodiment

[0094] FIG. 16 is a schematic view illustrating convex hot plates used in a manufacturing process in the other embodiment of the invention, and FIG. 17 is a schematic view illustrating a using method of a convex hot plate used in the manufacturing process in the other embodiment of the invention.

[0095] In the first, second, third, fourth fifth, or sixth embodiments, the supporters S1, S2, S3, or S4 are formed by setting the base fabric material 1a whose front and back are inverted, the core 1b, and the pad member 1d to which the adhesive film 1c is temporarily adhered on the concave mold K, K1, K2, or K3, and then heating the hot plate H from the side of the pad member 1d. However, in a seventh embodiment, it is possible to provide a base fabric material having a pad member with a core in which the core is made to project on the further outside and quickly and strongly joined in a beautiful finished state, and a manufacturing method thereof by using the convex hot plates HK1, HK2, HK3 equipped with a convex portion.

[0096] The convex hot plates HK1, HK2, HK3 are hot plates used in a state of facing the concave mold K when the supporter is manufactured, and respectively includes convex portions Ha1, Ha2, Ha3.

[0097] Although the convex portions Ha1, Ha2, Ha3 have a same sectional shape as a hole Ka or a groove Kb provided in the concave mold K to be used, the sizes thereof are made smaller than the hole Ka or the groove Kb, and the heights of the convex portions Ha1, Ha2, Ha3 are made shorter than the depth of the hole Ka or the groove Kb provided in the concave mold K.

[0098] The base fabric 1a whose front and back are inverted, the core 1b, and the pad member 1d to which the adhesive film 1c is temporarily adhered are set on the concave mold K having the hole or the groove made to match the shape and the thickness of the core 1b, and the convex portions Ha1, Ha2, Ha3 are pressed against the core 1b so that the core 1b sufficiently projects on the base fabric material surface side while the adhesive film 1c is melted by heating by the convex hot plates HK1, HK2, HK3 from the side of the pad member 1d. Since the section other than the convex portions Ha1, Ha2, Ha3 of the convex hot plates HK1, HK2, HK3 is also at high temperature, the adhesive film 1c between the base fabric material 1a and the pad member 1d located at an outer circumference of the adhesive surface of the core 1b is also melted by the convex hot plates HK1, HK2, HK3, and strong adhesion is simultaneously formed.

[0099] In this manner, by pressing the convex portions Ha1, Ha2, Ha3 against the core 1b so that the core 1b sufficiently projects on the base fabric material surface side while melting the adhesive film 1c from the side of pad member 1d by using convex hot plates HK1, HK2, HK3 respectively equipped with concave portions Ha1, Ha2, Ha3, it is possible to provide a beautifully finished base fabric material having a pad member with a core in which the core further projects on the outer side.

[0100] FIG. 12 is a perspective view illustrating a pillowcase (in a state where a pillow is inserted state)) of the invention, and FIG. 13 is a perspective view illustrating a pillowcase (in a state where a pillow is not inserted) of the invention. FIG. 14 is a schematic view illustrating a sock of the invention, and FIG. 15 is a schematic view illustrating a waist pad supporter of the invention. In the first, second third, fourth, fifth, and sixth embodiments, description is made with respect to the supporters S1, S2, S3, S4, but the invention is not limited to the supporters and is applicable to various members used by joining a core composed of a cushion material to a base fabric material, specifically, to the members such as a pillowcase (FIG. 12, FIG. 13), a sock (FIG. 14), and a waist pad supporter (FIG. 15). In this manner, in the invention, it goes without saying that appropriate alterations are possible without departing from the scope of the gist.

REFERENCE NUMERALS

[0101] S1, S2, S3, S4 supporter of the invention [0102] S5 pillow of the invention [0103] S6 sock of the invention [0104] S7 waist pad supporter of the invention [0105] 1a base fabric material constituting the supporter [0106] 1b core constituting the supporter [0107] 1c adhesive film constituting the supporter [0108] 1d pad member constituting the supporter [0109] 1e adhesion preventing cloth [0110] Sc fold in the supporter [0111] K mold of the invention [0112] K1 mold for rectangular core [0113] K2 mold for circular core [0114] K3 mold for a plurality of cores [0115] Ka hole of mold (hollow shape) [0116] Kb groove of mold (concave) [0117] Kc corner of mold [0118] H hot plate [0119] HK1 convex hot plate for rectangular core [0120] HK2 convex hot plate for circular core [0121] HK3 convex hot plate for a plurality of cores [0122] Ha1, Ha2, Ha3 convex portion [0123] B underlay [0124] V ventilation routes [0125] So supporter of conventional manufacturing method [0126] w crease of supporter [0127] M pillow