SYNTHETIC-TEXTILE HYBRID FABRIC AND MEANS AND METHOD FOR MANUFACTURING SAME

Abstract

A hybrid fabric made of at least one textile base layer and at least one synthetic layer, where the synthetic layer is at least partially embedded within the textile base layer. The embedded synthetic layer imparts numerous qualities to the hybrid fabric formed and possible designs visible through the surface of the fabric. The hybrid fabric may be manufactured in different methods including hot and cold press, knitting, felting and use of intermediate linking adhesive or polymeric layer.

Claims

1. A hybrid fabric comprising: at least one textile base layer; and at least one synthetic layer, wherein said synthetic layer is at least partially embedded within said textile base layer.

2. The hybrid fabric according to claim 1, wherein said textile base layer is obtained by weaving, knitting, spreading, crocheting, felting and bonding.

3. The hybrid fabric according to claim 2, wherein said textile base layer is made of materials selected from : wool, cashmere, silk, satin, velvet, taffetas, cotton, flax, jute, hemp, modal, bamboo fiber, seaweed, alginate, lyocell (manmade fabric derived from wood pulp), Cordura (nylon, nylon mixed with cotton or other natural fibers), basalt fibers (used for vinyl tiles, sheeting, curtains and fire blankets), metal fibers, synthetic fibers such as aramid, acrylic, nylon, spandex (i.e. lycra), olefin fibers, inego (polylactide fibers), lurex (metallic fibers), milk protein-based fibers, carbon fibers and mixtures of synthetic and natural fibers and any combination thereof.

4. The hybrid fabric according to claim 3, wherein said combination comprise parts of said materials of said textile base layer, said part unified into a single textile base layer with said synthetic layer embedded within.

5. The hybrid fabric according to claim 1, wherein said synthetic layer is made of synthetic polymeric materials selected from Olefin polymers, particularly PE (Polyethylene) and PP (Polypropylene), HDPE (High Density PE), MDPE (Medium-density polyethylene), LLDPE (Linear Low Density PE),and LDPE (Low Density PE), VLDPE (Very-low-density polyethylene), UHMWPE (Ultra-high-molecular-weight polyethylene), ULMWPE or PE-WAX (Ultra-low-molecular-weight polyethylene), HMWPE (High-molecular-weight polyethylene), HDXLPE, (High-density cross-linked polyethylene), PEX or XLPE (Cross-linked polyethylene), CPE (Chlorinated polyethylene), PVC (Poly Vinyl Chloride), m-LLDPE (Metallocene linear low density PE), PC (Polycarbonate), PVA (Polyvinylalcohol), EVA (Ethylene vinyl acetate) polymer, Polyester polymers (PSR), particularly PLA (Polylactic acid), PCL (Polycaprolactone), PEA (Polyethylene adipate), PBS (Polybutylene adipate), PET (Polyethyleneterphthalate), PBT (Polybutyleneterphthalate), PEN (Polyethylene naphtalane), Styrene polymers, particularly PS (Polystyrene), Styrene-Butadiene polymers, PUR (Polyurethane), foamed PUR, Fluorinated polymers, particularly Teflon, Nylon 6,6, and Nylon 6 and combination thereof.

6. The hybrid fabric according to claim 5, wherein said synthetic polymeric materials further comprise additives.

7. The hybrid fabric according to claim 6, wherein said additives are selected from plasticizers, softeners and flame retardants.

8. The hybrid fabric according to claim 1, wherein said synthetic layer is colored with a color imparted to said textile base layer, wherein said color is transparent or opaque.

9. The hybrid fabric according to claim 8, wherein said color is provided by colorants, pigments or dyes selected from azo dyes, anthraquinone dyes and phthalocyanines. Another classification of colorants may be used to distinguish between different families as follows: Dyes with varying water solubility including acid dyes, basic dyes, metal-complex dyes, direct dyes, disperse dyes; reactive dyes, vat dyes, sulfur dyes; Pigments, organic or synthetic, from azo and phthalocyanines families, which are usually employed in the plastic industry. The colorants may be provided as solid powders, liquids or powders soluble in water or any other liquid.

10. The hybrid fabric according to claim 1, wherein said synthetic layer is transparent and/or colorless.

11. The hybrid fabric according to claim 8, wherein surface of said synthetic layer further comprises a printed pattern or picture, said printed pattern or picture is visible through surface of said hybrid fabric.

12. The hybrid fabric according to claim 1, wherein said synthetic layer imparts said textile base layer with any one, part or all of protection from abrasion and tearing, repelling fluids, flexibility, elasticity, color, shading and texture.

13. The hybrid fabric according to claim 12, wherein said synthetic layer further imparting said textile base layer with any one, part or all of pleats and creases heat-set at higher temperatures, improved weathering properties, sunlight resistance, Softer “Hand”, elevated melting point, superior colorfastness, excellent abrasion resistance, easy dye, higher impact resistance, more rapid moisture absorption, greater elasticity and elastic recovery, variation of luster, between, for example very lustrous, semilustrous and dull, durability: high tenacity of fibers, particularly useful for seatbelts, tire cords, ballistic cloth and other uses, high elongation, high resilience, high resistance to insects, fungi, animals, as well as molds, mildew, rot and many chemicals, flame resistance: melting instead of burning, good specific strength, and transparency to infrared light.

14. The hybrid fabric according to claim 1, wherein thickness of said synthetic layer is between 50 μm and 6 centimeters.

15. The hybrid fabric according to claim 1, further comprising thermoplastic shrink fit sleeve covering said hybrid fabric.

16. The hybrid fabric according to claim 1, further comprising adhesive configured for adhering said synthetic layer to said textile base layer.

17. The hybrid fabric according to claim 1, further comprising intermediate synthetic layer configured for interlinking with said synthetic layer on one side and said textile base layer on the other side.

18. The hybrid fabric according to claim 17, wherein said intermediate synthetic layer is EVA (Ethylene vinyl alcohol) polymer.

19. The hybrid fabric according to claim 1, wherein outer surface of said hybrid fabric is surface of said textile base layer or textured mixture of said surface of said textile base layer and surface of said synthetic layer.

20. The hybrid fabric according to claim 19, wherein texture of said synthetic layer protrudes out of said surface of said textile base layer.

21. The hybrid fabric according to claim 19, wherein texture of said synthetic layer is embedded within said surface of said textile base layer.

22. The hybrid fabric of claim 1, wherein said synthetic layer is partly embedded within said textile base layer and covers outer surface of said textile base layer.

23. The hybrid fabric according to claim 1, comprising two of said synthetic layers, wherein each of said synthetic layers is embedded within said textile base layer on one surface of said textile base layer.

24. The hybrid fabric according to claim 1, comprising at least two textile base layers connected to each other with said synthetic layer.

25. The hybrid fabric according to claim 1, comprising a plurality of synthetic layers embedded in said at least one textile base layer.

26. The hybrid fabric according to claim 24 or 25, further comprising a filling placed within said hybrid fabric, said filling providing said hybrid fabric any one, part or all of volume, cushioning and shock absorption.

27. The hybrid fabric according to claim 1, wherein said synthetic layer comprises a pattern, wherein said pattern is visible through surface of said textile base layer.

28. The hybrid fabric according to claim 1, wherein said synthetic layer is made of low density material enabling efficient embedding within high density textile base layer.

29. The hybrid fabric according to claim 1, wherein said synthetic layer comprises holes or gaps in it, said holes or gaps enabling easier embedding within said textile base layer.

30. The hybrid fabric according to claim 1, wherein said synthetic layer is selected from recyclable foams, polyethylene bubble sheets, polyethylene bags, labels of bottled drinking water, boxes of different toilet paper, sixpacks of bottled drinking water, etc.

31. The hybrid fabric according to claim 1, suitable for manufacturing garment industry, footwear, wallpaper, cushions and garden furniture (pergola, sofas), and even jewelry.

32. A method for manufacturing hybrid fabric comprising: laying said synthetic layer onto a textile base layer; and embedding said synthetic layer in said textile base layer to form said hybrid fabric.

33. The method according to claim 32, further comprising: cleaning and drying said synthetic layer and textile base layer.

34. The method according to claim 32, further comprising: dying said synthetic layer, or using a pre-colored synthetic layer; removing residues of dye left on the hybrid fabric.

35. The method according to claim 32, further comprising: cooling the synthetic fabric formed.

36. The method according to claim 34, wherein said dying comprises one of: i. dying and drying said synthetic layer before embedding it in the textile base layer. ii. dying said synthetic layer before embedding and drying during embedding; and iii. dying said synthetic layer after embedding within said textile base layer.

37. The method according to claim 32, wherein said method is done with any one of hot press, cold press, felting and sewing.

38. The method according to claim 37, wherein said hot or cold press further comprising adhering said synthetic layer to said textile base layer with adhesive.

39. The method according to claim 37, wherein said hot or cold press further comprising interlinking said synthetic layer and textile base layer with EVA polymer.

40. The method according to claim 37, wherein said textile base layer is porous grid configured to lock said synthetic layer.

41. The method according to claim 37, wherein said hot or cold press further comprising covering said synthetic layer overlaid on said textile base layer with protective cover.

42. The method according to claim 41, wherein said protective cover is heat-durable paper or Teflon sheet.

43. The method according to claim 37, wherein temperature of heating in said method of hot press is between 80° C. and 300° C.

44. The method according to claim 43, wherein said temperature is 180° C.

45. The method according to claim 37, wherein pressure applied in said hot or cold press is between 3,000 psi and 300,000 psi.

46. The method according to claim 37, wherein time of retaining said synthetic layer and textile base layer in said hot or cold press is between 1 and 5 minutes.

47. The method according to claim 37, wherein temperature, pressure and time parameter values of said method are determined according to particular materials of said synthetic layer and textile-base layer for manufacturing said hybrid fabric.

48. The method according to claim 47, wherein said parameter values are further determined according to desirable result of hybrid fabric with said synthetic layer fully or partially embedded within said textile base layer and respective composite, fully covered or fully exposed surface of said textile base layer.

49. The method of claim 32, further comprising laminating with thermoplastic cover before or after manufacturing said hybrid fabric.

50. The method according to claim 37, wherein said textile base layer is pre-treated by increasing its vacant space between its fibers to allow said synthetic layer better embed within.

51. Means for manufacturing hybrid fabric, said means comprising any one of plate press, drum press and knitting and sewing means configured for embedding synthetic layer within textile base layer.

Description

EXAMPLES

[0092] The following describes particular non-limiting examples of hybrid fabrics and methods of manufacturing them.

[0093] Synthetic sheet made of polyethylene, recyclable plastic sheet, or foamed polyethylene sheet with thickness of between 2 and 5 millimeters is placed on a textile base layer. In one particular example, the polyethylene foamed sheet thickness was of 2 millimeters thickness.

[0094] The layers were placed one above the other on a plate press and covered with Teflon coating on single or both sides to avoid adhering of the synthetic layer(s) to the plates. The temperature of the press was elevated to 180° C. and the plates were pressed on the layers for about 2 minutes, then lifted and the hybrid fabric form removed and allowed to cool at room temperature. In another example, the hybrid fabric formed was immediately put in ice-bath for quenching.

[0095] In another example, the Teflon cover was replaced with heat-durable paper, such as paper used for baking ovens. This was a cost effective solution, but also produced a more opaque appearance to the hybrid fabric, where use of the Teflon cover produced a shinier look.

[0096] One of the advantages over current methods is the texture transformation achieved in the new material. This texture improvement, compared to either of the base components (synthetic or textile) on their own, or to other heat pressed fabric hybrids. From surveys and tests that the inventor performed, the newly achieved texture is significantly more desirable compared to other fabrics.

[0097] Another main advantage are the new colors that can be achieved in the produced new material via the method. The colors are never exactly repeated and the different textures of the synthetic layers enable new and different color patterns every time.

[0098] Upon painting and embedding with hot press, the hybrid fabric results in varying sub-tones throughout the surface of the fabric and no area is like another. The sub-tones created distinguish the new hybrid fabric produced. This is particularly relevant when dyes and/or a textured synthetic layer are used.

[0099] In one example, synthetic layers with water repellent or water resistant qualities were used over textile base layers made of materials, vulnerable when in contact with water. The synthetic and textile base layers were hot pressed in plate press and the hybrid fabric obtained proved to impart the water repellant or water resistant qualities to the textile layer, yet kept the original feel of the textile.

[0100] It should be noted that from a point of view of process efficiency, a bigger plate press or drum press enable faster production yet produces equally good hybrid fabric.

[0101] In the examples described above and other example, the usual temperature in the heat press ranged between 80° C. and 300° C. In preferable application, the temperature used was 180° C.

[0102] The time it takes to correctly join the layers by heat press is between 1.5 and 5 minutes. Preferably 2 minutes are required in heat press. The method process is thus time saving, compared to current production methods.

[0103] The hybrid fabric produced is essentially a new material by itself, which separates it from either of the two basic components from which it was made, and forms a new interpretation of fabric and a new raw material.

[0104] Regarding coloring, dyes or pigments are placed between the synthetic and textile base layers and “locked” there. The result is improved, enhanced or emphasized texture and color of the hybrid fabric. When dyes are used in situ, namely in the manufacturing process, the liquid that carries the pigments is volatile and evaporates upon heat pressing.

[0105] The embedded synthetic layer also enables the hybrid fabric to be washable, by hand, or in a washing machine. Superfluous dye may be washed off after several washings.

[0106] In the examples manufactured of the hybrid fabric, the new material can be sewn onto other fabrics, or to itself.

[0107] Once the heat press process is done, the partially molten synthetic layer becomes an integral part of the textile, and achieves special/new colors and textures.

[0108] In other examples, polyethylene sheets purchased, manufactured or recycled were used to manufacture the hybrid fabric. The reclaimed polyethylene abundantly used in packaging and protective covers indirectly helps in keeping clean environment and reducing production of new polyethylene batches. This is particularly helpful since polyethylene as well as many other polymeric materials (see the list of polymers above) is not biodegradable, and for which there are no effective recycling processes. Accordingly, such polymers turn into waste with high collateral damage, including storing, melting and re-manufacturing.

[0109] In another example of the method of manufacturing a hybrid fabric the following steps were carried out:

[0110] A. A white opaque synthetic sheet was manually colored with liquid colors (pigment or any other concentrated color combined with water which gives the special appearance after melting).

[0111] B. The colored synthetic layer was let to dry at room temperature. Alternatively, the colored synthetic layer was placed over a textile base layer.

[0112] C. The two layers were covered with Teflon cover or heat-durable paper and placed in plate hot press.

[0113] D. The press was heated and the plates were applied on the covered layers under pressure at a temperature of 180° C. and remained like this for 2 minutes.

[0114] E. Then the plates were lifted and the hybrid fabric was taken out, the cover was removed and the hybrid fabric was let to cool at room temperature.

[0115] The result was hybrid fabric colored by the synthetic layer with the feel of the original textile base layer.

[0116] The hybrid fabric is used as the basis for creating a wide range of products with a variety of colors. A custom fabric is determined to some extent by the consumer in order to have some control over the design.

[0117] The new hybrid fabric produced can expand the scope and purpose of materials in these products, and can be used for the garment industry, footwear, wallpaper, cushions and garden furniture (pergola, sofas), and even jewelry. Production of such items with hybrid fabric of the present invention can be used manually as well as in industrially.

[0118] In one example test, in which a wearable jeans was made from the new hybrid fabric, the color was retained in its close-to-original condition even after 10 washes.

[0119] In terms of heavy-type process, all types of textiles (natural and synthetic) were successfully used to produce the hybrid fabric of the present invention. In one example, interwoven fabric (which is less flexible) is found to be stronger than other fabrics and thus better for the method. For example, fabrics with looped weaving will be less desired for this method for their flexibility and tendency for distortion once under the heat-press.

[0120] In one example, synthetic layer made of low density polymeric material was found preferable for manufacturing hybrid fabric in hot press.

[0121] The following recyclable synthetic materials for were tested with similar results in terms of hybrid fabric density and qualities: foams, polyethylene bubble sheets, polyethylene bags, labels of bottled drinking water, boxes of different toilet paper, sixpacks of bottled drinking water, etc.

[0122] In another example, the confined liquid paints in nylon synthetic layer were obtained with different coloring methods. The results were not quite repeatable and only partly controllable.

[0123] In another example, the final hybrid fabric formed was laminated as follows: The hybrid fabric was dressed with shrink sleeves were and then put back in the hot press for 2 minutes. The laminated hybrid fabric gave stronger and water-tight with 100% water repellant fabric and not just the outside of the sheet.

[0124] In still another example, synthetic layer of bubble wrap was colored, placed over a textile base layer and covered with protective cover and hot pressed for 2 minutes. The hybrid fabric was taken out of the press plates, the cover removed and the hybrid fabric let to cool at room temperature. The bubble wrap was embedded in the textile base layer, and its bubble pattern was visible through the surface of the hybrid fabric.

[0125] Those skilled in the art to which this invention pertains will readily appreciate that numerous changes, variations and modifications can be made without departing from the scope of the invention mutatis mutandis.