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  Molded composite fabrics and methods of makingUSPTO Application #: 20060189238Title: Molded composite fabrics and methods of making Abstract: A molded composite fabric and methods of making are provided. The molded composite fabric has a polyethylene foam layer and a first fabric layer adhered to a first side of the polyethylene foam layer to define a composite fabric. The molded composite fabric also includes a feature molded in the composite fabric. The first fabric layer has a non-woven fabric with a web of randomly disbursed fibers. The method includes selecting a non-woven fabric having a web of randomly disbursed fibers, exposing the non-woven fabric to mechanical agitation, laminating the non-woven fabric to a first side of a polyethylene foam layer to a composite fabric, compressing the composite fabric between a top mold and a bottom mold, and maintaining the composite fabric between the top and bottom molds for a predetermined dwell time. (end of abstract) Agent: Charles N.j. Ruggiero, Esq. Ohlandt, Greeley, Ruggiero & Perle, L.L.P. - Stamford, CT, US Inventors: Roger D. Warren, Rick Kelley, Asli Begenir USPTO Applicaton #: 20060189238 - Class: 442182000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material), Woven Fabric Has An Elastic Quality The Patent Description & Claims data below is from USPTO Patent Application 20060189238. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/625,491 filed on Nov. 5, 2004 and U.S. Provisional Application Ser. No. 60/669,604 filed on Apr. 8, 2005, the contents of both of which are incorporated by reference herein. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention is related to molded composite fabrics and methods of making. More particularly, the present invention relates to composite fabrics having a layer of non-woven fabric and a layer of foam, where the composite fabrics include one or more features molded therein. [0004] 2. Description of Related Art [0005] A variety of apparel garments or items include one or more molded features. For example, brassieres include breast cups molded in a composite fabric that has a fabric layer and a foam layer. Similarly, protective products such as, but not limited to, kneepads, elbow pads, and the like include features molded in a composite fabric of fabric and foam. [0006] In addition, a variety of non-apparel products such as, but not limited to, automotive interiors, home furnishings, and others can include such molded composite fabrics. [0007] Typically, molded composite fabrics include a layer of thermoplastic urethane (TPU) foam adhered to a knit fabric. Unfortunately, TPU foam can be expensive and, thus, its use can be cost prohibitive in many consumer product applications. Also, TPU foams are sensitive to ultraviolet radiation present in ambient light. Specifically, ultraviolet radiation tends to cause TPU foams to yellow. In many applications, the yellowing of TPU foam is unacceptable. Therefore, many TPU foams are laminated or faced on both sides with a fabric layer to mask this yellowing. These additional facing layers can add cost and weight to the resultant product. [0008] The selection of TPU foam and knit fabric are particularly suited for use with one another in a molded composite fabric as both the TPU foam and the knit fabric typically require high molding temperatures and lengthy molding times (e.g., 400 degrees Fahrenheit for about 60 seconds). Unfortunately, the high molding temperatures and lengthy molding times can also make the use of these composite fabrics cost prohibitive in many consumer product applications. [0009] Accordingly, there is a continuing need for molded composite fabrics and methods of molding that overcome and/or mitigate one or more of the aforementioned and other drawbacks and deficiencies of the prior art. BRIEF SUMMARY OF THE INVENTION [0010] It is object of the present invention to provide a molded composite fabric having a layer of non-woven fabric and a layer of foam. [0011] It is another object of the present invention to provide a molded composite fabric having a layer non-woven fabric laminated to both sides a layer of foam. [0012] It is another object of the present invention to provide a method of molding a composite fabric having a layer of non-woven fabric and a layer of foam. [0013] It is yet another object of the present invention to provide a method of manufacturing a composite fabric from a non-woven fabric and a layer of foam. [0014] The aforementioned and other objects of the present invention are provided by a molded composite fabric. The molded composite fabric has a polyethylene foam layer and a first fabric layer adhered to a first side of the polyethylene foam layer to define a composite fabric. The molded composite fabric also includes a feature molded in the composite fabric. The first fabric layer has a non-woven fabric with a web of randomly disbursed fibers. [0015] A brassiere is provided that includes a garment body and a pair of molded breast cups having a first fabric layer adhered to a first side of a polyethylene foam layer. The first fabric layer has a non-woven fabric with a web of randomly disbursed fibers. [0016] A method of forming a molded non-woven fabric is also provided. The method includes selecting a non-woven fabric having a web of randomly disbursed fibers, exposing the non-woven fabric to mechanical agitation, laminating the non-woven fabric to a first side of a polyethylene foam layer to a composite fabric, compressing the composite fabric between a top mold and a bottom mold, and maintaining the composite fabric between the top and bottom molds for a predetermined dwell time. [0017] The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description, and drawings. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0018] FIG. 1 is a cross sectional view of an exemplary embodiment of a molded composite fabric according to the present invention; [0019] FIG. 2 illustrates a molding step for the composite fabric of FIG. 1 during a heating portion; [0020] FIG. 3 illustrates the molding step of FIG. 2 during a molding portion; Continue reading... Full patent description for Molded composite fabrics and methods of making Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Molded composite fabrics and methods of making patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Molded composite fabrics and methods of making or other areas of interest. ### Previous Patent Application: Synthetic fiber tire fabric for reinforcing rubber and pneumatic tire using the same Next Patent Application: Device, especially sporting equipment for use in surfing or similar activities, and a method for producing fiber composites Industry Class: Fabric (woven, knitted, or nonwoven textile or cloth, etc.) ### FreshPatents.com Support Thank you for viewing the Molded composite fabrics and methods of making patent info. IP-related news and info Results in 1.3391 seconds Other interesting Feshpatents.com categories: Medical: Surgery , Surgery(2) , Surgery(3) , Drug , Drug(2) , Prosthesis , Dentistry |
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