"MULTILAYER ASSEMBLY FOR TEXTILE APPLICATIONS"

[0001] The present invention regards the sector of manufacturing garments or medical braces and in particular the sector of solutions for bonding layers of fabric, preferably by heat-welding .

[0002] In order to best perform the function for which they are designed, some portions of certain garments or medical braces require a structure to maintain a desired shape during use . To achieve this feature , these portions are made by coupling multiple layers of fabric, since a single layer, no matter how rigid the material itsel f may be , cannot maintain the desired shape .

[0003] For this purpose , a thermo-adhesive tape , which is generally continuous and homogeneous , is often interposed between the fabric layers to hold the two layers together . The Applicant , for example , has for years been producing and marketing a wide range of thermo-adhesive tapes , including those in the Framilon® series , to the considerable satis faction of its customers .

[0004] However, the solutions known today have some drawbacks , such as in the case where the portion of the garment must have considerable elasticity, lightness , and breathability, such as in the case of the waistband of leggings , the underbust band of bras or the entire bra, girdles , or medical braces , such as knee braces , elbow braces , and the like .

[0005] In such cases , the thermo-adhesive tape often exerts too vigorous an action, which prevents the multilayer assembly from having the desired elastic elongation for the speci fic function of the garment .

[0006] Other known solutions are described, for example , in US2015/ 351474 , US4977011 , US2004 / 166756 , DE2746146, and WO2021 / 181160 .

[0007] The obj ect of the present invention is to provide a multilayer assembly which overcomes the drawbacks mentioned above and meets the needs o f the sector .

[0008] This obj ect is achieved by a multilayer assembly according to claim 1 . The dependent claims describe additional advantageous embodiments .

[0009] The features and advantages of the multilayer assembly according to this invention will become apparent from the following description, given by way of nonlimiting example according to the figures in the accompanying drawings , wherein :

- Fig . 1 is a schematic view of a multilayer assembly according to an embodiment of the present invention;

Fig . 2 is a diagram of a bonding layer of the multilayer assembly, according to an example embodiment ;

Fig . 3a, 3b and 3c show other examples of bonding layers of the multilayer assembly;

- Fig. 4 is a diagram of a multilayer assembly, according to another embodiment of the invention;

- Fig. 5 is a diagram of a multilayer assembly, according to yet another embodiment of the invention; and

- Fig. 6 schematically represents a bonding layer of a multilayer assembly according to the present invention.

[0010] According to a first embodiment (Fig. 1) , a multilayer assembly la for making a portion of a garment or the entire garment consists of: a first layer 2 made of textile material, having an inner face 2a and an outer face 2b; a second layer 4 made of textile material, having an inner face 4a and an outer face 4b; and a bonding layer 6 interposed between the first layer 2 and the second layer 4 and closely coupled superficially to the inner face 2a of the first layer 2 and the inner face 4a of the second layer 4. In other words, the first layer 2 is coupled to the second layer 4 via the bonding layer 6.

[0011] A fabric is defined as "elastic, " in accordance with the international standard ISO 13934, if the elongation up to maximum force is greater than or equal to 8% in the selvage direction (e.g., in the weft direction) and/or transversely thereto (e.g., in the warp direction) .

[0012] Preferably, the first layer 2 is a synthetic or natural or mixed elastic fabric.

[0013] For example, the first layer 2 is a polyester-based fabric (i.e., having a composition in which the polyester constitutes, by weight, the relative majority of the components) or a polyamide-based fabric or a cotton-based fabric or a polyurethane-based fabric, e.g., Elastane.

[0014] Preferably, the second layer 4 is a synthetic or natural or mixed elastic fabric.

[0015] For example, the second layer 4 is a polyester-based fabric or a polyamide-based fabric or a cotton-based fabric or a polyurethane-based fabric, e.g., Elastane.

[0016] The bonding layer 6 consists of a single piece that forms a perforated layer of polymeric material which, at a predefined temperature, activates adhesive properties toward the first layer 2 and the second layer 4, thus keeping them coupled even after cooling.

[0017] The bonding layer 6 is perforated in the sense of having a lattice structure with a plurality of openings 8 in orderly succession and with a predefined shape.

[0018] For example, according to a preferred embodiment (Fig. 2) , the bonding layer 6 has a lattice structure in which the openings 8 are in the shape of a rhombus having a major diagonal Dmax and a minor diagonal Dmin perpendicular to each other, wherein the major diagonal is greater than the minor diagonal. In other words, in such an embodiment, the bonding layer 6 consists of a plurality of first branches 10 that are substantially straight, parallel and spaced apart and a plurality of second branches 12 that are substantially straight, parallel and spaced apart; the first branches 10 intersect the second branches 12, forming a lattice with rhomboidal openings 8.

[0019] For example, the bonding layer 6 is a three- dimensional lattice in which:

- a first shape ratio (Rl) between the length of the major diagonal and the length of the minor diagonal (Rl=Dmax/Dmin) is between 0.5 and 4 (0.5<Rl<4) , e.g. equal to 1.5;

- a second shape ratio (R2) between the length of the major diagonal (Dmax) and the thickness (S) of the branches 10, 12 (R2=Dmax/S) is between 2 and 8 (2<R2<8) , e.g. equal to 4;

- a third shape ratio (R3) between the length of the major diagonal (Dmax) and the height (H) of the bonding layer (R3=Dmax/H) is between 10 and 30 (10<R3<30) , e.g. equal to 18;

- a fourth shape ratio (R4) between the thickness (S) of the branches and the height (H) of the bonding layer (R4=S/H) is between 2 and 7 (2<R4<7) , e.g. equal to 4.5. [0020] For example, the bonding layer 6 is a three- dimensional lattice in which:

- the major diagonal (Dmax) of the rhomboidal openings has a length preferably between 2 and 4 millimeters (2<Dmax<4) , e.g. equal to 3 millimeters;

- the minor diagonal (Dmin) of the rhomboidal openings has a length preferably between 1 and 3 millimeters (l<Dmin<3) , e.g. equal to 2 millimeters;

- the thickness (S) of the branches 10, 12 that delimit the rhomboidal openings is preferably between 0.50 and 1 millimeter (0.50<Sdl) , e.g. equal to 0.75 millimeters;

- the height (H) of the bonding layer 6 is uniform and preferably between 150 and 180 microns (150<H<180) , e.g. equal to 165 microns, with a tolerance of 3% (i.e. 165 microns ± 5 microns) .

[0021] The Applicant has found that the aforesaid specific dimensional ratios and/or specific dimensions allow for a garment or medical brace to be obtained that has excellent features of elasticity, breathability, and comfort .

[0022] Having defined a deformation direction X of a garment or medical brace, along which it is desired that said garment or brace exhibits pronounced deformation, the first branches 10 and the second branches 12 are inclined with respect to the deformation direction X. For example, preferably, the imaginary diagonals of side-by- side openings define, for the multilayer assembly, a diagonal direction Y substantially parallel to the deformation direction X.

[0023] In the context of this description, the terms "substantially straight" and "substantially parallel" are to be understood with relative reference to the normal tolerances associated with the technology for manufacturing the bonding layer.

[0024] According to other example embodiments, the bonding layer has circular or pseudo-circular openings (Fig. 3a) , or triangular openings with a common side (Fig. 3b) or mixed triangular and rhomboidal openings (Fig. 3c) .

[0025] Preferably, the bonding layer 6 is made of a thermoplastic elastomer.

[0026] For example, the bonding layer is made of thermoplastic polyurethane (TPU) , e.g., with a hardness of about 55 ShA, elongation at rupture of about 860% and a softening temperature between 130° - 140°C.

[0027] According to another example, the bonding layer is made of SEBS ( styrene-ethylene-butylene-styrene ) , e.g., with a hardness of about 15 ShA and a melting point of about 90°C.

[0028] Preferably, the first layer 2, the bonding layer 6 and the second layer 4 are coupled by hot lamination, generally activated between 120° - 150°C. [0029] According to another embodiment (Fig. 4) , a multilayer assembly lb consists of the first layer 2 described above and the bonding layer 6 described above, closely coupled superficially to the first layer 2.

[0030] According to yet another embodiment (Fig. 5) , a multilayer assembly 1c consists of the first layer 2 described above, the bonding layer 6 described above, closely coupled superficially to one side of the first layer 2, and an auxiliary layer 20 consisting of a polymeric material, e.g. polyethylene (PE) , closely coupled superficially to the first layer 2, on the opposite side of the bonding layer 6. Such an assembly is particularly suitable for making garment labels.

[0031] Preferably, the multilayer assembly la, lb, 1c is provided in a roll consisting of a continuous tape having a predetermined length, wound to form the roll.

[0032] The multilayer assembly described above is particularly suitable for making the waistband of leggings, the underbust band of a sport bra, bra cups, sport bras, men's underwear, girdles, portions of jeans, e.g., to create the push-up effect, or to make medical braces, such as knee braces, elbow braces, ankle braces and the like.

[0033] According to an example embodiment of the invention, in order to make the garment or brace, the first layer 2 of the multilayer assembly la is coupled to the bonding layer 6 and the bonding layer 6 to the second layer 4 by heat-welding, preferably simultaneously.

[0034] According to another example, the first layer 2 of the multilayer assembly lb is coupled to the bonding layer 6, preferably by heat-welding, thus forming a tape, e.g., in a first factory; the tape, subsequently, e.g., in a second factory, is coupled to the second layer 4 via the bonding tape 6.

[0035] According to yet another example, in order to create, e.g. a label, the first layer 2 of the multilayer assembly 1c is coupled to the bonding layer 6 by heatwelding, thus forming a tape, e.g. in a first factory; the tape, subsequently, usually in the same first factory, is coupled to the auxiliary layer 20 via the first layer 2.

[0036] Innovatively, the multilayer assembly described above overcomes the aforesaid drawbacks with reference to the prior art, as it allows for portions of garments that exhibit considerable elasticity to be created.

[0037] In addition, advantageously, these portions exhibit considerable comfort, provide a lightweight feel, and exhibit high breathability.

[0038] It is clear that a person skilled in the art may make changes to the multilayer assembly described above in order to meet incidental needs , these changes all falling within the scope of protection defined in the following claims .