Patent Application
20160160408
The disclosed technology relates to a lace fabric.
Lace fabric is widely used as ornamentation in industries such as clothing or stuffed toys. The lace fabric is distributed as an independent subsidiary material, or as attached to clothing or stuffed toys. Regardless of the distribution channel, the lace fabric tends to ultimately be used by being attached to an adherend, which is a base. However, there have been many difficulties and technical limitations in typical techniques related to attaching the lace fabric to the adherend.
Some implementations of the disclose technology provide a novel lace fabric that may be used by being conveniently attached to an adherend.
In an exemplary embodiment of the disclosed technology, a hot melt coating layer is formed on one surface (rear surface) of the lace fabric. Thus the user may use the lace fabric that is attached to the adherend, merely by placing the lace fabric onto the adherend and then ironing them. This revolutionary lace fabric embodying novel concepts is disclosed through the present specification.
In another exemplary embodiment of the disclosed technology, the revolutionary technique is disclosed in which the novel lace fabric having a hot melt function is easily manufactured without any technical disadvantage in the use thereof.
The disclosed technology also provide other unspecified objectives which are easily inferred within the scope of the following detailed description and advantageous effects thereof.
In one aspect of the disclosed technology, a lace fabric is provided to include a bottom thread layer, which is a covering area which covers about 10% to about 95% and in which a thread of a knit structure forms a surface, and a design pattern that includes an opening area, of about 5 to about 95%, in which the thread of the knit structure does not form a surface, wherein a surface of the bottom thread layer is configured as an uneven surface on which lace motif design patterns are formed to provide a plurality of layers, a rear surface of the bottom thread layer is configured as an even surface, and a hot melt adhesive, made of thermoplastic resin, that attaches to an adherend through application of heat and pressure is coated on a rear surface of the bottom thread layer to thereby form a hot melt coating layer on a rear surface of the covering area.
In the lace fabric according to an exemplary embodiment of the disclosed technology, the hot melt coating layer formed on the rear surface of the bottom thread layer of the lace fabric may be advantageously obtained by laminating a first paste dot layer and a second paste dot layer in sequence, and a paste adhesive may be advantageously coated on the rear surface of the covering area through roll printing to form the first paste dot layer, and then hot melt powder may be advantageously scattered on the first paste dot layer to form the second paste dot layer.
In a lace fabric according to an exemplary embodiment of the disclosed technology, the surface of the covering area may be advantageously configured as the uneven surface of the plurality of layers by forming the lace motif through reweaving of pattern members, made of differing materials, on and above a woven thread of the lace fabric.
In a lace fabric according to an exemplary embodiment of the disclosed technology, the paste that is used in the hot melt coating layer, the paste that is used in the first paste dot layer may be advantageously the same as or different from the paste that is used in the second paste dot layer.
In a second aspect of the disclosed technology for overcoming such limitations as above, a lace fabric, woven from two different kinds of threads, includes:
an opening area and a covering area which are formed by weaving a bottom thread, and a motif layer that is formed by weaving a motif thread on a surface of a bottom thread layer which is the covering area, wherein the surface of a core of the bottom thread is hot-melt coated, but the motif thread is not hot-melt coated.
In a lace fabric according to an exemplary embodiment of the disclosed technology, the opening area that is formed by weaving the bottom thread may advantageously occupy about 5% to about 95%
In a lace fabric according to an exemplary embodiment of the disclosed technology, the hot melt coating may be advantageously formed on the surface of the core of the bottom thread through processes of dipping the core into a hot melt suspension, drying, and winding.
In a third aspect of the disclosed technology, a method of attaching the above-described lace fabric to an adherend includes cutting and putting the lace fabric over a surface of the adherend, and attaching a rear surface of the lace fabric to the surface of the adherend by placing an iron on a motif layer of the lace fabric to apply pressure and heat at a temperature of at least 110° C.
The disclosed technology can be used to provide a significant advantage of easily and conveniently attaching a lace fabric to various clothing, stuffed toys, etc. Since no adhesive film is used in the disclosed technology, not only is manufacturing be done with ease, usage is also extremely easy. Attachment of the lace fabric is easily accomplished by merely placing the lace fabric on an adherend and then ironing.
By using the lace fabric of the disclosed technology, not only is it possible to showcase various fashions, new commercial possibilities that actively employ lace fabric in fabric do-it-yourself (DIY) may also be proposed.
Meanwhile, even if not clearly stated herein, advantageous effects that are disclosed in or inferred from the contents of the below specification and may be anticipated by the technical features of the disclosed technology, will be treated the same as those that are disclosed in the specification of the disclosed technology.
The above and other features and associated advantages are described in detail in the drawings, the description and the claims.
The accompanying drawings are provided merely as examples for better understanding the technical spirit of the disclosed technology, and should not be construed as limiting the scope of the disclosed technology.
According to typical techniques, a way of sewing is usually used in which, after placing the lace fabric on the adherend and making a seam margin on an edge of the fabric, a sewing machine is used to backstitch the seam margin part onto the adherend. However, unless a user of the lace fabric was an export, it was difficult to accurately sew the lace fabric onto the adherend, and a quick sewing job was even more difficult. In particular, in the case of the lace fabric of a design having numerous holes, and thus a very low covering degree, such technical difficulties were doubled.
Thus, the inventors of the disclosed technology explored a method, which is unlike typical techniques, of cutting the lace fabric to a desired size, and then using an adhesive to bond the cut lace fabric onto a base member. However, a procedure in which the user, while using the lace fabric, is coating the adhesive directly on a rear surface thereof is extremely difficult due to the low covering degree of the lace fabric. Thus, applying a technique in which an adhesive layer is formed on one surface of the lace fabric during a process of manufacturing the lace fabric is considered to be more advantageous. For example, Korean Patent No. 549816 discloses a method for manufacturing fabric that attaches to clothing through heating in which an adhesive film is laminated on an ornamental fabric, i.e., a fabric on which is formed an ornamental pattern, which is not a lace fabric. The lamination is done by using a roller to laminate the adhesive film on the ornamental fabric. Next, a half cutter of the manufacturing apparatus is used to repeatedly cut the laminated fabric. This technique cannot be applied to the lace fabric in part because the design of the lace fabric is extremely varied so that it is inconvenient and uneconomical to adjust a cutting pattern of the half cutter in the manufacturing apparatus. In addition, since the lace fabric includes a roughness of a weave and numerous holes, the lace fabric cannot be sufficiently laminated with the adhesive film and it is generally difficult to attach the lace fabric to the adherend. Even if the adhesive film is managed to be attached to the lace fabric, there is a critical limitation of the user being unable, due to the many holes, to separate the adhesive film from the lace fabric.
The inventors developed the disclosed technology based on recognition of the above and other technical issues and after a long research effort.
In a lace fabric, a part that, according to shape, has a lot of knitting, and thus many interlocking threads, has a high covering degree. Conversely, a part that has little knitting is characterized by having a very low covering degree, such as being see-through or having a hole. Here, the covering degree represents an area, per unit surface area of the fabric surface, occupied by warp and weft (or fiber).
Hereinafter, with reference to the accompanying drawings, detailed description will be given of modes for carrying out the disclosed technology. In describing the disclosed technology, detailed descriptions of known techniques that are obvious to a person with ordinary skill in the art will be excluded so as not to unnecessarily obscure the essence of the disclosed technology.
In this way, when the motif layer 112 is added onto the bottom thread layer 110, ridges, whose members differ in height from each other, are formed on the surface 100 of the lace fabric 1, and thus the surface 100 forms an uneven surface.
Meanwhile, it is further stated that the bottom thread layer 110 of the lace fabric 1 does not exclude an opening. This is because even the bottom thread layer 110, which is the covering area, includes a mesh from the knitting. Only the size of the mesh, which forms the opening, differs for each position of the covering area 110.
In the case of the lace fabric 1 of the disclosed technology, a ratio between the bottom thread layer 110, which is the covering area, and the opening area 130 is different for each lace design. The lace fabric 1 of the disclosed technology is attached to an adherend (not shown), such as clothing or stuffed toys, and when the bottom thread layer 110, the covering area, is increased, there are more interlocking threads, and thus it becomes more difficult to see through to the adherend, through the lace fabric 1. Conversely, as the opening area 130 increases, there are less interlocking threads, and thus it becomes easier to see through to the adherend through the lace fabric 1. Desirably, the bottom thread layer 110 of the disclosed technology may occupy a surface area ratio of about 10% to about 95% per unit area (for example, per square yard) of the lace fabric 1. When the surface area ratio of the bottom thread layer 110 is less than about 10%, it is difficult to form a hot melt coating layer (see 150 in
The lace fabric of the disclosed technology, despite the low ratio of the covering area, may not only form the hot melt coating layer more effectively than typical techniques, but also demonstrates an advantage of allowing the user to easily use the lace fabric of the disclosed technology. This is because there is no additional adhesive film that must be removed by the user.
First, using rotating screen rollers 201 and 202, the paste adhesive, which is in a liquid state, is coated, in a manner similar to printing, to form a first paste dot layer 103 on the rear surface 101 of the fabric 1. Specifically, the doctor blade 203 of the screen roller 201 is manipulated to employ a paste 205 in printing base dots on the rear surface 101 of the lace fabric 1.
In the composition of the paste, water makes up about 55 wt % to about 70 wt % of the paste and functions as a medium for dispersing the paste. A hot melt powder (about 25 to 35 wt %), which makes up the majority of the portion except water, may include polyamide hot melt or polyester hot melt. Desirably, dispersing agents, which are surfactants that act as wetting agents and function to facilitate a stable dispersion of the hot melt powder in the water; protective colloids, which are water soluble polymers that prevent each other from solidifying in the paste; plasticizers that bond with the hot melt adhesive to lower the melting temperature range and viscosity; lubricants that use polyethylene glycol to facilitate a transfer of the dot from the screen to the lace fabric; and thickeners that use polyacrylic acid to regulate the appropriate viscosity for the mechanical conditions may be further included. In addition, the paste may include plastic dispersing agents such as polyacrylate, polyurethane, latex, etc.
Various materials may be selected for the hot melt that is used in the disclosed technology. The hot melt materials such as styrene-based thermoplastic elastomer formed through alternating copolymerization of polystyrene blocks and blocks of polybutadiene and polyisoprene, ethylene-vinyl acetate-based resin containing between about 18 wt % to about 40 wt % of vinyl acetate, ethylene-acrylic acid copolymer, olefin-based resin, polyester-based resin, polyamide-based resin, polyurethane-based resin, etc. may be appropriately used.
Next, the about 80 to about 200 micron hot melt powder 221 in a hopper 220 is provided to the lace fabric 1 through a sputtering roller 230, and an oscillating brush 231 scatters the hot melt powder 221 onto the rear surface 101 of the lace fabric 1. Here, the hot melt powder 221 lands on the first paste dot layer 103 to form a second paste dot layer 105.
Afterwards, powder, other than the second paste dot layer 105 that landed on the first paste dot layer 103, is suctioned and removed by a suction apparatus 240. The substrate 200 is passed through an air circulation-type chamber 250 to evaporate moisture contained in the dot layer of the lace fabric 1, and to dry the hot melt coating layer 150 that includes the paste dots. In a melting process, the second paste dot layer 105, which is the hot melt powder disposed on the first paste dot layer 103, melts, and at the same time is clumped together with the first paste dot layer 103. For complete drying, an infrared radiator 260 may be installed. The dots are cooled and solidified by undergoing a cooling operation, and by winding the lace fabric 1, the lace fabric 1 that is provided with the hot melt coating layer 150 of the disclosed technology may be manufactured.
Desirably, the dot weight of the first paste dot layer 103 may be about 3 to about 5 g/m2, and the dot weight of the second paste dot layer may be about 5 to about 7 g/m2. The size of the dots may be modified in various ways according to the intended use and design of the lace fabric. Moreover, it is further stated that compositions of the hot melt powder used to form the first paste dot layer 103, and the hot melt powder used to form the second paste dot layer 105 may be combined in various ways.
The method for forming the hot melt coating layer on the lace fabric 1 may be modified in various ways. For example, an embodiment in which the method of forming the first paste dot layer 103 as shown
In the above Example 1, the hot melt coating layer 150 is formed on the rear surface of the lace fabric 1, but the following desirable Example 2 of the disclosed technology may be differentiated from Example 1 in that the hot melt coating is made to be performed on the thread itself of the lace fabric. The other configuration is substantially the same.
As shown in
The surface 100 configuration of the lace fabric 1 is as described in
As described in
When the motif layer 112 is formed on the covering area, the ridges, whose members differ in height from each other, are formed on the surface 100 of the lace fabric 1, and thus the surface 100 forms an uneven surface.
Meanwhile, it is further stated that the covering area, which is woven by using the bottom thread of the lace fabric 1 of the disclosed technology, does not exclude openings. This is because even the bottom thread layer 110 includes the mesh from the knitting. It is merely the size of the mesh that differs for each position of the covering area.
The surface area ratio between the bottom thread layer 110, which is the covering area, and opening area 130 differs for each lace design. When the bottom thread layer 110 is increased, there are more interlocking threads, and thus it becomes more difficult to see through to the adherend through the lace fabric 1. Conversely, as the opening area 130 increases, there are less interlocking threads, and thus it becomes easier to see through to the adherend through the lace fabric 1. Desirably, the bottom thread layer 110 of the disclosed technology may occupy a surface area ratio of about 5% to about 95% per unit area (for example, per square yard) of the lace fabric 1. When the surface area ratio of the bottom thread layer 110 is less than about 5%, there are an excessive number of holes in the lace fabric, and when the ratio is greater than about 95%, number of holes becomes excessively small, and thus the use-value of the lace fabric 1 may be decreased. Thus, the opening area, formed through weaving of the bottom thread, desirably occupies the surface area ratio of about 5% to about 95%.
As described above, the surface of the bottom thread 11 forming the bottom thread layer 110 of the disclosed technology is hot melt coated with the thermoplastic resin. That is, in the lace fabric of the disclosed technology, the bottom thread 11 produced through the hot melt coating process is woven to form the bottom thread layer 110.
A hot melt suspension is coated on the surface of the thread by sufficiently dipping the core of the thread, to be used in the lace fabric, in the hot melt suspension that is in a molten state of about 110° C. to about 180° C. Desirably, the core of the thread is dipped in the hot melt suspension for about 15 to about 30 hours. By undergoing the process of taking out the dipped core to dry, the hot melt-coated bottom thread 11 may be obtained. Desirably, the hot melt coating layer is sufficiently dried by leaving at room temperature for about 10 to 15 minutes. An air cooler may be used to reduce the drying time.
The bottom thread 11 obtained as such is wound with a winder. When manufacturing the lace fabric, the bottom thread 11 is woven into a predetermined pattern to thereby form the bottom thread layer 110.
Various materials may be selected as the hot melt suspension used in the disclosed technology. The hot melt materials such as styrene-based thermoplastic elastomer formed through alternating copolymerization of polystyrene blocks and blocks of polybutadiene and polyisoprene, ethylene-vinyl acetate-based resin containing between about 18 wt % to about 40 wt % of vinyl acetate, ethylene-acrylic acid copolymer, olefin-based resin, polyester-based resin, polyamide-based resin, polyurethane-based resin, etc. may be appropriately used.
Moreover, the functionality of the hot melt suspension may be improved by including known polymerization initiators, surfactants, dispersion stabilizers, or other additives in the hot melt suspension.
By hot melt coating the yarn itself, which forms the bottom thread layer of the lace fabric, the technical disadvantage of the Strike Back limitation being easily induced when forming the hot melt coating on one surface of the lace fabric may be completely overcome. Moreover, the optimum hot melt technique that can be easily applied to the physical properties of the lace fabric, which is a thin fabric, may be provided. In addition, there is an advantage of obtaining the lace fabric that has the hot melt function and is also much thinner than the lace fabric of the above Example 1.
The lace fabric that is manufactured in this way provides the novel method that differs from typical techniques with regard to attaching lace fabric to the adherend such as clothing or stuffed toys. The lace fabric of the disclosed technology may be cut into the desired size, and the rear surface thereof may be placed on the surface of the adherend. Next, after placing an iron on the surface of the lace fabric, that is, the uneven surface, the iron may be used to apply heat and pressure at a temperature of at least about 110° C., and desirably about 120° C. to about 170° C. Consequently, the rear surface of the lace fabric and the surface of the adherend attach to each other as the hot melt layer of the lace fabric melts.
The scope of the disclosed technology is not limited to the clearly described Examples which are disclosed above. Moreover, it should be understood that the scope of the disclosed technology cannot be limited by modifications or substitutions that are obvious in the technical field.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2014-0015187 | Feb 2014 | KR | national |
| 10-2014-0047205 | Apr 2014 | KR | national |
This patent document is a continuation-in-part application of, and claims priority and benefits of, Patent Cooperation Treaty (PCT) application number PCT/KR2015/001195, entitled “LACE FABRIC HAVING HOT-MELT FUNCTION”, filed with the Korean Intellectual Property Office (KIPO) on Feb. 5, 2015, which further claims priority of Korean Patent Application No. 10-2014-0015187, filed Feb. 11, 2014, and Korean Patent Application No. 10-2014-0047205, filed on Apr. 21, 2014. The entire disclosures of the above applications are incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/KR2015/001195 | Feb 2015 | US |
| Child | 15045765 | US |
