US2096710A - Starchless sheet - Google Patents

Description

Oct. 26, 193 7.

C. EMMEY STARCHLESS SHEET Filed Feb. 18. 1955 INVENTOR. (Zak/e5 Emm B6 g) M ATTORNEY.

Patented Oct. 26, 1931 UNITED STATES PATENT orrlce 4 Claims.

This invention relates to the production of a starchless spontaneous permanently self stiffening fabric or sheet material and more particularly to the use thereof in combination with articles of apparel.

While I describe my invention as particularly applied to collars either of the attached or detached type it will be understood that this is for the purposes of illustration only and that my invention is not limited thereto but applies to any other articles compatible with the disclosure thereof.

My invention contemplates the provision of an article of apparel which may be stiffened to any desired degree, without the use of starch or other extraneous stiffening means, and upon which ironing always produces the stiff shiny appearance of a laundered starched article and which repeated laundering will always spontaneously restore.

My invention further contemplates the provision of an article of apparel that is impervious to water and which will not wilt or soften under the influence of perspiration and body heat.

My invention further contemplates the provision of such an article .of apparel which is strong and durable and which may be produced at a comparatively lower cost than like articles heretofore produced.

My invention further contemplates the production of a fabric or sheet material which is permanently thermoplastic and which upon repeated ironing, will spontaneously further produce on the article of apparel with which it is associated, a slight waxy finish, ordinarily obtained by beeswax or other extraneously applied waxy substance commonly used in laundering, and which waxy finish will be produced without the use of extraneous material.

It has heretofore been proposed to use various cementitious binders to provide a stiffened article of apparel adapted to be laundered without starching and which is water proof and unaffected by body heat. These materials are not permanently thermoplastic, require extraneous materials to efiect thereon the waxy laundered finish common in the laundry art and are usually produced from cellulose derivatives, which are in most cases highly inflammable.

The present invention is concerned with the use of an impregnating material and cementitious binder comprising vinyl resins, resulting from the polymerization of vinyl compounds, and provides a permanently thermoplastic cementitious binder which is noninflammable.

It has been proposed in the prior art to fabricate articles of apparel with cellulose derivatives which are non-cementitious in themselves and to then chemically treat the entire fabricated article in order to thereby make the cellulose cemen- 5 titious. This method makes the article impermeable both to moisture and air and therefore is uncomfortable to wear in warm weather.

Another disadvantage resulting from such process is the difficulty encountered in properly laundering the article which due to its waterproof properties will not permit the water to pass through the body of the collar.

I am likewise aware that it has been proposed in the prior art to produce a lining comprising a woven fabric composed of yarns or threads of cotton and additional yarns or threads of a cellulose derivative.

While such process has the advantages of producing a starchless spontaneous stiffening article of apparel permeable to water and air, it has the same disadvantage inherent to all such binders of requiring chemical treatment of the entire fabricated article to make the binder cementitious after the article has been fabricated, with the attendant necessity of special machinery and special process of manufacture.

The present invention provides a self stiffening permanently thermoplastic sheet or fabric which is permeable to air and water and which eliminates the necessity of chemical treatment of the fabricated article as heretofore required, and which may be readily applied to any common lining material now used, as for example the cotton lining commonly used in the manufacture of ordi- 5 nary collars and cufis. According to the present invention a permanently thermoplastic cementitious binder having compounded therein a slight quantity of an oily or waxy substance, is applied in the form of a plurality of extremely thin streaks of film interlaced or parallel on the surface of a sheet of material or fabric, preferably an unbleached woven sheet having relatively large interstices and therefore readily absorbent, such as the lining material ordinarily used in the manufacture of collars and cuffs.

To carry out the present invention I prefer to use a permanently thermoplastic cementitious 50 material formed from the solution of a vinyl resin in any compatible solvent, such as acetone. To such a solution of proper proportions to provide a comparatively stiff mixture, I prefer to incorporate a plasticizing agent made up of butyl acetate, toluene and phthalates.

Vinyl resins are inherently permanently thermoplastic and do not require the use of plasticizers such as enumerated above to impart a plastic quality, but I have found that they are not completely suitable for the purpose of providing a starchless spontaneous self stiffening binder for articles of apparel, such as contemplated by the present invention, because they produce in such articles when handled, the stiff sensation experienced in the handling of heavy paper or card board and evoke therein the crackling noise occasioned by the milling of paper sheets.

The addition of a plasticizer or softening material to the thermoplastic resin provides in the fabric with which my thermoplastic stiffening binder is associated, a smooth feeling and eliminates the disadvantageous crackling noise usually associated with the cementitious binders heretofore used, and which to a certain extent adversely affects their commercial value.

In addition to the above mentioned ingredients I prefer to compound in my thermoplastic binder an extremely small quantity of a waxy or oily substance, such as paraffin oil. Upon ironing the article of apparel with which my starchless spon taneous self stiffening fabric is associated, this waxy or oily substance will seep to a slight extent through the article to thereby produce therein the shiny starched appearance, generally associated with laundered articles, resulting from the extraneous use thereon of beeswax or other commonly employed wax or tallow.

The following illustrative formula will serve as an example of a. thermoplastic binder which has been found suited for use in the present invention.

di-butyl phthalate. or other Percent Vinyl resin 29.0 Butyl acetate 5.4 Toluene 7.1 Di-butylphthalate 4.5 Paraffin oil 3 Acetone 51.0

It will, of course, be understood that the proportions of these ingredients are illustrative only and that they may be varied and the ingredients modified to include other thermoplastic stiffening agents and other plasticizers or to eliminate entirely or in part the plasticizers suggested, and mxy or oily substances.

The proportions of these ingredients will vary in accordance with the lining material which is i to be impregnated with the thermoplastic material and the degree of stiffness required for the article with which my impregnated sheet is associated.

The accompanying drawing illustrates an application of my invention as applied to a collar. Figure 1 is a view of the collar laid fiat and unfolded, with a portion of the fabric broken away to show my thermoplastic impregnated sheet.

Figure 2 is a diagrammatic plan view of a piece of the thermoplastic lining, greatly magnified.

Figure 3 is a cross sectional view on the line 3-3 of Figure 2.

Figure 4 is an enlarged section showing the collar folded.

Figure 5 is a diagrammatic plan view of a piece of lining showing a modified application of thermoplastic thereto, greatly magnified.

In the practice of my invention a thermoplastic having a comparatively stiff consistency is applied .7 to a fabric sheet [0, preferably having large interstices and comprising the usual lining material such as found in the collar and cuff manufacturing art, in the form of a plurality of extremely thin streaks ll of film, preferably by a plurality of rollers, which apparatus need not be shown in this application as it is not a part thereof and only so much of which is herein described as is necessary to explain generally the method of applying such streaks of thermoplastic film.

Two hollow metal rollers preferably perforated along the periphery to permit the viscous thermoplastic cementitious material to escape therethrough upon the application of air pressure to the hollow rollers, may be used to impregnate the sheet II). This sheet is carried between the rollers by any suitable means, which need not here be described, and as it passes therebetween, air is forced in to the rollers, thereby forcing the liquid thermoplastic cementitious material through the perforations in the roller and streaking the sheet with a plurality of streaks of film ll approximately .003 to .004 inch in thickness and width.

These streaks of film are separated by areas of unimpregnated sheet material l2, thereby providing a plurality of air spaces between the thermoplastic. These areas of fabric, unencumbered by any thermoplastic material, vary from approximately .0625 to .25 inch in width. The form which the said streaks of film assume may be varied by changing the type of rollers used, for

' example these streaks may assume a wavy like formation I! or a web like weave (Fig. 5), but will always be separated by air spaces slightly greater than the width and thickness of the streaks of film. By applying the thermoplastic material in this fashion instead of the heretofore complete impregnation of the material with which it is associated, the cost of producing such sheet is greatly reduced and its resulting weight greatly lessened, since a comparatively small quantity of thermoplastic is thereby used.

After the application of the cementitious material to the fabric, it may then be passed over a plurality of rollers to permit the volatile solvents to completely evaporate the thermoplastic drying thereon and adhering thereto. The resulting fabric is dry and non-sticky at ordinary room temperatures and is produced in an economical and cheap manner and without excess of thermoplastic cementitious material.

This resulting fabric may then be formed into rolls, preparatory to shipping and may then be associated with any article without further chemical treatment as heretofore required.

When applied to collars as illustrated in the accompanying drawing, these sheets may be fashioned into the desired shape of the collar lining inset [3 as has heretofore been the common practice in this art, by the usual cutting or stamping machines. It is apparent that the use of this resulting fabric produces no change in the method of manufacture of any article heretofore used with which my novel fabric is to be associated and does not require the use of new machines or changes to existing machines.

This starchless spontaneously self stiffening fabric lining is placed between the plies l4 and I 5 of the collar, in the usual manner now followed in conjunction with the use of the ordinary unimpregnated collar lining, and is then sewed between the plies, in any suitable manner, as by means of the stitching l6 well known in the art andwhich need not be further described here.

The collar is then ready for pressing by any suitable means as a hot iron, a slight mist being applied to the finished collar immediately prior to this operation.

The heat, steam and pressure of the hot iron causes the thermoplastic ll, adhering to the lining I0, and which is moldable, to fiow into the interstices l2 and to slightly impregnate the collar plies l4 and I5 and the lining fabric to thereby permanently cement the lining and plies together. The heat and pressure mold the plastic and therefore shape the collar to the desired, pressed and laundered appearance.

Upon cooling, the finished collar becomes permanently stiff, the extent of which varies with the temperature of the pressing means which is applied to article, the temperature for a semistiif material ranging from 220 F. to 250 F., a higher temperature producing greater rigidity in the article.

The'oily or waxy substance compounded in the thermoplastic material, is volatilized by the heat and seeps slightly through the plies during the ironing process to thereby produce on the article the shiny waxy appearance of a properly laundered-article.

The streaks of film of thermoplastic material are sufficiently spaced apart to always leave after the pressing operation, slight areas of unimpregnated lining between the plies, to thereby provide air spaces and to produce a finished product that is permeable to water and air, but one which will not wilt or ruffle from prespiration, exposure to water, or body heat, but will remain permanently stiif.

I have found that the surface of the areas of fabric separating the streaks of film and unencumbered by the thermoplastic cement may, if desired, be coated with a wax, by any means known in the art. Upon the application of heat and pressure as heretofore described, this waxy substance is volatilized and bailed off and causing the thermoplastic to flow more freely and be more readily moldable.

The boiling off of thewax insures the formation of air spaces in the thereby cemented parts of the article and prevents the possibility, in the event that the streaks of film are not properly spaced apart, of the streaks of thermoplastic being molded together.

The article so produced may be thoroughly washed, the air spaces permitting the water to penetrate through the article and thoroughly cleanse it and to similarly permit air to pass therethrough, so that it will not be uncomfortable for wear.

The thermoplastic is sufiiciently pliable at washing temperatures, 150 F. to 225 F. to permit manipulation of the article to enable it to be thoroughly washed. I

After washing, the article may be ironed in the usual manner, whereby the thermoplastic material is pressed and remolded to the desired laundered shape and a shiny waxy appearance reproduced thereon, and upon cooling, the article becomes rigid again. This process may be repeated indefinitely, a durable strong article having been produced by my novel process and composition.

The composition of thermoplastic cement heretofore described may, itself, be produced in rolls of extremely thin sheets, which may be cut to any desired shape and placed between the plies of the collar or other article as heretofore described, to thereby eliminate the impregnated lining fabric. The collar is then sewed in the usual manner and pressed in the manner heretofore described.

The heat and pressure cause the thermoplastic sheet to flow and impregnate the collars to permanently cement them together and provide a moldable stiffened article, provided with a waxy finish, as heretofore described.

The cementitious binders, heretofore used to provide a stiffened article, chemically react with the fabrics with which they are associated espedially when heat is applied to the article to stiffen it, thereby affecting the color of the article and making it diflicult to produce such articles in the desired colors and shades. This is especially true ofthe cementitious binders which require chemical treatment of the entire fabricated article to make them cementitious and thermoplastic, a true fast color, particularly in different shades thereof, being difficult to obtain.

My novel cementitious spontaneously uponlaundering self stiffening binder eliminates this very important disadvantage, as it is colorless and no chemical reaction takes place either in the binder or with the fabric with which it is associated upon heating. If desired this binder may itself be colored any shade with dyes or pigments.

It will be apparent self stiffening fabrics may be produced with my invention and provided with any color, combinations of color or shade desired.

It will be apparent that my invention does not, in any way, change the manner of manufacturing the articles with which it is associated, or require the use of any different machines now used in the art or any change to such existing machines.

It will be apparent that my invention provides a novel article spontaneously self stiffening liningtwhich may be produced at comparatively low cos While the invention has been described in detail with specific examples, such examples are illustrative and are not given as limitations, since other modifications within the spirit and scope of the invention will be apparent to those skilled in the art. Hence the invention is to be understood as limited only as indicated in the appended claims, in which the intent is to set forth all the novelty over the prior art.

I claim:

1. A stiffening lining for association with a collar or similar article of apparel, whereby said article of apparel is made premanently remoldable upon laundering, having an adhering thermoplastic film comprising a vinyl resin, a plasticizer and a paraffin oil, said vinyl resin being.

flexibly rigid at ordinary atmospheric temperatures and moldable at ironing temperatures, colorless and moisture proof.

2. A stiffening lining for association with a collar or similar article of apparel, whereby said article of apparel is made permanently remoldable upon. laundering having an adhering thermoplastic film comprising a vinyl resin and a paraflin oil, said vinyl resin being flexibly rigid at ordinary atmospheric temperatures and moldable at ironing temperatures, colorless and moisture proof.

3. The process of cementing plies of a spontaneously self stiffening upon ironing washable collar or similar article of apparel which comprises impregnating a sheet of fabric with a pluable at ironing temperatures, colorless and moisture proof.

4. A remoldable upon laundering collar or similar article of apparel of the character described made of fabric plies fused together by a fabric sheet having a coating thereon consisting of vinyl resin and a paraflin oil contained therein, said vinyl resin being flexibly rigid at ordinary atmospheric temperatures and moldable at ironing temperatures, colorless and moisture proof.

CHAS. EMMEY.

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