US4878974A
Expired / Lapsed
US
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Method of producing a gas-permeable, waterproof composite sheet
Assignee: Tonen Chemical Corp
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Filing: 1989-02-06
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Granted: 1989-11-07
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Expires: 2009-02-06
Abstract
Abstract A method of producing a waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a film from a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer and 30-60 weight % of an ethylene-vinyl acetate copolymer; and (b) adhering the film to a woven or nonwoven fabric by hot pressing while causing the heat shrinkage of the film simultaneously, thereby making the film microporous. The composition may further contain linear low-density polyethylene to improve film-forming properties. By subjecting the hot-pressed composite sheet to a plurality of heating-cooling steps, it is provided with high heat resistance. In addition, by foaming the film and hot-pressing it to a stretchable woven or nonwoven fabric and then stretching, the composite sheet is further provided with high stretchability.
Inventors
- 👤 Seiji Kagawa
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 03:53
CPC Classifications
A; A41; A41D; A41D31/00; A41D31/04; A41D31/10; A41D31/102; B; B32; B32B; B32B27/00; B32B27/12; B32B27/18; B32B27/20; B32B37/00; B32B37/06; B32B37/14; B32B37/144; B32B38/00; B32B38/0008; B32B38/0032; B32B5/00; B32B5/02; B32B5/022; B32B5/024; B32B5/22; B32B38/0012; B32B2038/0028; B32B2270/00; B32B2307/00; B32B2307/70; B32B2307/724; B32B2307/726; B32B2307/7265; B32B2309/00; B32B2309/02; B32B2310/00; B32B2310/08; B32B2310/0875; B32B2310/0887
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
65 words
A method of producing a waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a film from a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer and 30-60 weight % of an ethylene-vinyl acetate copolymer; and (b) adhering said film to a woven or nonwoven fabric by hot pressing while causing the heat shrinkage of said film simultaneously, thereby making said film microporous.
Claim 2
Independent Claim
65 words
A method of producing a waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a film from a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer and 30-60 weight % of an ethylene-vinyl acetate copolymer; and (b) adhering said film to a woven or nonwoven fabric by hot pressing while causing the heat shrinkage of said film simultaneously, thereby making said film microporous.
Claim 3
Dependent Claim
18 words
The method according to claim 1, wherein said hot pressing is conducted at a temperature of 70°-150° C.
Claim 4
Independent Claim
78 words
A method of producing a waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a film from a composition comprising 35-68 weight % of an ethylene-propylene-diene copolymer, 30-55 weight % of an ethylene-vinyl acetate copolymer and 1-20 weight % of linear low-density polyethylene; and (b) adhering said film to a woven or nonwoven fabric by hot pressing at a temperature of 70°-150° C. while causing the heat shrinkage of said film simultaneously, thereby making said film microporous.
Claim 5
Independent Claim
78 words
A method of producing a waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a film from a composition comprising 35-68 weight % of an ethylene-propylene-diene copolymer, 30-55 weight % of an ethylene-vinyl acetate copolymer and 1-20 weight % of linear low-density polyethylene; and (b) adhering said film to a woven or nonwoven fabric by hot pressing at a temperature of 70°-150° C. while causing the heat shrinkage of said film simultaneously, thereby making said film microporous.
Claim 6
Dependent Claim
31 words
The method according to claim 3, wherein said ethylene-propylene-diene copolymer is 50-68 weight %, said ethylene-vinyl acetate copolymer is 30-48 weight % and said linear low-density polyethylene is 2-20 weight %.
Claim 7
Dependent Claim
45 words
The method according to claim 4, wherein the hot pressing of said film to said woven or nonwoven fabric is conducted by three steps consisting of a first step at 70°-90° C., a second step at 90°-110° C. and a third step at 110°-150° C.
Claim 8
Dependent Claim
17 words
The method according to claim 4 or 5, wherein said film has a thickness of 10-40 μm.
Claim 9
Independent Claim
112 words
A method of producing a heat-resistant, gas-permeable composite sheet comprising the steps of: (a) stretching a film made of an ethylene-propylene-diene copolymer and an ethylene-vinyl acetate copolymer uniaxially or biaxially; (b) adhering the resulting stretched film to a woven or nonwoven fabric by heat pressing while causing the heat shrinkage of the stretched film simultaneously, thereby making said film microporous: and (c) repeating a plurality of steps of heating said film at such a temperature that said film is not melted and then cooling it, the heating temperature being elevated stepwise from one step to a subsequent step, thereby causing the cross-linking of said film while retaining the microporosity of said film.
Claim 10
Independent Claim
112 words
A method of producing a heat-resistant, gas-permeable composite sheet comprising the steps of: (a) stretching a film made of an ethylene-propylene-diene copolymer and an ethylene-vinyl acetate copolymer uniaxially or biaxially; (b) adhering the resulting stretched film to a woven or nonwoven fabric by heat pressing while causing the heat shrinkage of the stretched film simultaneously, thereby making said film microporous: and (c) repeating a plurality of steps of heating said film at such a temperature that said film is not melted and then cooling it, the heating temperature being elevated stepwise from one step to a subsequent step, thereby causing the cross-linking of said film while retaining the microporosity of said film.
Claim 11
Dependent Claim
31 words
The method according to claim 7, wherein said film is made of a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer, and 60-30 weight % of an ethylene-vinyl acetate copolymer.
Claim 12
Dependent Claim
37 words
The method according to claim 7, wherein said film is made of a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer, 30-60 weight % of an ethylene-vinyl acetate copolymer and 5-15 weight % of a filler.
Claim 13
Independent Claim
24 words
The method according to any of claims 7-9, wherein said film is stretched by 1.5 times or more uniaxially or biaxially before hot pressing.
Claim 14
Dependent Claim
27 words
The method according to claim 7, wherein the hot pressing of said stretched film to said woven or nonwoven fabric is conducted by using a heat roll.
Claim 15
Dependent Claim
45 words
The method according to claim 7, wherein said hot pressing is conducted at 80°-150° C. on the side of said woven or nonwoven fabric and at 75°-5° C. on the side of said stretched film, under a hot pressing pressure of 1.0-10 kg/cm 2 .
Claim 16
Dependent Claim
32 words
The method according to claim 7, wherein in a plurality of said heating-cooling steps, the heating temperature is elevated stepwise by 50° C. or less from one step to a subsequent step.
Claim 17
Dependent Claim
21 words
The method according to claim 13, wherein the cooling temperature in each of said heating-cooling steps is 45° C. or less.
Claim 18
Independent Claim
103 words
A method of producing a heat-resistant, gas-permeable composite sheet comprising the steps of: (a) stretching a film made of an ethylene-propylene-diene copolymer and an ethylene-vinyl acetate copolymer uniaxially or biaxially; (b) hot-pressing the resulting stretched film to a woven or nonwoven fabric to adhere them while simultaneously causing the heat shrinkage of said stretched film, thereby making said film microporous: (c) conducting at least one step of heating said film at such a temperature that said film is not melted and then cooling it: and (d) irradiating electron beam of 5-20 Mrad to said film to cause the further cross-linking of said film.
Claim 19
Independent Claim
103 words
A method of producing a heat-resistant, gas-permeable composite sheet comprising the steps of: (a) stretching a film made of an ethylene-propylene-diene copolymer and an ethylene-vinyl acetate copolymer uniaxially or biaxially; (b) hot-pressing the resulting stretched film to a woven or nonwoven fabric to adhere them while simultaneously causing the heat shrinkage of said stretched film, thereby making said film microporous: (c) conducting at least one step of heating said film at such a temperature that said film is not melted and then cooling it: and (d) irradiating electron beam of 5-20 Mrad to said film to cause the further cross-linking of said film.
Claim 20
Dependent Claim
31 words
The method according to claim 15, wherein said film is made of a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer and 60-30 weight % of an ethylene-vinyl acetate copolymer.
Claim 21
Independent Claim
101 words
A method of producing a stretchable, waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a foamed film from a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer, 30-60 weight % of an ethylene-vinyl acetate copolymer, and 0.1-1.0 parts by weight of a foaming agent per 100 parts by weight of said ethylene-propylene-diene copolymer+said ethylene-vinyl acetate copolymer: (b) adhering said foamed film to a stretchable woven or nonwoven fabric by hot pressing; and (c) stretching the resulting composite sheet along the stretchable direction of said stretchable woven or nonwoven fabric, thereby providing said foamed film with micropores penetrating therethrough.
Claim 22
Independent Claim
101 words
A method of producing a stretchable, waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a foamed film from a composition comprising 40-70 weight % of an ethylene-propylene-diene copolymer, 30-60 weight % of an ethylene-vinyl acetate copolymer, and 0.1-1.0 parts by weight of a foaming agent per 100 parts by weight of said ethylene-propylene-diene copolymer+said ethylene-vinyl acetate copolymer: (b) adhering said foamed film to a stretchable woven or nonwoven fabric by hot pressing; and (c) stretching the resulting composite sheet along the stretchable direction of said stretchable woven or nonwoven fabric, thereby providing said foamed film with micropores penetrating therethrough.
Claim 23
Independent Claim
116 words
A method of producing a stretchable, waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a foamed film from a composition comprising 35-65 weight % of an ethylene-propylene-diene copolymer, 30-55 weight % of an ethylene-vinyl acetate copolymer, 1-10 weight % of linear low-density polyethylene, and 0.1-1.0 parts by weight of a foaming agent per 100 parts by weight of said ethylene-propylene-diene copolymer+by weight of said ethylene-propylene-diene said ethylene-vinyl acetate copolymer+said linear low-density polyethylene; (b) adhering said foamed film to a stretchable woven or nonwoven fabric by hot pressing; and (c) stretching the resulting composite sheet along the stretchable direction of said stretchable woven or nonwoven fabric, thereby providing said foamed film with micropores penetrating therethrough.
Claim 24
Independent Claim
116 words
A method of producing a stretchable, waterproof, gas-permeable composite sheet comprising the steps of: (a) preparing a foamed film from a composition comprising 35-65 weight % of an ethylene-propylene-diene copolymer, 30-55 weight % of an ethylene-vinyl acetate copolymer, 1-10 weight % of linear low-density polyethylene, and 0.1-1.0 parts by weight of a foaming agent per 100 parts by weight of said ethylene-propylene-diene copolymer+by weight of said ethylene-propylene-diene said ethylene-vinyl acetate copolymer+said linear low-density polyethylene; (b) adhering said foamed film to a stretchable woven or nonwoven fabric by hot pressing; and (c) stretching the resulting composite sheet along the stretchable direction of said stretchable woven or nonwoven fabric, thereby providing said foamed film with micropores penetrating therethrough.
Claim 25
Dependent Claim
54 words
The method according to claim 17, wherein the formation of said foamed film is conducted at a resin temperature of 120°-170° C. and at a film-forming rate of 15 m/minute or less, and then the hot pressing is conducted at a temperature of 70°-140° C. and at a pressure of 0.1-10 kg/cm 2 .
Claim 26
Dependent Claim
54 words
The method according to claim 18, wherein the formation of said foamed film is conducted at a resin temperature of 120°-170° C. and at a film-forming rate of 15 m/minute or less, and then the hot pressing is conducted at a temperature of 70°-140° C. and at a pressure of 0.1-10 kg/cm 2 .
Claim 27
Dependent Claim
19 words
The method according to claim 17, wherein said hot pressing is conducted by a plurality of hot pressing steps.
Claim 28
Dependent Claim
19 words
The method according to claim 18, wherein said hot pressing is conducted by a plurality of hot pressing steps.
Claim 29
Dependent Claim
27 words
The method according to claim 17, wherein said stretchable woven or nonwoven fabric adhered to said foamed film is stretched by 1.2-2.0 times to produce said micropores.
Claim 30
Dependent Claim
27 words
The method according to claim 18, wherein said stretchable woven or nonwoven fabric adhered to said foamed film is stretched by 1.2-2.0 times to produce said micropores.
References Cited (Backward Citations)
US3741841A
Cited
US3959051A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1992-11-06 | 1993-05-08 | 1993-11-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-11-06 | 1997-05-08 | 1997-11-07 | $3760.00 | Window Closed / Lapsed |
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