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;  
         [0021]      FIG. 4  illustrates a manufacturing process for molded composite fabrics according to the present invention;  
         [0022]      FIG. 5  illustrates a first exemplary embodiment of a garment having a molded composite fabric in an unassembled state; and  
         [0023]      FIG. 6  illustrates a second exemplary embodiment of a garment having a molded composite fabric in an unassembled state. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]     Referring to the drawings and in particular to  FIG. 1 , a molded composite fabric according to the present invention is illustrated generally by reference numeral  10 . Composite fabric  10  includes one or more fabric layers  12  adhered to a foam layer  14 , where the fabric and foam layers have been molded to define a molded feature  16 .  
         [0025]     Feature  16  can be any desired feature as required by the end use of composite fabric  10 . For example, composite fabric  10  can find use in a garment, such as a brassiere that requires breast cups. In this example, feature  16  can define the breast cups of the brassiere. In another example, composite fabric  10  can find use in a protective apparel item, such as a kneepad that requires shaping to approximate the shape of the protected body part. In yet another example, composite fabric  10  can find use in an insulating apparel garment, such as a coat, jacket, or sweatshirt. In this example, feature  16  can be a plurality of expanded sections. In yet another example, composite fabric  10  can find use in a decorative garment where feature  16  is provided to add a pattern or design to the garment.  
         [0026]     It should be recognized that composite fabric  10  is described above by way of example in use as a garment. Of course, it is contemplated by the present disclosure for composite fabric  10  to find use in other non-garment applications.  
         [0027]     Fabric layer  12  can be adhered to foam layer  14  by any known method. Preferably, fabric layer  12  is adhered to foam layer  14  by a solvent-based adhesive  18  such as, but not limited to, a web adhesive, a film adhesive, a dot adhesive, and others. Of course, it is contemplated by the present disclosure for fabric layer  12  and foam layer  14  to be adhered to one another by other methods such as, but not limited to, sonic welding. It is further contemplated by the present disclosure for fabric layer  12  and foam layer  14  to be adhered one another continuously or discontinuously across their mating surfaces.  
         [0028]     For purposes of clarity, composite fabric  10  is described herein having fabric layer  12  adhered to one side of foam layer  14 . However, it is also contemplated by the present disclosure for composite fabric  10  to have a second fabric layer (not shown) adhered to the opposite side of foam layer  14  so that the composite fabric defines a three layer structure having a middle foam layer.  
         [0029]     Feature  16  is molded in composite fabric  10  after fabric layer  12  and foam layer  14  are adhered to one another. Advantageously, the materials of fabric layer  12  and foam layer  14  are configured for use with one another in composite fabric  10  as both can be molded at low molding temperatures and short molding times. Preferably, fabric layer  12  is made of materials that can be molded at temperatures of less than about 300 degrees Fahrenheit for about 20 seconds. Similarly, foam layer  14  is made of a material that can withstand the molding temperatures composite fabric  10  is exposed to during the molding process.  
         [0030]     In an exemplary embodiment, fabric layer  12  is a non-woven fabric having a web of randomly disbursed fibers or filaments (hereinafter “fibers”), where the web preferably has uniform fiber orientation in all directions. It is also preferred that the fibers be bonded to and/or entangled with one another. The individual fibers can be mono-component, multi-component, or any combinations thereof.  
         [0031]     Fabric layer  12  can be substantially inelastic or inextensible (hereinafter “rigid”) or can be substantially elastic depending on the end use of composite fabric  10 . In one exemplary embodiment, fabric layer  12  provides hand feel acceptable for soft fabric applications. The hand feel, as well as other physical characteristics (e.g., elasticity) of fabric layer  12  can be affected by the structure of the individual fibers, the composition of the fiber materials, the size of the individual fibers, or any combinations thereof.  
         [0032]     For example, fabric layer  12  can include about 100% of a polymer such as, but not limited to, nylon, polypropylene, polyester, and other polymers. It is also contemplated by the present invention for at least a portion of the fibers in fabric layer  12  to be natural fibers (e.g., cotton, wool, hemp).  
         [0033]     In another example, fabric layer  12  includes multi-component fibers having a blend of polymers such as fibers having a blend of a low-melting temperature polymer and a high-melting temperature polymer. The low-melting temperature polymer allows the non-woven fabric to be molded, while the high-melting temperature polymer introduces structural stability to the fabric. By way of example, the low-melting temperature polymer allows the non-woven fabric to be molded at temperatures of less than about 300 degrees Fahrenheit. In yet another embodiment, fabric layer  12  can include at least two different mono-component fibers. One of the mono-component fibers has a low-melting temperature polymer, while another of the mono-component fibers has a high-melting temperature polymer. In still another example, fabric layer  12  can include fibers having two or more different diameters.  
         [0034]     Accordingly, it is contemplated by the present disclosure for fabric layer  12  to have individual fibers sized, positioned, configured, and composition of materials sufficient to provide the physical characteristics desired for composite fabric  10 .  
         [0035]     Fabric layer  12  can be produced using a non-woven process such as, but not limited to, a melt-blowing process, a spun-bonding process, a hydroentanglement process, a carding process, or any combinations thereof.  
         [0036]     An exemplary non-woven fabric suitable for fabric layer  12  used in soft fabric applications includes EVOLON, which is commercially available from Freudenberg Nonwovens of Durham, N.C. EVOLON is made using a spunbonding and hydroentangling process. The spunbonded fibers are multi-component fibers having 70% PET and 30% NYLON. During the hydroentanglement portion of the process, the fibers are split into segments.  
         [0037]     It has been found that the low molding temperatures afforded by the use of non-woven fabric layer  12  advantageously allows foam layer  14  to be made of foams also having a low molding temperature such as, for example, polyethylene foam. Preferably, foam layer  14  is low-density polyethylene foam. Polyethylene foam is cheaper than the TPU foams used in the prior art. In addition, polyethylene foam does not yellow or discolor when exposed to ultraviolet radiation present in ambient light and, thus, composite fabric  10  eliminates the need for facing of foam layer  14  with additional protective layers. As such, composite fabric  10  can be made lighter and less expensive than prior art faced foams.  
         [0038]     The thickness, softness and level of stretch of foam layer  14  and/or fabric layer  12  can be selected to match the desired end-use of composite fabric  10 .  
         [0039]     Referring now to  FIGS. 2 and 3 , a molding step according to the present invention for feature  16  is illustrated generally by reference numeral  20 . Composite fabric  10  is illustrated in  FIG. 2  before the molding of feature  16  and is illustrated in  FIG. 3  during the molding of the feature.  
         [0040]     Molding step  20  includes a heating station  22  and a molding station  24 . Heating station  22  can include, for example, one or more radiant heating plates for heating composite fabric  10  as it is moved past the heating station in a machine direction  26  towards molding station  24 .  
         [0041]     Heating station  22  heats composite fabric  10  so that the composite fabric is heated to a predetermined temperature. For example, heating station  22  heats composite fabric  10  to a temperature of less than about 375 degrees Fahrenheit. In a preferred embodiment, heating station  22  heats composite fabric  10  to about 300 degrees Fahrenheit.  
         [0042]     Next, molding step  20  moves the heated composite fabric  10  to molding station  24 . Molding station  24  includes a molding cavity  28  having a desired shape. In the illustrated embodiment, molding cavity  28  has a shape for forming a breast cup for a brassiere. Preferably, molding station  24  is a vacuum molding station that draws the heated composite fabric  10  into cavity  28  in a molding direction  30 . Molding station  24  maintains composite fabric  10  in cavity  28  for a predetermined dwell time. For example, molding station  24  maintains composite fabric  10  in cavity  28  for less than about 30 seconds. In a preferred embodiment, molding station  24  maintains composite fabric  10  in cavity  28  for about 20 seconds.  
         [0043]     Advantageously, the predetermined temperature and dwell time of molding step  20  (e.g., 300 degrees Fahrenheit for about 20 seconds) are less than those currently used in the manufacture of composites having TPU foam and knit fabric (e.g., 400 degrees Fahrenheit for about 120 seconds). Thus, molding step  20  can form composite fabric  10  into the desired shape faster and more economically than prior processes.  
         [0044]     Referring now to  FIG. 4 , a manufacturing process according to the present invention for making composite fabric  10  is illustrated generally by reference numeral  40 . In addition to molding step  20  described above, manufacturing process  40  includes a washing or agitation step  42  and a lamination step  44 . During process  40 , fabric layer  12  is first exposed to agitation step  42 , then the fabric layer and foam layer  14  are adhered to one another during lamination step  44  to define composite fabric  10 , and finally the composite fabric is molded during molding step  20 .  
         [0045]     Preferably, agitation step  42  exposes the desired non-woven fabric  12  to mechanical agitation, more preferably in the presence of a wetting agent such as, but not limited to, water and/or fabric softener. For example, it is contemplated for agitation step  42  to be carried out in a typical household washing machine or a typical industrial dyeing process (processed with or with out dyes). In this manner, agitation step  42  subjects fabric layer  12  to agitation in the presence of the wetting agent to permit the individual fibers of the non-woven fabric to achieve a desired position with respect to each other as discussed immediately below.  
         [0046]     While not wishing to be bound by a particular theory, it is believed that agitation step  42  introduces an element of freedom to the individual fibers of the non-woven fabric  12 . It is believed that this freedom allows the fibers to move and/or slide with respect to one another to mitigate tearing of the fabric during subsequent lamination and molding steps. For example, it is believed that the agitation of agitation step  42  weakens and/or breaks at least some of the bonds and/or entanglements between the individual fibers of the non-woven fabric  12 .  
         [0047]     In a preferred embodiment of agitation step  42 , the agitation step includes the use of fabric softener as the wetting agent. While not wishing to be bound by a particular theory, it is believed that the fabric softener provides a degree of lubrication to the individual fibers of the non-woven fabric. It is believed that the lubrication of the individual fibers allows the fibers to slide with respect to one another.  
         [0048]     After agitation step  42 , fabric layer  12  and foam layer  14  are adhered to one another in lamination step  44 . During lamination step  44 , fabric layer  12  is adhered to foam layer  14  by, for example, applying an adhesive to the fabric and/or foam layers and compressing the layers together to define composite fabric  10 .  
         [0049]     In some embodiments of the present invention, manufacturing process  40  can include a perforating step  46  before lamination step  44 . Many of the low molding temperature foams available for use as foam layer  14  (e.g., low-density polyethylene foam) are closed cell foams. Thus, it is contemplated by the present invention for manufacturing process  40  to include perforating step  46  to induce a predetermined level of permeability and/or breathability to foam layer  14 . In a preferred embodiment, perforating step  46  removes material from foam layer  14  to provide the desired permeability. For example, perforating step  46  can punch a plurality of holes through foam layer  14 .  
         [0050]     After defining composite fabric  10  at lamination step  44 , manufacturing process  40  exposes the composite fabric to molding process  20  to define one or more molded features  16  in the composite fabric.  
         [0051]     It should be recognized that process  40  is described above having lamination step  44  before molding step  20 . However, it is also contemplated by the present disclosure for the lamination and molding steps to occur simultaneously with one another.  
         [0052]     Advantageously, the composite fabric of the present invention overcomes the expense and weight associated with prior art molded composite fabrics. For example, molded composite fabric  10  can be used in the formation of a brassiere  50  as illustrated in  FIG. 5 . Brassiere  50  includes a garment body  52  and a pair of breast cups  54 . Garment body  52  includes only non-woven fabric layer  12 , while breast cups  54  include both the non-woven fabric layer and foam layer  14 . Thus, brassiere  50  includes composite fabric  10  only in the areas of the breast cups, which are molded to a desired cup depth. Brassiere  50  can be configured so that foam layer  14  of breast cups  54  is in contact with the user when worn as shown. Alternately, brassiere  50  can be configured so that fabric layer  12  of breast cups  54  is in contact with the user when worn.  
         [0053]     An alternate exemplary embodiment of a brassiere  60  having molded composite fabric  10  is illustrated in  FIG. 6 . Brassiere  60  includes a garment body  62  and a pair of molded breast cup inserts  64 . Garment body  62  can be one or more layers of woven and/or non-woven fabrics. Inserts  64  are formed from composite fabric  10  and, thus, include both non-woven fabric layer  12  and foam layer  14 . Inserts  64  can be secured to garment body  62  using any known method such as, but not limited to, sewn seams, adhesives, welds, and others. Preferably, inserts  64  are secured to garment body  62  so that foam layer  14  is in contact with the garment body and fabric layer  12  is in contact with the user when worn as shown in  FIG. 6 . Alternately, inserts  64  can be secured to garment body  62  so that fabric layer  12  is in contact with the garment body and foam layer  14  is in contact with the user when worn.  
         [0054]     It should also be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.  
         [0055]     While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims.
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.