A woven textile fabric having an ultrasonically cut and sealed edge and apparatus and process for producing same

Claim 2

A woven textile fabric (T) having a cut and sealed edge (E) characterized by a wash durability of at least 25 to 50 washings without significant raveling of said cut and sealed edge (E); said fabric (T) comprising a plurality of woven warp and filling yarns (W,F) respectively extending in generally parallel side-by-side relationship in the longitudinal and transverse directions of said fabric (T) and including at least 65% thermoplastic fibers; and said cut and sealed edge (E) comprising a fused mass of thermoplastic fibers bonded to each other and to any other fibers in said mass, said mass being of a thickness no greater than the thickness of said fabric (T) and extending in either the longitudinal or transverse direction of said fabric (T) and generally parallel with said respective warp or filling yarns (W,F) and being of a width of from about 0.01 to 0.10 inch and encompassing from 2 to 4 of said respective parallel warp or filling yarns (W,F).

Claim 3

A woven textile fabric (T) having an ultrasonically cut and sealed edge (E) characterized by a wash durability of at least 25 to 50 washings without significant raveling of said ultrasonically cut and sealed edge (E); said fabric (T) comprising a plurality of woven warp and filling yarns (W,F) respectively extending in generally parallel side-by-side relationship in the longitudinal and transverse directions of said fabric (T) and having thermoplastic and cotton fibers including about 65 to 80% thermoplastic fibers in said fabric and at least 65% thermoplastic fibers in said warp yarns; and said ultrasonically cut and sealed edge (E) comprising a fused mass of thermoplastic fibers bonded to each other and to the cotton fibers in said mass, said mass being of a thickness no greater, than the thickness of said fabric (T) and extending in the longitudinal direction of said fabric (T) and generally parallel with said respective warp yarns (W) and being of a width of from about 0.01 to 0.10 inch and encompassing from 2 to 4 of said respective parallel warp yarns (W).

Claim 4

A woven textile fabric (T) having an ultrasonically cut and sealed edge (E) characterized by a wash durability of at least 25 to 50 washings without significant raveling of said ultrasonically cut and sealed edge (E); said fabric (T) comprising a plurality of woven warp and filling yarns (W,F) respectively extending in generally parallel side-by-side relationship in the longitudinal and transverse directions of said fabric (T) and having thermoplastic and cotton fibers including about 65 to 80% thermoplastic fibers in said fabric and at least 65% thermoplastic fibers in said warp yarns; and said ultrasonically cut and sealed edge (E) comprising a fused mass of thermoplastic fibers bonded to each other and to the cotton fibers in said mass, said mass being of a thickness no greater, than the thickness of said fabric (T) and extending in the longitudinal direction of said fabric (T) and generally parallel with said respective warp yarns (W) and being of a width of from about 0.01 to 0.10 inch and encompassing from 2 to 4 of said respective parallel warp yarns (W).

Claim 5

A woven textile fabric as claimed in claim 1 or 2, characterised in that the width of said cut and sealed edge (E) and of said mass is from about 0.02 to 0.06 inch.

Claim 6

A woven textile fabric as claimed in any preceding claim, characterised in that said fabric (T) has a weight of from about 2.25 to 6.00 oz./yd .

Claim 7

A woven textile fabric as claimed in any preceding claim, characterised in that said fabric (T) has a yarn count in the warp (W) of from about 68 to 108 and in the filling (F) of from about 52 to 64.

Claim 8

A woven textile fabric as claimed in any preceding claim, characterised in that said fabric (T) has yarn sizes in the warp (W) of from about 50/1 to 22/1 and in the filling (F) of from about 35/1 to 15/1.

Claim 9

Ultrasonic apparatus (10) for edge cutting and sealing moving lengths of at least partially thermoplastic material, particularly textile fabric (T) having at least some thermoplastic fibers, and including anvil means (17) and vibrating sonic horn means (16) having a flat working face (18) cooperating with and vibrating against said anvil means (17) for the ultrasonic edge cutting and sealing as the material (T) moves between said sonic horn means (16) and said anvil means (17); said anvil means (17) being characterized by effecting clean and sharp edge cutting and desired amounts of edge sealing in the material (T) while resisting wear on said anvil means (17), said anvil means (17) comprising: an anvil member defining a peaked cutting edge (20) for cutting the moving material (T) as said sonic horn means (16) vibrates against said cutting edge (20) and first and second surfaces (21,22) extending in respective opposite directions from said peaked cutting edge (20); said first surface (21) forming a predetermined included acute angle with said horn face (18) from said cutting edge (20) for fusing the thermoplastic material (T) and sealing the cut edge (E) of the material a predetermined distance inwardly of the cut edge (E) as said sonic horn means (16) vibrates against said anvil means (17), the predetermined distance of sealing being determined by and increasing with the increasing acuteness of the predetermined included angle of said first surface (21); and said second surface (22) forming a predetermined included acute angle with said horn face (18) from said cutting edge (20) for reinforcing said anvil cutting edge (20) to resist wear on said anvil cutting edge (20), the included angle of said second reinforcing surface (22) being greater than the included angle of said first sealing surface (21) so that said first and second surfaces (21,22) will form a sharpness for said peaked anvil cutting edge (20) which will effect a clean and sharp cutting of the moving material (T).

Claim 10

Ultrasonic apparatus (10) for edge cutting and sealing moving lengths of at least partially thermoplastic material, particularly textile fabric (T) having at least some thermoplastic fibers, and including anvil means (17) and vibrating sonic horn means (16) having a flat working face (18) cooperating with and vibrating against said anvil means (17) for the ultrasonic edge cutting and sealing as the material (T) moves between said sonic horn means (16) and said anvil means (17); said anvil means (17) being characterized by effecting clean and sharp edge cutting and desired amounts of edge sealing in the material (T) while resisting wear on said anvil means (17), said anvil means (17) comprising: an anvil member defining a peaked cutting edge (20) for cutting the moving material (T) as said sonic horn means (16) vibrates against said cutting edge (20) and first and second surfaces (21,22) extending in respective opposite directions from said peaked cutting edge (20); said first surface (21) forming a predetermined included acute angle with said horn face (18) from said cutting edge (20) for fusing the thermoplastic material (T) and sealing the cut edge (E) of the material a predetermined distance inwardly of the cut edge (E) as said sonic horn means (16) vibrates against said anvil means (17), the predetermined distance of sealing being determined by and increasing with the increasing acuteness of the predetermined included angle of said first surface (21); and said second surface (22) forming a predetermined included acute angle with said horn face (18) from said cutting edge (20) for reinforcing said anvil cutting edge (20) to resist wear on said anvil cutting edge (20), the included angle of said second reinforcing surface (22) being greater than the included angle of said first sealing surface (21) so that said first and second surfaces (21,22) will form a sharpness for said peaked anvil cutting edge (20) which will effect a clean and sharp cutting of the moving material (T).

Claim 11

Ultrasonic apparatus as claimed in claim 7, characterised in that said peaked anvil member comprises a wheel having a beveled periphery defining therearound said peaked cutting edge (20) and said first and second surfaces (21,22).

Claim 12

Ultrasonic apparatus as claimed in claim 7 or 8, characterised in that the included angle of said first sealing surface (21) of said anvil member (17) is about 3 to 20 degrees.

Claim 13

Ultrasonic apparatus as claimed in any one of claims 7-9, characterised in that the included angle of said first sealing surface (21) of said anvil member (17) is about 5 to 15 degrees.

Claim 14

Ultrasonic apparatus as claimed in any one of claims 7-10, characterised in that the included angle of said second reinforcing surface (22) is at least 2-1/2 degrees larger than the included angle of said first sealing surface (21) and no greater than 45 degrees.

Claim 15

Ultrasonic apparatus as claimed in any one of claims 7-11, characterised in that the included angle of said second reinforcing surface (22) of said anvil is about 30 degrees.

Claim 16

13 . Ultrasonic apparatus as claimed in any one of claims 7-12, characterised in that the predetermined frequency of vibration of said sonic horn means (16) is from about 15,000 to 1,000,000 hertz and preferably from about 20,000 to 40,000 hertz.

Claim 17

Ultrasonic apparatus as claimed in any one of claims 7-13, characterised by means (11,12) for feeding the fabric through the apparatus at a substantially constant predetermined rate of speed, and ultrasonic apparatus as claimed in any one of claims 7-13.

Claim 18

Ultrasonic apparatus as claimed in claim 14, characterised in that the predetermined pressure of said sonic horn mounting means (30) is about 18 to 20 psig and the predetermined pressure of said anvil mounting means (32) is about 20 to 60 psig and preferably about 40 to 50 psig for providing forces of about 11.5 to 34 and preferably about 23 to 29 pounds on the fabric (T) upon contact of said anvil means (17) by said horn means (16).

Claim 19

Ultrasonic apparatus as claimed in claim 14 or claim 15, characterised in that said anvil mounting means (32) provides for movement of said anvil means (17) a distance of from about 1/16 to 1/8 inch away from said horn means (16) upon contact of said anvil means (17) by said horn means (16).

Claim 20

Ultrasonic apparatus as claimed in any one of claims 14-16, characterised in that said means (32) mounting said anvil means (17) under a predetermined pressure and for movement away from said horn means (16) a predetermined distance comprises clevis means (38) supporting said anvil means (17), spring means (39) supporting said clevis means (38) for compressing upon movement of said anvil means (17) away from said horn means (16) upon contact of said anvil means (17) by said horn means (16), and air-operated piston and cylinder means (32) operatively connected with said spring means (39) for exerting the predetermined presure on said anvil means (17).

Claim 21

Ultrasonic apparatus as claimed in any one of claims 14-17, characterised in that said means (30) mounting said sonic horn means (16) under predetermined pressure comprises air-operated piston and cylinder means (34,35).

Claim 22

Apparatus for ultrasonically edge cutting and sealing textile fabric having thermoplastic fibers characterised by means (11,12) for feeding the fabric through the apparatus at a substantially constant predetermined rate of speed, and ultrasonic apparatus as claimed in any one of claims 7-18.

Claim 23

Apparatus as claimed in claim 19, characterised in that the predetermined rate of speed of the fabric is about 20 yards per minute and the predetermined frequency of vibration of said sonic horn means (16) is about 20,000 hertz.

Claim 24

Apparatus as claimed in claim 19, in which the predetermined rate of speed of the fabric is about 40 yards per minute and the predetermined frequency of vibration of said sonic horn means (16) is about 40,000 hertz.

Claim 25

Apparatus for ultrasonically edge cutting and sealing woven textile fabric having at least 65% thermoplastic fibers and being characterized by the construction which will produce a clean and sharp cut and sealed edge having a wash durability of 25 to 50 washings without significant raveling; said apparatus comprising: means (11,12) for feeding the fabric (T) through said apparatus at a substantially constant predetermined rate of speed of from about 20 to 40 yards per minute; sonic horn means (16) including transducer and booster means (15) and a flat working face (18) on said horn means (16) of hardened metal for vibrating at a predetermined frequency of from about 20,000 to 40,000 hertz; anvil means (17) positioned for receiving the moving fabric (T) between said vibrating horn face (18) and said anvil means (17) and for contact by said horn face (18) during its vibrations to edge cut and seal the cut edge (E) of the moving fabric (T), said anvil means (17) comprising a wheel having a beveled periphery defining therearound a peaked cutting edge (20) and first and second surfaces (21,22) extending in respective opposite directions from said peaked cutting edge (20), said first surface (21) extending inwardly of the cut edge (E) being formed on the moving fabric (T) and forming a predetermined included angle of from about 3 to 20 degrees with said horn face (18) from said cutting edge (20) for fusing the thermoplastic fibers and sealing the cut edge of the fabric a predetermined distance of from about 0.01 to 0.10 inches inwardly of the cut edge (E) of the fabric which is determined by and increases with the increasing acuteness of the predetermined included angle, said second surface (22) extending outwardly of the cut edge (E) being formed on the moving fabric for reinforcing said anvil cutting edge (20) to resist wear and forming a predetermined included acute angle at least 2-1/2 degrees larger than the included angle of said first sealing surface (21) and no greater than 45 degrees with said horn face (18) from said cutting edge (E) so that said first and second surfaces (21,22) will form a desired sharpness for said peaked anvil cutting edge (20) which will effect a clean and sharp cutting of the moving fabric (T); and means (30) mounting said sonic horn means (16) under a predetermined pressure of from about 18 to 20 psig and means (32) mounting said anvil means (17) under a predetermined pressure of from about 40 to 50 psig for movement away from said horn means (16) a predetermined distance of from about 1/16 to 1/8 inch upon contact of said anvil means (17) by said horn means (16) during its vibrations, so that predetermined forces of about 23 to 29 pounds are exerted by said horn means (16) and said anvil means (17) on the moving fabric (T) upon contact between said horn means (16) and said anvil means (17) and said anvil means (17) will float as it is contacted by said horn means (16) for aiding in providing the desired cutting and sealing action on the textile fabric (T).

Claim 26

Apparatus for ultrasonically edge cutting and sealing woven textile fabric having at least 65% thermoplastic fibers and being characterized by the construction which will produce a clean and sharp cut and sealed edge having a wash durability of 25 to 50 washings without significant raveling; said apparatus comprising: means (11,12) for feeding the fabric (T) through said apparatus at a substantially constant predetermined rate of speed of from about 20 to 40 yards per minute; sonic horn means (16) including transducer and booster means (15) and a flat working face (18) on said horn means (16) of hardened metal for vibrating at a predetermined frequency of from about 20,000 to 40,000 hertz; anvil means (17) positioned for receiving the moving fabric (T) between said vibrating horn face (18) and said anvil means (17) and for contact by said horn face (18) during its vibrations to edge cut and seal the cut edge (E) of the moving fabric (T), said anvil means (17) comprising a wheel having a beveled periphery defining therearound a peaked cutting edge (20) and first and second surfaces (21,22) extending in respective opposite directions from said peaked cutting edge (20), said first surface (21) extending inwardly of the cut edge (E) being formed on the moving fabric (T) and forming a predetermined included angle of from about 3 to 20 degrees with said horn face (18) from said cutting edge (20) for fusing the thermoplastic fibers and sealing the cut edge of the fabric a predetermined distance of from about 0.01 to 0.10 inches inwardly of the cut edge (E) of the fabric which is determined by and increases with the increasing acuteness of the predetermined included angle, said second surface (22) extending outwardly of the cut edge (E) being formed on the moving fabric for reinforcing said anvil cutting edge (20) to resist wear and forming a predetermined included acute angle at least 2-1/2 degrees larger than the included angle of said first sealing surface (21) and no greater than 45 degrees with said horn face (18) from said cutting edge (E) so that said first and second surfaces (21,22) will form a desired sharpness for said peaked anvil cutting edge (20) which will effect a clean and sharp cutting of the moving fabric (T); and means (30) mounting said sonic horn means (16) under a predetermined pressure of from about 18 to 20 psig and means (32) mounting said anvil means (17) under a predetermined pressure of from about 40 to 50 psig for movement away from said horn means (16) a predetermined distance of from about 1/16 to 1/8 inch upon contact of said anvil means (17) by said horn means (16) during its vibrations, so that predetermined forces of about 23 to 29 pounds are exerted by said horn means (16) and said anvil means (17) on the moving fabric (T) upon contact between said horn means (16) and said anvil means (17) and said anvil means (17) will float as it is contacted by said horn means (16) for aiding in providing the desired cutting and sealing action on the textile fabric (T).

Claim 27

A process for ultrasonically cutting and sealing woven textile fabric to produce a clean and sharp sealed edge of a thickness no greater than the thickness of the textile fabric and having a wash durability of 25 to 50 washings without significant raveling with an ultrasonic apparatus including a vibrating sonic horn and an anvil positioned for contact by the vibrating horn; said process being characterised by the steps of: passing woven textile fabric having at least 65% thermoplastic fibers through the ultrasonic apparatus and between a vibrating sonic horn and an anvil at a substantially constant predetermined rate of speed and in a generally linear path of travel substantially parallel to either the warp or the filling yarns of the fabric; cutting an edge through the textile fabric substantially parallel with either a warp or a filling yarn which is parallel to the path of travel of the fabric through the ultrasonic apparatus by vibrations of the sonic horn against the anvil; and simultaneously sealing the cut edge of the fabric by fusing and bonding a mass of thermoplastic fibers in the fabric adjacent to and extending inwardly of the fabric from the cutting edge from about O.Ol to 0.10 inch and encompassing from about 2 to 4 of either the warp or filling yarns extending parallel to the cut edge by vibrations of the sonic horn against the anvil.

Claim 28

A process for ultrasonically cutting and sealing woven textile fabric to produce a clean and sharp sealed edge of a thickness no greater than the thickness of the textile fabric and having a wash durability of 25 to 50 washings without significant raveling with an ultrasonic apparatus including a vibrating sonic horn and an anvil positioned for contact by the vibrating horn; said process being characterised by the steps of: passing woven textile fabric having at least 65% thermoplastic fibers through the ultrasonic apparatus and between a vibrating sonic horn and an anvil at a substantially constant predetermined rate of speed and in a generally linear path of travel substantially parallel to either the warp or the filling yarns of the fabric; cutting an edge through the textile fabric substantially parallel with either a warp or a filling yarn which is parallel to the path of travel of the fabric through the ultrasonic apparatus by vibrations of the sonic horn against the anvil; and simultaneously sealing the cut edge of the fabric by fusing and bonding a mass of thermoplastic fibers in the fabric adjacent to and extending inwardly of the fabric from the cutting edge from about O.Ol to 0.10 inch and encompassing from about 2 to 4 of either the warp or filling yarns extending parallel to the cut edge by vibrations of the sonic horn against the anvil.

Claim 29

A process as claimed in claim 23, characterised by providing an included acute angle of from about 3 to 20 degrees between the sonic horn and the anvil in the region thereof effecting said sealing of the cut edge of the fabric for effecting the fusing and bonding steps.

Claim 30

A process for ultrasonically cutting and sealing woven textile fabric to produce a clean and sharp sealed edge of a thickness no greater than the thickness of the textile fabric and having a desired wash durability without significant raveling with an ultrasonic apparatus including a vibrating sonic horn having a flat working face and an anvil positioned for contact by the vibrating horn; said process being characterised by the steps of: providing an anvil defining a peaked cutting edge, a first surface extending from the peaked cutting edge in a first direction and forming a predetermined included acute angle with the horn face of from about 3 to 20 degrees and a second surface extending from the peaked cutting edge in the opposite direction and forming an included angle with the horn face at least.2-1/2 degrees greater than the included angle of the first surface and no more than 45 degrees for forming a desired sharpness and for reinforcing the peaked anvil cutting edge; passing woven textile fabric having thermoplastic fibers through the ultrasonic apparatus and between the vibrating sonic horn and the anvil at a substantially constant predetermined rate of speed and in a generally linear path of travel substantially parallel to either the warp or the filling yarns of the fabric and with the peaked cutting edge of the anvil and positioned so that the edge of the fabric to be sealed is passed over the first surface of the anvil; cutting an edge through the textile fabric substantially parallel with either a warp or a filling yarn which is parallel to the path of travel of the fabric through the ultrasonic apparatus by vibrations of the sonic horn against the peaked cutting edge of the anvil; simultaneously sealing the cut edge of the fabric by fusing and bonding a mass of thermoplastic fibers in the fabric adjacent to and extending inwardly of the fabric from the cutting edge from about 0.01 to 0.10 inch and encompassing from about 2 to 4 of either the warp or filling yarns extending parallel to the cut edge by vibrations of the sonic horn toward the first surface of the anvil; and applying a predetermined pressure to the anvil and to the vibrating sonic horn for exerting predetermined forces on the fabric passing therebetween for aiding in the ultrasonic cutting and sealing.

Claim 31

A process for ultrasonically cutting and sealing woven textile fabric to produce a clean and sharp sealed edge of a thickness no greater than the thickness of the textile fabric and having a desired wash durability without significant raveling with an ultrasonic apparatus including a vibrating sonic horn having a flat working face and an anvil positioned for contact by the vibrating horn; said process being characterised by the steps of: providing an anvil defining a peaked cutting edge, a first surface extending from the peaked cutting edge in a first direction and forming a predetermined included acute angle with the horn face of from about 3 to 20 degrees and a second surface extending from the peaked cutting edge in the opposite direction and forming an included angle with the horn face at least.2-1/2 degrees greater than the included angle of the first surface and no more than 45 degrees for forming a desired sharpness and for reinforcing the peaked anvil cutting edge; passing woven textile fabric having thermoplastic fibers through the ultrasonic apparatus and between the vibrating sonic horn and the anvil at a substantially constant predetermined rate of speed and in a generally linear path of travel substantially parallel to either the warp or the filling yarns of the fabric and with the peaked cutting edge of the anvil and positioned so that the edge of the fabric to be sealed is passed over the first surface of the anvil; cutting an edge through the textile fabric substantially parallel with either a warp or a filling yarn which is parallel to the path of travel of the fabric through the ultrasonic apparatus by vibrations of the sonic horn against the peaked cutting edge of the anvil; simultaneously sealing the cut edge of the fabric by fusing and bonding a mass of thermoplastic fibers in the fabric adjacent to and extending inwardly of the fabric from the cutting edge from about 0.01 to 0.10 inch and encompassing from about 2 to 4 of either the warp or filling yarns extending parallel to the cut edge by vibrations of the sonic horn toward the first surface of the anvil; and applying a predetermined pressure to the anvil and to the vibrating sonic horn for exerting predetermined forces on the fabric passing therebetween for aiding in the ultrasonic cutting and sealing.

Claim 32

A process as claimed in claim 25, characterised in that said anvil is wheel-shaped having a beveled periphery defining therearound said peaked cutting edge and said first and second surfaces.

Claim 33

A process as claimed in claim 25 or claim 26, characterised in that the textile fabric has a wash durability of 25 to 50 washings without significant raveling, and has at least 65% thermoplastic fibers.

Claim 34

A process as claimed in claim 27, characterised in that said first surface extends from the peaked cutting edge in a first direction and forming a predetermined included acute angle with the horn face of from about 5 to 15 degrees, said woven textile fabric has thermoplastic and cotton fibers including about 65 to 80% thermoplastic fibers in the fabric and at least 65% thermoplastic fibers in the warp, a weight of from about 2.25 to 6.0 0 oz./yd 2 , a yarn count in the warp of from about 68 to 108 and in the filling of from about 52 to 64, and yarn sizes in the warp from about 50/1 to 22/1 and in the filling of from about 35/1 to 15/1 and said mass of thermoplastic fibers extends inwardly of the fabric from the cutting edge from about 0.02 to 0.06 inch.

Claim 35

A process as claimed in any one of claims 23-28, characterised by vibrating the sonic horn against the anvil at a frequency of from about 20,000 to 40,000 hertz per second and passing the woven textile fabric through the ultrasonic apparatus at a rate of speed of from about 20 to 40 yards per second.

Claim 36

A process as claimed in claim 29, characterised by vibrating the sonic horn against the anvil at a frequency of 20,000 hertz per second and passing the textile fabric through the ultrasonic apparatus at a rate of speed of up to 20 yards per minute.

Claim 37

A process as claimed in claim 29, characterised by vibrating the sonic horn against the anvil at a frequency of about 40,000 hertz per second and passing the textile fabric through the ultrasonic apparatus at a rate of speed of about up to 40 yards per minute.

Claim 38

A process as claimed in any one of claims 23-31, characterised by applying a predetermined pressure on the sonic horn of from about 18 to 20 psig and on the anvil of from about 40 to 50 psig for providing forces of about 23 to 29 pounds on the fabric.

Claim 39

A process as claimed in any one of claims 23-32, characterised by moving the anvil from about 1/16 to 1/8 inch away from the sonic horn upon contact of the anvil of the horn during said cutting and sealing allowing the anvil to float with the sonic horn during contact by the sonic horn for aiding in cutting and sealing.