An ironing board cover, a method for manufacturing the same and a method for ironing fabric

Description

[0001] The present invention relates to an ironing board cover comprising at least three layers, viz. a top layer, an intermediate layer and a substrate layer, respectively. The present invention further relates to a method for manufacturing such an ironing board cover as well as to a method for ironing fabric.

[0002] An ironing board cover is known from Dutch patent No. 1022534, likewise in the name of Widemex Geldrop B.V. The object of said known patent is to provide the cover with one or more materials for reducing the friction between the fabric to be ironed and the heating device. Comparable ironing board covers are known from EP-A-0 378 229 and British patent No. 1,091,110.

[0003] From Dutch Patent NL 1004242 granted to Widemex Geldrop N.V. there is furthermore known an ironing board cover which consists of a fabric arranged over a foam layer, in which foam layer an aromatic substance is incorporated. According to such a construction, the intended transfer of certain fragrances, such as blossom fragrance, can be carried out without there being a need to add aromatic substances to water which is often added to an iron. Such a fragrance is released in the desired concentration when ironing takes place at an elevated temperature of the heating element.

[0004] A drawback of the prior art ironing board covers is that they function less well when used in combination with the modern irons comprising a steam delivery system, which provide a significant and continuous supply of steam. Thus, conventional ironing board covers will allow steam to pass therethrough, which may lead to leakage and thus to the formation of water puddles on the floor under the ironing board, which is undesirable.

[0005] The object of the present invention is to provide an ironing board cover which prevents water from leaking through and forming puddles under the ironing board.

[0006] Another object of the invention is to provide an ironing board cover which provides a good heat distribution over the entire ironing area.

[0007] Yet another object of the present invention is to provide an ironing board cover which is in particular suitable for the use of steam irons and steam systems.

[0008] The ironing board cover described in the first paragraph is characterised in that the intermediate layer is made of a metal foil.

[0009] Using such a metal foil, a barrier layer to steam and water is formed. Said barrier layer has a dual function. In the first place, the steam passing through the upper layer and any intermediate layers during ironing is stopped by the metal foil and reflected, as it were. Thus an air cushion is formed and the fabric to be ironed is provided with steam from two sides, i.e. the upper side and the underside. This leads to improved ironing results and a shorter ironing time.

[0010] The metal foil is preferably aluminium foil. The present inventor obtained the best results when using this material.

[0011] In one embodiment, one or more additional intermediate layers may furthermore be present between the top layer and the metal foil and/or between the metal foil and the substrate layer, which one or more intermediate layers are preferably selected from layers made of flannel, cotton fabric, foam or metal foil. Said additional intermediate layers provide a soft and flexible surface on which ironing can take place. Preferably, the additional intermediate layers are arranged between the top layer and the metal foil. It is preferable to provide only one metal foil.

[0012] In a special embodiment it is in particular desirable that a flannel layer be present between the top layer and the metal foil. Such a flannel layer has a damping effect and, by providing a soft foil, prevents creasing of the material while it is being ironed. The flannel layer is furthermore pervious to steam and moisture, so that the advantageous effect of the present invention is retained. The flannel layer preferably has a thickness from 1.0 mm to 6.0 mm. Using such a thickness, optimum results are obtained as regards realising the damping effect of said layer and preventing the material from creasing while it is being ironed.

[0013] In another preferred embodiment, a foam layer is present between the top layer and the flannel layer. In another embodiment, the substrate layer is a foam layer.

[0014] In the embodiment that is currently especially preferred, the ironing board cover consists of five layers, a decorative top layer, preferably a cotton fabric, a first foam layer, a flannel layer, an aluminium foil and a second foam layer, respectively. Particularly preferred is an embodiment as described above in which the top layer, the first foam layer, and the flannel layer are bonded together over substantially their entire surface area. It is furthermore in particular preferable if the metal foil and the substrate layer are bonded together over substantially their entire surface area. To obtain a good "air cushion effect" it is preferable if the metal foil is not bonded to the layer that directly overlies said metal foil (being the top layer or an intermediate layer); the metal foil and the layer overlying said metal foil are preferably only bonded together at the circumferential edge, for example by sewing.

[0015] The foam layers preferably have a thickness from 1.0 mm to 8.0 mm. Foam layers having such a thickness provide a firm base for ironing. The first foam layer preferably has a thickness from 1.0 mm to 4.0 mm. The advantageous effect of the underlying metal layer will be retained when such a thickness is used. The second foam layer preferably has a thickness from 1.0 mm to 8.0 mm. Such a thickness makes the foam layer sufficiently strong for being used as a substrate layer. Such a foam layer also protects the metal foil against any external influences that may cause damage to the foil, as a consequence of which the foil may become leaky, so that its advantageous effect is lost.

[0016] The foam layers may separately consist of polyester foam or polyether foam; preferably said layers consist of polyester foam. Such a foam is resistant to the heat from an iron during ironing.

[0017] In a preferred embodiment of the present invention, the various layers are bonded together by gluing or flame fusion, preferably by flame fusion. When flame fusion is used, the layers are properly bonded together without the advantageous effect of the individual layers being lost.

[0018] The present invention further relates to a method for manufacturing an ironing board cover, said method comprising the steps of providing an assembly of at least three layers, viz. a substrate layer, an intermediate layer and a top layer, then cutting the assembly to the correct size to form separate ironing board covers and subsequently bonding the individual layers together.

[0019] It is possible to provide the assembly in the form of separate layers, which are only bonded together after they have been cut to size. It is also possible to bond one or more layers of the assembly together prior to cutting said layers to size. Said bonding together can be done by means of an adhesive or by stitching.

[0020] In one embodiment of the method, the substrate layer and the metal foil are bonded together before the assembly is cut to the desired size, whilst the top layer is bonded to the substrate layer and the metal foil after the assembly has been cut to the desired size.

[0021] In another embodiment, the top layer is bonded to a foam layer and a flannel layer, respectively, before the assembly is cut to the desired size, wherein the top layer, the foam layer and the flannel layer on the one hand and the substrate layer and the metal foil on the other hand are bonded together in such a manner that the flannel layer faces the metal foil after the assembly has been cut to the desired size.

[0022] In another embodiment, said bonding together of the assembly comprises the sewing together of the various layer around the circumference of the ironing board cover, possibly using a sleeve-like holder provided with an opening, through which a stretching element can be passed.

[0023] In a preferred embodiment, the assembly of layers is undetachably provided all around with a sleeve-like holder provided with an opening, through which a stretching element can be drawn, which stretching element terminates at one end of the assembly and which is provided with a tightening element at that location for tightening the stretching element round the ironing board. In this way the ironing board cover can be installed on an ironing board with a correct fit. Such an ironing board cover is for example described in Dutch patent NL 1035357 in the name of Widemex Geldrop B.V.

[0024] The present invention further relates to a method for ironing fabrics, which method comprises the following steps:

i) heating the heating element to the correct temperature,

ii) placing the fabric to be ironed on the ironing board cover obtained according to one or more of claims 1-7 or produced according to one or more of claims 8-11;

iii) bringing the heated heating element and the fabric to be ironed into sliding contact with each other.

[0025] Further embodiments of the ironing board cover and the methods are defined in the appended claims.

Claims

1. An ironing board cover comprising at least three layers, viz. a top layer, an intermediate layer and a substrate layer, respectively, characterised in that the intermediate layer is made of a metal foil.

2. An ironing board cover according to claim 1, characterised in that said metal foil is aluminium foil.

3. An ironing board cover according to one or more of the preceding claims, characterised in that one or more additional intermediate layers are present between the top layer and the metal foil and/or between the metal foil and the substrate layer, which one or more intermediate layers are preferably selected from layers made of flannel, cotton fabric, foam or metal foil.

4. An ironing board cover according to one or more of the preceding claims, characterised in that a flannel layer is present between the top layer and the metal foil.

5. An ironing board cover according to claim 4, characterised in that a foam layer is present between the top layer and the flannel layer.

6. An ironing board cover according to one or more of the preceding claims, characterised in that the substrate layer is a foam layer.

7. An ironing board cover according to one or more of the preceding claims, characterised in that the top layer is made of a cotton fabric.

8. A method for manufacturing an ironing board cover as defined in one or more of the preceding claims, characterised in that the method comprises the steps of providing an assembly of at least three layers, viz. a substrate layer, an intermediate layer and a top layer, then cutting the assembly to the correct size to form separate ironing board covers and subsequently bonding the individual layers together.

9. A method according to claim 8, wherein the substrate layer and the metal foil are bonded together before the assembly is cut to the desired size, whilst the top layer is bonded to the substrate layer and the metal foil after the assembly has been cut to the desired size.

10. A method according to claim 9, wherein the top layer is bonded to a foam layer and a flannel layer, respectively, before the assembly is cut to the desired size, and wherein the top layer, the foam layer and the flannel layer on the one hand and the substrate layer and the metal foil on the other hand are bonded together in such a manner that the flannel layer faces the metal foil after the assembly has been cut to the desired size.

11. A method according to any one of claims 8-10, wherein said bonding together of the assembly comprises the sewing together of the various layer around the circumference of the ironing board cover, possibly using a sleeve-like holder provided with an opening, through which a stretching element can be passed.

12. A method for ironing fabric, characterised in that the method comprises the following steps:

i) heating the heating element to the correct temperature,

ii) placing the fabric to be ironed on the ironing board cover obtained according to one or more of claims 1-7 or produced according to one or more of claims 8-11;

iii) bringing the heated heating element and the fabric to be ironed into sliding contact with each other.