AU773361B2 - A fabric used in wool packing, and a process of preparing for the same - Google Patents

Description

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-1I- P/00/00 II Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

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Name of Applicant: Actual Inventors: Address for service in Australia: Invention Title: KOLON INDUSTRIES, INC.

KWANG OH1, KIM; SANG MOK, LEE and TAE HWAN,

AHN

CARTER SMITH BEADLE 2 Railway Parade Camberwell Victoria 3124 Australia A FABRIC USED IN WOOL PACKING, AND A PROCESS OF PREPARING FOR THE SAME The following statement is a full description of this invention, including the best method of performing it known to us IP Australia C Documents received on: M 0

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B~atch No:I A FABRIC USED IN WOOL PACKING, AND A PROCESS OF PREPARING FOR THE SAME TECHNICAL FIELD e The present invention relates to a fabric used in wool packing(hereinafter we refer to it as "wool packing fabric") and it's preparing process for the same. As the wool acquired from sheep has to be pressed and put into a certain frame with strong pressure for its packing and transportation, the packing material used for containing wool(hereinafter we refer to it as "wool pack") needs to maintain higher level of tensile strength and heat resistance for the purpose of preventing any tear.

It is desirable that the tensile strength of wool pack is over than 250kg/5cm measured in ASTM D 5035 method, and the tear strength of wool pack is over than 45kg measured in Australian Wool Pack standard No.3 2.3 1 A Additionally, the wool pack is required to have certain stability against UV rays considering the deterioration of its properties during outdoor operation. Another important properties required in wool pack are stiffness and anti-slip(surface friction coefficient) which allow the stability of packing form.

A wool pack containing wool shall be stacked in several bundle on vehicle or shipping container for its transportation. If the anti-slip coefficient of wool pack is too low, then the bundle of stacked wool pack may collapse during the transportation due to its low frictional force. Whereas the anti-slip *4 coefficient is too high, it is not easy to handle. So, it is favorable to have -8.ON of surface friction coefficient measured in Australian Wool Pack standard No.3 2.5 and, more favorably 3.5-6.ON.

o DESCRIPTION OF THE PRIOR ART Prior method of producing wool packing fabric which has to satisfy those specific requisites as fabric used in wool packing is described -2hereinbelow.

Wool pack prepared by plain weaving the polyprophylene fabric or high density polyethylene fabric is widely used as packing materials for containing wool. For the better performance of packing prepared in the said wool pack, a steel pipe is penetrated through the side of wool pack. though the wool pack prepared in the said method shows better performance in packing, it potentially comprises the high tear possibility. If the wool pack gets torn, polyprophylene fiber or high density polyethylene fiber consisting of wool pack may mixed up with wool stored in wool pack. As a result, there may be a problem of unequality in wool dyeing. This unequality is caused by the difference of dyeing between wool and polyprophylene fabric or high density polyethylene fabric.

Recently, new wool pack material comprising similar dyeing property with wool has been researched for practical use. In general, acid dye, acid mordant dye, and metallic complex salt dye are mainly used in wool dyeing.

Vat dye and reaction dye may also applicable for wool dyeing.

Silk and nylon having similar dyeing property with wool may be dyed 3 by the said dye. Silk however, is fairly expensive and has too low properties to meet the requirement of wool pack.

Generally, polyester though it has high properties, is not good for wool pack since it cannot be dyed at all with the dye for wool.

Accordingly, polyamide fabric is variously used in preparing wool packing fabric these days in order to eliminate the dyeing unequality problem.

In the mean time, researches are disclosed to provide wool packing fabric with anti-slip and stiffness; dipping, or spraying, or printing treatments to binder resin comprising acryl resin and/or melamin resin as main S component.

These methods, however, can provide wool packing fabric with stiffness, it is not possible to meet the anti-slip at the same time. in order to solve the said problem, it is necessary to add an additional process of mechanical method such as forming irregularity on the binder layer.

In addition, the former wool packing fabric has following several drawbacks due to low or high air permeability that: the lower part of wool pack may swell just like a balloon during filling 004458050 wool in the wool pack, in case of high air permeability, difficult packing due to pressure repulsion toward the opposite direction of filling wool due to the pressure elevation in wool pack, or in case of low air permeability, wool may extrude out of wool pack through the chasm of wool packing fabric.

The purpose of the present invention relates to a wool packing fabric having adequate air permeability to allow easy packing, no wool extrusion out of wool pack, maintenance of dyeing equality of contained wool with excellent stiffness and anti-slip.

SUMMARY OF THE INVENTION The present invention relates to a fabric for use in wool packing characterized by having binder resin layers on the surface of the fabric weaved by total denier 630-2,500 0 0: denier of polyamide multi-filament with the following properties: an air permeability measured at 125PA pressure difference by ASTM D737 15 method of 3-100CFM; a stiffness measured by ASTM D1388 cantilever method of over 100mm; a surface friction coefficient measured at standard conditions by Australian Wool Pack standard No.3 2.5 method of 2.5-8.N; and a cover factor(CF) is 1,100-2,000. Moreover the present invention relates 20 to a process of preparing a fabric used in wool packing characterized by the following process: weaving a fabric with air permeability of 3-100CFM measured at 125PA pressure difference by ASTM D737 method; 004458050 6 a stiffness of more than 100mm measured by ASTM D1388 cantilever method; a surface friction coefficient of 2.5-8.0N measured at standard condition by Australian Wool Pack standard No.3 method; and a cover factor(CF) of 1,00-2,000 using polyamide of total denier as weft and warp, then drying the fabric by either dipping the treated fabric in binder resin solution wherein salicylic acid derivative is the main component, or spraying the treated fabric with binder resin solution comprising salicylic acid derivative.

In the said process, it is characterized by providing anti-slip to the fabric through adding salicylic acid derivative in the binder resin solution.

Also, the present invention relates to a preparing process of wool packing fabric characterized by the following process: eeoc *oo Weave 1,100-2,000 Cover Factor(CF) of fabric by using polyamide airtexturing processed filament having 2-7 denier of mono filament, 1,000- 2,500 denier of total denier as weft and warp, then Dry up the either of dipping treated the said fabric in binder resin solution or spraying treated the said fabric with binder resin solution.

In the said process, it is characterized by totally or partially adopting airtexturing processed filament to warp and weft so as to achieve favorable anti-slip through the small amount of binder treatment.

That is to say, the process is characterized by preparing wool packing fabric adopting either of: Totally use airtexturing processed polyamide multi-filament as warp and weft; or Partially use airtexturing processed polyamide multi-filament as warp and weft together with the use of polyamide mult-filament (which has not been airtexturing processed filament) to the rest part of warp and weft.

7 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS First of all, weave polyamide multi-filament as warp and weft to prepare in plain weaving, ribstop weaving or rib weaving. Polyamide multi-filament such as polyamide 6 or polyamide 66 are favorable.

Since the polyamide filament has -CONH, -NH 2 or -COOH radical in its molecular formula, its dyeing characteries are similar to wool. Compared polyamide 6 and polyamide 66, each has same participating radical of dye adhesiveness, but has some difference in hydrogen cohesion; though the cohesion direction of -CONH radical in polyamide 6 is same with molecular Schain, those in polyamide 66 is reverse direction to the molecular chain.

Therefore, polyamide 6 comprising little quantity of hydrogen cohesion, is relatively easier to dye and has more amount of saturated dye adhesive than polyamide 66 due to more quantity of non-crystallization area which shall be a place for dye adhesive.

In the present invention, it is favorable to set the mono filaments of warp and weft at 2-7 denier, total denier at 630-2,500 denier. If the -8filaments of warp and weft are less than 630 denier, it is not possible to acquire the strength wool pack required but to use more binder in order to secure the weight of 1.3-1.7kg/pack. If the filaments of warp and weft are over than 2,500 denier, total weight of wool pack after all preparing process shall be too heavy nevertheless the improvement of strength. The most S favorable filaments of warp and weft are 1,200-2,000 denier.

The favorable mono filament of polyamide multi-filament used as warp and weft is 2-7 denier lest dye unequality should happen due to the o* difference of mono filament in wool. During weaving, control the density of warp and weft in order to satisfy the tensile strength(over than 250kg/5cm) and air permeability at the same time that wool pack requires. Particularly, adjust the density of warp and weft so as to the Cover Factor(CF) which is calculated by the following formula shall be 1,100-2,000.

Cover Factor(CF) [warp density(end/inch)] x warp total denier [weft density(pick/inch)] x V weft total denier -9- In case, 1,890 denier of filament is used as warp and weft, it is favorable to adjust the density of warp and weft at 14.5 ends/inch. It is possible to secure the air permeability (measure by ASTM D 737 method at 125PA pressure difference) of final product at the level of 3- 100ft 3 /ft 2 min. provided that the resin pick-up rate, density and Cover Factor(CF) are controlled within proper range.

Hereinafter we refer to "ft 3 /ft 2 min.", the measuring unit of air permeability, as "CFM".

In case, either the Cover Factor is lower than the said range or the air permeability is higher than the said range, contained wool may come out from wool pack through the empty chasm of wool pack fabric.

Also if, either the Cover Factor is higher than the said range or the air permeability is lower than the said range, the lower part of wool pack may swell just like a balloon during filling wool in the wool pack and shall be difficult to pack due to pressure repulsion toward the opposite direction of filling based on the pressure elevation inside of wool pack.

Also the air permeability of wool pack depends on the pick-up rate of 10 resin. If the pick-up rate fo resin is high, the air permeability of wool pack become to low.

Plain weaving, ribstop weaving or rib weaving can be applied in the present invention.

In order to provide the said weaved wool packing fabric with appropriate stiffness and anti-slip, dry up the either of dipping treated the said weaved wool packing fabric in binder resin wherein salicylic acid derivative of general formula(I) is main component or spraying treated the 9 said wool packing fabric with binder resin comprising the salicylic acid derivative.

*0 0 II II S- 0 C -Z C (I) In the above formula, X is aromatic compounds such as Benzene, Phenol and etc, Z is II B group metal such as Zn, Cd and Hg.

The binder resin is prepared by melting the said salicylic acid derivative in water. In this process, it is possible to add an antibacterial 11 additive such as polyvinyl alcohol resin.

Control the density of binder resin solution, that is to say, the content amount of salicylic acid derivative in the binder resin solution at If the density of binder resin is less than 15weight%, the fabric shall be too flexible, and its structure shall be wide open due to slipping warp and weft originated from its low adherence. If the density of binder resin is 0o* over than 50weight%, the heat resistance and anti-slip shall be deteriorated.

The most favorable density of Binder resin solution is to adjust between

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Now, dipping the weaved fabric in the binder resin solution, and pass the dipped fabric through mangle. After squeezing the said fabric, dry up for

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one minute at 70-230°C. More favorably, one minute dry at 130-180 C.

Should the drying temperature is too low, the adherence of fabric shall not be made properly. Then the anti-slip shall be elevated too much, and wool contained in wool pack shall be adhered to the surface of wool pack. If the drying temperature is too high, the fabric shall be coarse.

Also, it is possible to form binder resin coating layer on the surface of 12 the weaved fabric by spraying the said binder resin solution.

In the mean time, use airtexturing processed polyamide multi-filament to one direction of warp and weft during the process of weaving, and use polyamide mult-filament (which has not been airtexturing processed filament) to another direction of warp and weft. Or partially use airtexturing processed polyamide multi-filament as warp and weft together with the use of polyamide mult-filament (which has not been airtexturing processed filament) to the rest part of warp and weft in turn. Airtexturing is a process to form a irregular loop on multi-filament by over feeding multi-filament through 9 airtexturing nozzle which makes minglement of pressured air.

9 Multi-filament shall be exited by exiting roller after it has been provided in the said airtexturing nozzle by feeding roller and been winded on winding roller. In this process, control the speed of feeding roller faster than that of exiting roller. The difference of speed between these two rollers is so called over feed rate.

In order to eliminate the irregular loop formed on the multi-filament, it is desirable to provide tensile strength by accelerating the speed of winding 13 roller faster than that of exiting roller. The said feeding roller may be organized in one pair or two pairs. In case, the feeding roller is two pairs, airtexturing can be made by combining two kinds of multi-filaments. In addition, it is possible to select core filament and effect filament separately by differentiating the speeds of two pairs of feeding roller.

S. In the present invention, it is favorable to control the over feed rate of airtexturing at 20-50%, the air pressure at 4-10bar, and exiting speed at 300 -800m/min. The present invention, however, does not specifically restrict the .i conditions of airtexturing process.

If the air pressure and over feed rate be increased, the air minglement shall be increased. And then, this increased minglement causes more loops on the multi-filament, and deteriorates the stability of loop. Furthermore, strength of multi-filament and cutting shrinkage shall be decreased, but finess of filament shall be increased. Consequently, it is desirable to manipulate the air pressure and over feed rate to a certain appropriate range during airtexturing process.

Since the fabric weaved with airtexturing processed filament has high 14 surface friction coefficient, it is possible to obtain fairly good anti-slip through the small amount of usual binder resin such as melanin, acryl, polyvinyl alcohol, polyvinyl acrylate or polyurethane. As a result, the drying time of binder resin can be shortened, the productivity shall be improved with no necessity of using salicylic acid derivative.

In the process of weaving the airtexturing processed filament as warp and weft, the preparing conditions like the denier of mono filament, total denier, weaving method, Cover Factor are same as aforesaid.

Wool packing fabric prepared by the present invention has following properties: Air permeability 3 100CFM, Stiffness Over than 100mm, Cover Factor 1,100-2,000, and Surface Friction Coefficient 2.5-8.0N In conclusion, wool packing fabric of the present invention can support easy wool packing based on appropriate air permeability and Cover Factor, can 15 prevent any wool extrusion out of wool pack. Further, The present invention provide stiffness and anti-slip on wool packing fabric by simpler process and lower production cost.

Every important properties of wool packing fabric are evalulated by the following measures in the present invention: Surface Friction Coefficient(Anti-Slip) Measure by Australian Wool Pack standard NO.3 2.5 in normal condition.

Stiffness Measure by ASTM D 1388 cantilever method.

SCover Factor(CF) CF [warp density(end/inch)] x V warp total denier [weft density(pick/inch)] X V weft total denier 16 Air Permeabilitv(CFM) Measure by ASTM D 737(pressure difference 125Pa) in normal condition Tensile Strength Measure by Australian Wool Pack standard NO.3 2.1 in normal condition.

0* examples and comparative examples. However, the present invention shall not be confined only to those examples.

600: EXAMPLE 1 Using filament of polyamide 6 having 1,260 denier and 204 filament as warp and weft, weave a fabric having 21 ends/inch x 22 picks/inch density warp and weft by rib construction.

After dipping both side of the said fabric in binder resin water density) wherein Zn salicylate is main component, squeeze the said fabric with mangle. Prepare wool packing fabric having 22 ends/inch 17 x 23 picks/inch density warp and weft after one(l) minute heat-setting the said fabric at 150°C. Every properties of prepared wool packing fabric are shown in Table 1.

EXAMPLE 2 Using filament of polyamide 6 having 1,890 denier and 306 filament as warp and weft, weave a fabric having 14.5 ends/inch x 14.5 picks/inch density warp and weft by rib construction.

After dipping both side of the said fabric in binder resin water density) wherein Zn salicylate is main component and small amount(0.5weight%) of antibacterial additive is comprised, squeeze the said fabric with mangle. Prepare wool packing fabric having 15 ends/inch x picks/inch density warp and weft after one(l) minute heat-setting the said fabric at 150°C. Every properties of prepared wool packing fabric are shown in Table 1.

EXAMPLE 3 18 Using airtexturing processed filament of polyamide 6 having 1,260 denier and 204 filaments as warp, and using filament of polyamide 6(which has not been airtexturing processed filament) having 1,260 denier and 204 filaments as weft, weave a fabric having 21ends/inch x 22 pciks/inch density warp and weft by ribstop construction. The above airtexturing process is executed under the conditions of 25% over feed rate, 6bar air pressure, and winding speed. After spraying both side of the said fabric with spray solution comprizing 100 weight part of water, 90 weight part of melanin binder, 90 weight part of acryl binder and 9 weight part of catalyzer, prepare wool packing fabric by one(l) minutes heat-setting the said fabric at 150 C.

SEvery properties of prepared wool packing fabric are shown in Table 1.

EXAMPLE 4 Using airtexturing processed filament of polyamide 6 having 1,260 denier and 204 filaments and filament of polyamide 6(which has not been airtexturing processed filament) having 1,260 denier and 204 filaments as warp and weft in turn at the rate of 2:2, weave a fabric having 21ends/inch x 22 pciks/inch 19 density warp and weft by ribstop construction. The above airtexturing process is executed under the conditions of 25% over feed rate, 6bar air pressure, and winding speed. After spraying both side of the said fabric with spray solution comprizing 100 weight part of water, 90 weight part of melanin S binder, 60 weight part of acryl binder and 9 weight part of catalyzer, prepare wool packing fabric by one(l) minutes heat-setting the said fabric at 150°C.

Every properties of prepared wool packing fabric are shown in Table 1.

COMPARATIVE EXAMPLE 1 Using filament of polyamide 6 having 1,260 denier and 204 filament as Swarp and weft, weave a fabric having 14 ends/inch x 14 picks/inch density warp and weft by rib construction.

After dipping both side of the said fabric in dipping solution comprizing 100 weight part of water, 30 weight part of melanin binder, weight part of anti-slip additive and 0.3 weight part of catalyzer, squeeze the said fabric with mangle. Prepare wool packing fabric having 15 ends/inch x picks/inch density warp and weft after one(l) minute heat-setting the said 20 fabric at 150 C. Every properties of prepared wool packing fabric are shown in Table 1.

COMPARATIVE EXAMPLE 2 S" Using filament of polyamide 6 having 1,890 denier and 306 filament as warp and weft, weave a fabric having 11 ends/inch x 11 picks/inch density warp and weft by rib construction.

*9 9 After dipping both side of the said fabric in binder resin water solution(25weight% density) wherein Zn salicylate is main component, squeeze the said fabric with mangle. Prepare wool packing fabric having 12 ends/inch 9 *9 9 Sx 12 picks/inch density warp and weft after one(l) minute heat-setting the said fabric at 150"C. Every properties of prepared wool packing fabric are shown in Table 1.

COMPARATIVE EXAMPLE 3 Using filament of polyamide 6 having 1,260 denier and 204 filament as warp and weft, weave a fabric having 29 ends/inch x 29 picks/inch density 21 a a.

warp and weft by rib construction.

After dipping both side of the said fabric in binder resin water density) wherein Zn salicylate is main component, squeeze the said fabric with mangle. Prepare wool packing fabric having 30 ends/inch x 30 picks/inch density warp and weft after one(l) minute heat-setting the said fabric at 150 C. Every properties of prepared wool packing fabric are shown in Table 1.

TABLE 1 Result of measured property Surface Friction Tensile Strength(Kg) Stiffness(mm) Cover Air Coefficient (N) Factor Permeability wet Warp Weft Warp Weft Warp Weft (CF)

(CFM)

Direction Direction Direction Direction Direction Direction Example 1 458 442 130 126 1,597 11 5.2 4.8 Example 2 471 469 135 139 1,304 34 5.5 4.6 Example 3 463 452 131 130 1,597 13 5.8 Example 4 449 471 132 133 1,597 14 5.7 Comparetive mparetive 368 358 155 157 1,064 115 4.4 2.1 Example 1 Comparative Exmplaie 511 492 153 155 1,043 120 5.5 Example 2 Comparative Exmprae 503 521 148 146 2,129 2.8 5.0 4.7 Example 3 22 a a.

In comparative example 1 and comparative example 2, wool contained in wool pack may extrude through the chasm of the wool pack fabric because the air permeability are too high and the Cover Factor are too low. In comparative example 3, packing is difficult due to its low air permeability.

*a a 23

Claims (12)

1. A fabric for use in wool packing characterized by having binder resin layers on the surface of the fabric weaved by total denier 630-2,500 denier of polyamide multi- filament with the following properties: an air permeability measured at 125PA pressure difference by ASTM D737 method of 3-1 OOCFM; a stiffness measured by ASTM D1388 cantilever method of over 100mm; a surface friction coefficient measured at standard conditions by Australian Wool Pack standard No.3 2.5 method of 2.5-8.0N; and a cover factor(CF) is 1,100-2,000.

2. A fabric for use in wool packing of claim 1, wherein the mono filament of *:pi polyamide multi-filament is 2-7 denier.

3. A fabric for use in wool packing of claim 1 or 2, wherein the polyamide multi- filament is airtexturing processed filament.

4. A fabric for use in wool packing of any one of claims 1-3, wherein the stiffness measured by ASTM D 1388 cantilever method is 100-150mm. A fabric for use in wool packing of any one of claims 1-4, wherein the binder resin is salicylic acid derivative, melanin, acryl, polyvinyl alcohol, polyvinyl acrylate or polyurethane.

6. A fabric for use in wool packing of any one of claims 1-5, wherein the binder resin comprises an antibacterial additive.

7. A fabric for use in wool packing of any one of claims 1-6, wherein the fabric is weaved by the method of plain, rib or ribstop. 004458050

8. A process of preparing a fabric used in wool packing characterized by the following process: weaving a fabric with air permeability of 3-100CFM measured at 125PA pressure difference by ASTM D737 method; a stiffness of more than 100mm measured by ASTM D1388 cantilever method; a surface friction coefficient of 2.5-8.0N measured at standard condition by Australian Wool Pack standard No.3 method; and a cover factor(CF) of 1,00-2,000 using polyamide of total denier as weft and warp, then drying the fabric by either dipping the treated fabric in binder resin solution wherein salicylic acid derivative is the main component, or spraying the .i treated fabric with binder resin solution comprising salicylic acid derivative.

9. A process of preparing a fabric for use in wool packing of claim 9, wherein the content amount of salicylic acid derivative in the binder resin solution is 50 weight%. A process of preparing a fabric for use in wool packing of claim 9, wherein the weaving method is plain, rib, or ribstop. S.11. A process of preparing a fabric for use in wool packing of claim 9 or 10, wherein the binder resin comprising an antibacterial additive. 004458050 26

12. A process of preparing a fabric for use in wool packing of any one of claims 9-11, wherein the salicylic acid derivative is the compound of general formula O O (I) in which X is a an aromatic compound and, Z is a II B group metal.

13. A process of preparing a fabric for use in wool packing characterized by the following process: weaving a fabric having an airpermeability of 3-100CFM at 125PA pressure difference by ASTM D737 method; a stiffness of more than 100mm measured by ASTM D1388 cantilever method; a surface friction coefficient of 2.5-8.0 N measured at standard conditions by Australian Wool Pack standard No.3 2.5 method; and a Cover Factor (CF) of 1,00-200 using airtexturing processed polyamide multi-filament having 2-7 denier of mono filament, and 1,000-2,500 denier of total denier as weft and/or warp, then drying the fabric by weight dip treating the said fabric in a binder resin solution wherein salicylic acid derivative is main component or spray treating the fabric with binder resin solution comprising salicylic acid derivative. *.i

14. A process of preparing a fabric for use in wool packing of claim 14, wherein the binder resin is melanin, acryl, polyvinyl alcohol, polyvinyl acrylate or polyurethane. 004458050 27 A fabric according to any one of claims 1 to 8, substantially as hereinbefore described with particular reference to the examples.

16. A process according to any one of claims 9 to 15, substantially as hereinbefore described with particular reference to the examples. 29 March 2004 By Freehills Carter Smith Beadle Registered Patent Attorneys for the Applicant KOLON INDUSTRIES, Inc. *o *o*o