CA1087818A - Method for the production of a polymer substrate with a fibrous surface - Google Patents
Method for the production of a polymer substrate with a fibrous surfaceInfo
- Publication number
- CA1087818A CA1087818A CA248,472A CA248472A CA1087818A CA 1087818 A CA1087818 A CA 1087818A CA 248472 A CA248472 A CA 248472A CA 1087818 A CA1087818 A CA 1087818A
- Authority
- CA
- Canada
- Prior art keywords
- polymer
- film
- recited
- substrate
- melting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H11/00—Non-woven pile fabrics
- D04H11/08—Non-woven pile fabrics formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
- B29C59/025—Fibrous surfaces with piles or similar fibres substantially perpendicular to the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/765—Articles provided with piles, e g. nap on cloth
Abstract
A METHOD FOR THE PRODUCTION
OF A POLYMER SUBSTRATE WITH A FIBROUS SURFACE
ABSTRACT OF THE DISCLOSURE
The present invention relates to a process for the production of thermoplastic substrate with fibrous surfaces.
The fibers of these surfaces are formed by drawing away from a heated surface a molten polymer component backed by an unmelted polymer residue layer or substrate. Simultaneous with the drawing, the nascent fibers are stabilized by cooling.
For this purpose, cooling media are introduced in the fiber-forming zone. The thermoplastic polymer compounds should be applied in a thickness of at least 50 microns, and preferably 150 microns (when only 1 polymer forms the molten component), on a heated drawing surface of a drum or a conveyor belt apparatus.
This invention relates to the production of fibrous surfaces on polymer substrates. Typically the substrates are in the form of webs. The use of webs makes the cooling process more efficient.
OF A POLYMER SUBSTRATE WITH A FIBROUS SURFACE
ABSTRACT OF THE DISCLOSURE
The present invention relates to a process for the production of thermoplastic substrate with fibrous surfaces.
The fibers of these surfaces are formed by drawing away from a heated surface a molten polymer component backed by an unmelted polymer residue layer or substrate. Simultaneous with the drawing, the nascent fibers are stabilized by cooling.
For this purpose, cooling media are introduced in the fiber-forming zone. The thermoplastic polymer compounds should be applied in a thickness of at least 50 microns, and preferably 150 microns (when only 1 polymer forms the molten component), on a heated drawing surface of a drum or a conveyor belt apparatus.
This invention relates to the production of fibrous surfaces on polymer substrates. Typically the substrates are in the form of webs. The use of webs makes the cooling process more efficient.
Description
B~CKGROUND_OI TIIE INVENTION
A process for the productlon of shee~ products with fibrous surfaces has been known in the prior art in which the sheet products are composed of a substrate which is covered with a thermoplastlc fiber nap. The substrate acts as a carrier. This process presses polymer foils on a heated drum until they begin to melt. As the molten polymer foils adhere to the drum and to the substrate, the substrate is drawn off with a simultaneous cooling of the molten film. Following this drawing process, a plurality of uniform fibers are formed from ~the molten polymer. These fibers adhere to the substrate.
This process produces surfaces which have textures of velour, plush or pelt (see, for e~ample, U.S. Patent No. 3,708,565).
-~ The prior art required a polymer-unrelated substrate made .''! out of textile fabric, paper or fleece. However, many enterprises required plastic webs or films with fibrous outer surfaces with substrates which consisted totally of polymeric materials. It is desirable that a substrate be produced out of fiber naps in " ::
which the fibers combine the positive properties of several polymers which have been amalgamated within the fiber.
Alternatively, it ~s desirable that the fibers should consist of another polymer, similar to the substrate.
SUMMARY OF THE INVENTION
An ob~ect of this invention is to provide a process for the production oE a polymer substrate with a Eibrous surface.
In one particular aspect the present invention provides a process for producing~polymeric substrates.having fibrous sur~aces comprising the steps of: drawing a precursor polymeric .-j l /J o - 2 -. .. . . . . . . .. . . . .
.. , . ,, .~ , , , . .. ~ ... ;;.. . .
J ~
~-`lm al~ng and i~ contact with a drawlng surEace having a melting zone; ~leatlng th~ pr~cur~or polymeric film :in the me:Lting zone to melt the surface adjacent the drawing surface and yield an unmelted substrate covered with a film of molten po:Lymerlc component; and deElec~ing the unme:Lted substratecovered with the fllm of molten polymeric component from the drawing surface while simultaneously cooling the molten component, whereby fibers are formed which are strongly bound to the surface of the substrate.
10Previous to this invention, processes which involved the use of calendars or extrusion were known in the prior art, but were characterized by the great difficulty or the impossibility - of amalgamating or compounding polymers.
DETAILED DESCRIPTION OF THE INVENTION
; According to the process of this invention, a polymer film with a thickness of at least 50 mlcrons, and preferably . 150 microns, is applied to a heated drawing surface upon which the film will cling until drawn away. Part of the film will melt and cove~ the unmelted film or substrate. The unmelted :.......................................................................... :
substrate may be half of the total film thickness. For example, if a thickness of 50 microns is used, then not more than 2/3 of the polymer (30 microns) is to be melted. Otherwise there is too great a risk of breaking or tearing the substrate as it is being drawn away from the heated drawing surEace. Fo]lowing melting, the nascen~ Elbers are drawn away Erom the drawlng surface and stabilized under simultaneous cooling. As a result the melted part of the film is detached from the heated surface thus commensing formation of a fiber nap. The unmelted part of :, .
the film is the substrate for the newly formed fiber nap. This : j , ~ jlt~ -3-u~
~iber nap adh~res very strong:Ly to the proxlmate surface oE the substrate.
~ lso thls inventlon of.Eers a possihility of making the film as a compos:ite with 2 or more diEferent polymers layered upon a substrate cons:Lsting of another polymer~ These films are made by using polymers with distinctive melting polnts and/or melting viscosities. The total thickness of the combined polymers in .` the film should be at least 50 microns, and preferably 100 microns.
The composite ilm is then applied to the heated drawing surface.
In the composite film, a polymer with the lowest melting point and/or lowest melting viscosity is deposited so that it will be ~ closest to the heated drawing surface. This invention provides .~ for a relatively uniform mixture of fibers by mixing of the molten polymers. Following the melting of the desired portions of the film, intimate mixing is assisted by the shearing stress which is formed between the unmelted substrate and the heated : drawing surface during drawing.
This.invention can be further modified such that two or more ,- . .
films of different polymers are applied successively on the ` 20 drawing surface, rather than simultaneously. Still further, .:,. this invention makes it possible to draw one of two or more .. ~. -.
::` different layered polymers, which comprise the composite film, upon the heated drawlng surface, and then to melt and pull the ~ layer away from the heated drawing surEace causing the formation ': `:' ` of homogeneous or heterogeneous fiber naps which adhere on the ~ unmelted film substrate.
This modification of the invention makes po~sible very simple operations for the production of polymer substrates with fibrous . surfaces. Of all the horizontal polymer layers present, the ~:.
.: 30 '' ~ ` `.~ , , .
: ~ j 1/JG _4_ ~
.~- . . . : : . ,: .: . . - . , ~ , , ' ,: ' . . :'' ' ' -' : , . ' ~ "" '': ' ' : . , 'f81~3 ~ibers c~re ~ormed only out of the me:Lted polymer layer whicll is, for exampIe, proximate ~o tlle heated drawing xurface.
Another mo~lfLcation provides for the addltion of polymers ln the form of particulate matter, such as granules or powder, upon the polymer substrate.
An essentlal characterlstic of the inventlon is that ~ the nascent fibers are cooled until they are hardened, ; stabili~ed an~ solidified. The invention provides for cooling which operates within the drawing angle, which is , .
between the unmelted film residue which forms the substrate and the drawing surface. Air cooling is preferable. It may ~.
be advantageous to conduct secondary cooling of the substrate on the back side which is opposite the side to which the fibers adhere. Also with secondary cooling, one can prevent single or combined films from completely melting through.
. ~, , The cooling may, indeed, take place along with all of the steps of feeding the film, for example by means of back side coolers, or it may take place only in a single zone.
Polymers which have in the molten state a low viscosity are suitable as a meltable thermoplastic Eilm andlor as components .: , of a`composite film and as the substrate include, inter alia:
polyethylene having a MFI 190/2 of 10-300 grams/10 minutes;
ethylene/vinyl acetate having a MFI 190/2 above 10 grams/10 minutes; polypropylene having a MFI 190/5 of 10-70 grams/10 ;, .
minutes; polymethylmethacry:late havililg a MFI 2:lO/10 above 10 , grams/10 minutes, cellulose acetate, cellulose acetate-butyrate, and cellulose propionate, CA, CAB, CP having a MiFI 190/2 about ~ `
;! 8; polyoxymethylene having a MFI 190/2 above 13 grams/10 minutes;
polyvinyl chloride/acetate having a K value below 60 and ~,~
J o -5-~`.
C taining ~It least 15% plasticizer, polyam:lde 6 h~vln~ a relative vlscosLty between 2.1 ~n~l 3.~; polyamide 12 having a relative viscosity between 1.7 and 21.:l; and polyethylenetere-phthalate having a relative viscosity above 1.6; and soft polyvinyl chlorlde.
Polyvinyl chloride is preferred as the molten component.
The following considerations, inter alia, govern the selection of , .
'~ polymers.
~ ~ A low melt viscosity improves the adhesion so that much .
~ 10 more fiber nuclei are formed than in the case of a high melt , .
viscosity.
A molten material at a high temperature results in a lower melt viscosity so that the f iber-drawing time is prolonged, and ., -, .
i this prolongation provides for a longer time in which measures ;~ to control the process can be carried into effect.
.,' , ,.
~, The mechanism of the fiber forming process oE the lnvention `~; is that the forces of cohesion in the polymer cause the solidified ' fibers to visibly constrict near their point of contact wlth the heatable drawiLIg surface causing tearing and breaking apart at a distance from the drawing surface. The distance traveled by ., ~ .
the substrate prior to deflection depends on the curvature of the ~ heatable drawing surface. Within the scope of the invention, the ;; , distance traveled may amount to between a few millimeters and some ~ centimeters, preferably between 5 and 50 millimeters and up to an ~. J
~, upper limit of about 100 millimeters. As a result oE the ~ .
deflection of the substrate, the root portion oE the fiber is withdrawn from the intense action of the flowing molten fluid so that this portion is extended to a smaller thickness and a ~ ~1 longitudinal malecular orientation is imparted to the fibers t;,: , ~; ~
il/Jct -6-'f'~ 8 , . . .
fore the t-ips of the fibers ars~ torn Erom the heated dr~wing surface near thelr upper encls.
It has been found to be necessary to provide for a - proportionality or approxlmate:ly proportionality between the solidification ra~e of the polymer and the flbers' temperature.
Thus, if the solidificat:Lon ~s too rapid, the molten polymer is torn apart only as coarse fibers so that flakes rather than the desired fibers would be formed from molten material of high viscosity, whereas only thin filaments having bulblike roots could be pulled from molten polycondensates of low viscosity.
For this reason, the process of the invention is applied -~ primarily to polymerization products which have a low molecular weight and, correspondingly, a high melt index.
On the other hand, the use of highly crystalline high ` polymers, particularly of polycondensates of such polymers, is rendered difficult by the high crystallization rate. It has thus proved desirable to use such high polymers ln the form of copolymers or in polyblends together with other polymers so that the tendency to crystalli~e is reduced and the solidification range is increased. For instance, pure polyoxymethylene ~POM) when used alone results in thin and brittle Eibers but, in admixture with 10% by weight low density polyethylene, it can be .
used to produce a useful product having a catsklnlike feel or hand. An admixture oE polyamides Erom POM also improves the fiber-forming process. On the other hand, pure Polyamlde 6 (PA 63 when used alone results in thin fibers which look like . . :
cotton-wool. If this material is copolymerized with Polyamide 66 (PA 66) or with ethylene or is mlxed with 12% by weight poly-me~hylmethacrylate of low viscosity, a fabric-like textile plush . .
; ` 3 0 ; :, . . .
~,.
7 - :
... ,~,~ ,. . - ~
~: ` - , . . .
: ,. . . .
::. , ., . , . . , ~ . , . , ::
n be produc~cl. ~lix~lrcs oE PolyaolLde 6 (PA 6) with Polyamlde 11 (PA 11) or PA 12 or P~ 6.10 exhlblt a wlder sol:Ldlflcatlon range; in thcse cases, ~he .;econd component may be added in an amount ~Ip to 30% by ~eight. Other mixtures which have given favorable results comprlse saturated polyesters, such as poly-ethyleneterephthalate or polybutyleneterephthalate, together wlth Polyamlde 6, PA 11, PA 12 or copolyamides. The fiber-forming process and the quality of the product can be improved if such polyblends are addltionally cross-linked as they are processed.
; 10 The use of pure polypropylene (PP) having an MFI at 190/2 of 20 normally results in a fiber having a thickness of, e.g. 10 microns. The addition of Polyamide 12 reisult~ in increasingly ; thinner flbers until the proportlon of PA 12 is so large that a structure like that of cotton-wool is obtained.
: , :
Inorganlc substances, such as flllers and dyestuffs or additives have a high thermal conductivity, and when used in the , polymer layer accelerate solidification during the formation of fibers. In most cases, such fibers tear off sooner. In the `
process according to the invention, the use of such substances in a concentration up to 50% by weight is facilitated by the use ., . :
-~ of polymers having a low melt viscosity.
;~ ~An important feature of the process of the invention is that the polymer substrates are deflected by at least 5 and at most 90~ from their direction of travel along the drawing surface.
;~ :
The degree of deflection of the substrate is chosen mainly by consideration of the nature of the polymer and of the desired quality of the product. Where mainly linear polymers are used, a larger angle of deflection is preferred than with branched , . ~, polymers. Optimum results are to be expected if, in the , "
.~', ,, ~.
jl/~5 -8-f 8~l3 rroce~sing of polyoleflns (otller than low densLty polyethylene), the angles of deflection lie bctween 30 a~d 80 whereas ln the processing of low densLty polyethylene they slloul~l lie in a range between 10 and 60. Ill the process:Lng of saturat:ed linear polyesters, the selected angles lle wlthin the range of 50 a~d 80 and in the processing of cellulose acetate and cellulose acetate¦butyrate, this selected range if between 20 and 60.
Polyblends can be processed with good results if the angle of deflection, also known as ~he drawing angle, i9 at least 80~.
The polymer film is supplied to the fiber-forming region at a temperature which i.s above, and preferably considerably above its melting point; i.e., at a temperature of 10-200~C above the ~` melting point. This temperature melts the polymers closest to the melting zone.
Another feature is that, for example, a small soft mass of ,j polyamide in which there are wads o~ polyethylene or polyamide 6.6 ~1 which is compressed with polymethylmethacrylate, can be used in the invented process.
BRI~F DESCRIPTION OF THE DRAWING
Figure 1 is a magnified representation of the fiber drawing - process in which a single film has been applied;
, Figure 2 shows the fiber drawing process with two films each respectively representing one of the two polymer layers o~
thecomposite film; and Figure 3 shows the fiber drawing process with the application of three polymer layers.
DESCRIPTION OF PREFERRED EMBODIMENT
Figure 1 represents a heatable drum or drawing surface 10.
The drawing surface moves in the direction of the arrow 12. The ; 30 ~3 " ". , .
jl/lo _9_ / -~- . . . .
~ ly~ner f :i~.m 11 runs first throu~h a meltlng zone 13 in whicll it is mel~ed as is indlca~ed by ~lle arrows li~ and the dotLed line~
15. As was prcv;ously stated, no more than 2/3 of E:Llm 11 is per~itted to be melted. The un~elted portion of Eilin 11 ls substrate 16. The polymer passes througll thls ~one layerwise in a molten condition. The drawlng surface 10 ls heated above the melting po:Lnt of the polymer. The substrate 16 is not melted.
Next to the melting zone 13 ls the actual fiber formation ~one 17. At the beginning of this zone the fllm 11 shows a more solid consistency on the substrate 16 as the substrate is drawn away from the drawing surface 10 by the deflector 29 under simultaneous cooling. In the preferred embodiment, secondary cooling is used and is arranged as backside cooler 40, which acts to prevent the substrate 16 from completely melting and consequently breaking under the stress caused by drawing. By drawing away the substrate 16, the fibers 18 are formed on the proximate surface of substrate 16. These fibers are formed as a consequence of the temperature drop which resulted,as the molten polymer was torn away from the heat,ed drawing surface 10. By this means, individual torn points of the fibers 18 are formed on the drawing surface 10. After pulling away and deflecting the molten polymer and the substrate, a residue film 19 adheres upon the drawing surface 10. The deflector 29 is so constructed that it can simultaneou~ly provide for cooling of the residue film. Also a cooling apparatus operates in the directicn of arrow 39 directly inside ~h~ drawing angle between the drawn film and the drawing surface. Through the cooling as indicated by arrow 39, the nascent fibers 18 are ... .
', stabilized so that they form a continuing fiber coating on the ", substrate 16. The individual fibers 18 are firmly and durably :" :.
~;, 30 , ,,~
~ ~ 1 /J ~ - 1 o - - ~ ~
: . :: , . . ; . . . .. ,`, , .~ . ,",, . , . . ,., . . ~ ,......... .
- l~oun(l witll the substrate 16. The len~th and qucllity of ~he fibers 18 can be a:Ltered by adjusting the intensity of the coollngl by al~er:ing the def:Lecting angle, by challglllg the velocity of the drawing surface and by controlling the temperature of the drawing surface. Also c~ntributing to the quality and the length of the fibers 18 are the coolln~ system and the drawing tension.
Similarly, the depth of melting can be controlled, for example, by choosing the thickness of the layering. In order to obviate the problem of completely melting both the substrate and molten component, in practice one varies the depth of the layers which are ; passed through the melting æone.
Figure 2 shows two films, 20 and 21, which are present on the drawing surface 10. Films 20 and 21 may be different polymers ~ or they may be polymer isomer which have different melting points i or differerlt meltlng viscosities. As is shown by the dotted line 25 which illustrates the depth oE the melting, film 20 has com-petely melted in the melting zone 23, while there is stlll an ~, ~
unmelted residue of film 21, which is substrate 26. The melted ; polymer components are, for example, mixed with each other intensively through the influence of the shearing stress 22. In the fiber formation zone 27, a good union of both film polymers is achieved. Next, fibers 28 are formed. The properties of fibers 28 will be dependebt on how much of the lower film 21 is melted and, therefore, mi~ed wlth the molten polymer of the upper film 20.
Figure 3 depicts a third modification. Figure 3 shows the drawing surEace 10 with 3 polymer Eilms 30, 31 and 32, respe.ctively.
Three polymers, which could be different polymers, form miY~ed ~ibers because fllms 30 and 31 melt completely in the melting ' ~ zone while a part of the third fi.tm 32 is melted. The substrate , . ..
~,,, jl/Jo ,i: ; :
7~
is the unmeLted res-ldue of film 32. In the fiber formatlon zone 37, the mixed fibers 38 are drawn. Tlle mixed fibers 38 consist of a mixture of the polymers of f il7ns 30 and 31. By ad~usting the melting dep~h (see dotted line 35) one can achieve inclusion of a definLte part of the third polymer fllm 32.
Similarly, adj-lstments can be made which will preclude inclusion of any polymer of film 32 in the polymer mixture (of layers 30 and 31) which will form the fibers. Such a process makes it possible to utilize special physical properties, such as adhesive or binding properties, of the polymer of film 32, such special qualities can be adjusted to meet the unique requirements of utility for special cases of application. A cooler which is used for the production of the fiber nap is indicated through ` the arrow 39. By using this cooler, immediate stabilization of the nascent Eibers is assisted. The melting roller 10 can be ;`l replaced with another customary melting apparatus such as a heatable conveyor belt installation.
With the invented process, one can produce thermoplastic webs, substrates and sheets having fibrous surfaces; previously, this was not feasible. According to what was well-known in the prior art regarding the operation of processes of extrusions or spreading vent nozzles, blending could only be produced with difficulty if it could b~ produced at all.
The process of the invention is especially suitable Eor the production of new artlcles which could not be produced .. . .
feasibly by the prior art. Polymer webs, substrates or sheets -have always had a smooth glossy finish which was maximized by calenders which transformed the surfaces. According to the present invention, these films, sheets and webs can be produced ~. ;. .
'". ''' ~ :
o -12-economlcal:Ly with velour, plusll or pel~ ke surfaces. Further-..lore, these r~sults can be procluccd o~tt of one and the same meltable matcrlal :Ln ~n economical process wlthout the need of either any mater:ial in addltLon to the molten polymer component and the polymer snbstrate or more steps in ~he process.
Such a new mater:lal opens the previously-known film, sheets, and web materials to completely new possibilities. For example, this invention could be applied to decorated regions, pouched articles, floor, wall or celling overlays, for packaging, for outer clothing, for cars, power propelled vehicles, trailers, boat building, shoes and stuffed animals. Furthermore, numerous variations or after treatments can be made to the invented :~ , process such as stamping, shearing, embossing, friezing or printing.
This economical process of production by a systematic operation without the requirement of a non-polymeric material will have, for the seller, lmportant favorable eEfects on the price structure. This effect will, of course, be important for a great volume of sales. A further important modification is the independence of the products produced by the claimed invention from the fiber market. Furthermore, another advantage is that ~` the quality in form of the produc~s of the present invention can . ............. .
be determined by the operator ~f he makes simple adjustments.
Using the apparatus as shown in Figure 3, film 30 is polyamide 6 with a melting viscosity oE 2.1 to 3 b~, film 31 is polyethylene 190/2 from 10 to 300 g./10 minutes and Eilm 32 is polyamide 6 with a melting viscosity of 2.1 to 3.4. The thickness of each film is 50 microns. Films 30 and 31 are supported by film ' ,:j',' 32 which acts as a substrate. Films 30 and 31 encircle the ,.
:.
~ /J~ : -13- ~ ~
~awing surface 10 as f~lm 32 :i5 dra~/n. The me:Ltlng zone 17 is on the drawing surEace L0. Zone 17 :Lncludes the areas of the drawing surface ln wh:lch the temperature i.5 about 240C - a temperature wh:lch ls larger than the melting points of both polyamlde 6 and polyethy:lene 190/2.
Film 30 is completely melted. The temperature is also in excess of the meltlng point of polyethylene 190/2; film 31 completely melts. A part of the substrate - film 32 (Yolyamide 6) is melted. Because of the use of a backside cooler 40, film 32 melts only to a depth indicated by arrows 35. No more than 2/3 of film 32 is melted; melting more than 2/3 would risk breakage of the substrate because of drawing tension. ThereEore, at least a 20 micron thickness of film 32 must remain unmelted. The depth of melting can be controlled for example by regulating the amount of heat ~ransferred from the melting zone to the proximate solid film. Molten polymer still covers film 32. The deflector 29 guides film 32 and its covered surface away from the heated drawing surface. The nascent fibers are then stabilized by cooling - air which is blown in the direction oE arrow 39 from a cooler. The ;
fibers are strongly attached to the polyamide ~ substrate.
-~. Finally, the fibrous product is removed from the apparatus.
.. ..
.
" , .
. .
;' ' :~ .
~, 3 ', 30 , ~ ;, , ~, ,., ,, ~ , ..
~ 14-!~ ~'- . ! ; ' '
A process for the productlon of shee~ products with fibrous surfaces has been known in the prior art in which the sheet products are composed of a substrate which is covered with a thermoplastlc fiber nap. The substrate acts as a carrier. This process presses polymer foils on a heated drum until they begin to melt. As the molten polymer foils adhere to the drum and to the substrate, the substrate is drawn off with a simultaneous cooling of the molten film. Following this drawing process, a plurality of uniform fibers are formed from ~the molten polymer. These fibers adhere to the substrate.
This process produces surfaces which have textures of velour, plush or pelt (see, for e~ample, U.S. Patent No. 3,708,565).
-~ The prior art required a polymer-unrelated substrate made .''! out of textile fabric, paper or fleece. However, many enterprises required plastic webs or films with fibrous outer surfaces with substrates which consisted totally of polymeric materials. It is desirable that a substrate be produced out of fiber naps in " ::
which the fibers combine the positive properties of several polymers which have been amalgamated within the fiber.
Alternatively, it ~s desirable that the fibers should consist of another polymer, similar to the substrate.
SUMMARY OF THE INVENTION
An ob~ect of this invention is to provide a process for the production oE a polymer substrate with a Eibrous surface.
In one particular aspect the present invention provides a process for producing~polymeric substrates.having fibrous sur~aces comprising the steps of: drawing a precursor polymeric .-j l /J o - 2 -. .. . . . . . . .. . . . .
.. , . ,, .~ , , , . .. ~ ... ;;.. . .
J ~
~-`lm al~ng and i~ contact with a drawlng surEace having a melting zone; ~leatlng th~ pr~cur~or polymeric film :in the me:Lting zone to melt the surface adjacent the drawing surface and yield an unmelted substrate covered with a film of molten po:Lymerlc component; and deElec~ing the unme:Lted substratecovered with the fllm of molten polymeric component from the drawing surface while simultaneously cooling the molten component, whereby fibers are formed which are strongly bound to the surface of the substrate.
10Previous to this invention, processes which involved the use of calendars or extrusion were known in the prior art, but were characterized by the great difficulty or the impossibility - of amalgamating or compounding polymers.
DETAILED DESCRIPTION OF THE INVENTION
; According to the process of this invention, a polymer film with a thickness of at least 50 mlcrons, and preferably . 150 microns, is applied to a heated drawing surface upon which the film will cling until drawn away. Part of the film will melt and cove~ the unmelted film or substrate. The unmelted :.......................................................................... :
substrate may be half of the total film thickness. For example, if a thickness of 50 microns is used, then not more than 2/3 of the polymer (30 microns) is to be melted. Otherwise there is too great a risk of breaking or tearing the substrate as it is being drawn away from the heated drawing surEace. Fo]lowing melting, the nascen~ Elbers are drawn away Erom the drawlng surface and stabilized under simultaneous cooling. As a result the melted part of the film is detached from the heated surface thus commensing formation of a fiber nap. The unmelted part of :, .
the film is the substrate for the newly formed fiber nap. This : j , ~ jlt~ -3-u~
~iber nap adh~res very strong:Ly to the proxlmate surface oE the substrate.
~ lso thls inventlon of.Eers a possihility of making the film as a compos:ite with 2 or more diEferent polymers layered upon a substrate cons:Lsting of another polymer~ These films are made by using polymers with distinctive melting polnts and/or melting viscosities. The total thickness of the combined polymers in .` the film should be at least 50 microns, and preferably 100 microns.
The composite ilm is then applied to the heated drawing surface.
In the composite film, a polymer with the lowest melting point and/or lowest melting viscosity is deposited so that it will be ~ closest to the heated drawing surface. This invention provides .~ for a relatively uniform mixture of fibers by mixing of the molten polymers. Following the melting of the desired portions of the film, intimate mixing is assisted by the shearing stress which is formed between the unmelted substrate and the heated : drawing surface during drawing.
This.invention can be further modified such that two or more ,- . .
films of different polymers are applied successively on the ` 20 drawing surface, rather than simultaneously. Still further, .:,. this invention makes it possible to draw one of two or more .. ~. -.
::` different layered polymers, which comprise the composite film, upon the heated drawlng surface, and then to melt and pull the ~ layer away from the heated drawing surEace causing the formation ': `:' ` of homogeneous or heterogeneous fiber naps which adhere on the ~ unmelted film substrate.
This modification of the invention makes po~sible very simple operations for the production of polymer substrates with fibrous . surfaces. Of all the horizontal polymer layers present, the ~:.
.: 30 '' ~ ` `.~ , , .
: ~ j 1/JG _4_ ~
.~- . . . : : . ,: .: . . - . , ~ , , ' ,: ' . . :'' ' ' -' : , . ' ~ "" '': ' ' : . , 'f81~3 ~ibers c~re ~ormed only out of the me:Lted polymer layer whicll is, for exampIe, proximate ~o tlle heated drawing xurface.
Another mo~lfLcation provides for the addltion of polymers ln the form of particulate matter, such as granules or powder, upon the polymer substrate.
An essentlal characterlstic of the inventlon is that ~ the nascent fibers are cooled until they are hardened, ; stabili~ed an~ solidified. The invention provides for cooling which operates within the drawing angle, which is , .
between the unmelted film residue which forms the substrate and the drawing surface. Air cooling is preferable. It may ~.
be advantageous to conduct secondary cooling of the substrate on the back side which is opposite the side to which the fibers adhere. Also with secondary cooling, one can prevent single or combined films from completely melting through.
. ~, , The cooling may, indeed, take place along with all of the steps of feeding the film, for example by means of back side coolers, or it may take place only in a single zone.
Polymers which have in the molten state a low viscosity are suitable as a meltable thermoplastic Eilm andlor as components .: , of a`composite film and as the substrate include, inter alia:
polyethylene having a MFI 190/2 of 10-300 grams/10 minutes;
ethylene/vinyl acetate having a MFI 190/2 above 10 grams/10 minutes; polypropylene having a MFI 190/5 of 10-70 grams/10 ;, .
minutes; polymethylmethacry:late havililg a MFI 2:lO/10 above 10 , grams/10 minutes, cellulose acetate, cellulose acetate-butyrate, and cellulose propionate, CA, CAB, CP having a MiFI 190/2 about ~ `
;! 8; polyoxymethylene having a MFI 190/2 above 13 grams/10 minutes;
polyvinyl chloride/acetate having a K value below 60 and ~,~
J o -5-~`.
C taining ~It least 15% plasticizer, polyam:lde 6 h~vln~ a relative vlscosLty between 2.1 ~n~l 3.~; polyamide 12 having a relative viscosity between 1.7 and 21.:l; and polyethylenetere-phthalate having a relative viscosity above 1.6; and soft polyvinyl chlorlde.
Polyvinyl chloride is preferred as the molten component.
The following considerations, inter alia, govern the selection of , .
'~ polymers.
~ ~ A low melt viscosity improves the adhesion so that much .
~ 10 more fiber nuclei are formed than in the case of a high melt , .
viscosity.
A molten material at a high temperature results in a lower melt viscosity so that the f iber-drawing time is prolonged, and ., -, .
i this prolongation provides for a longer time in which measures ;~ to control the process can be carried into effect.
.,' , ,.
~, The mechanism of the fiber forming process oE the lnvention `~; is that the forces of cohesion in the polymer cause the solidified ' fibers to visibly constrict near their point of contact wlth the heatable drawiLIg surface causing tearing and breaking apart at a distance from the drawing surface. The distance traveled by ., ~ .
the substrate prior to deflection depends on the curvature of the ~ heatable drawing surface. Within the scope of the invention, the ;; , distance traveled may amount to between a few millimeters and some ~ centimeters, preferably between 5 and 50 millimeters and up to an ~. J
~, upper limit of about 100 millimeters. As a result oE the ~ .
deflection of the substrate, the root portion oE the fiber is withdrawn from the intense action of the flowing molten fluid so that this portion is extended to a smaller thickness and a ~ ~1 longitudinal malecular orientation is imparted to the fibers t;,: , ~; ~
il/Jct -6-'f'~ 8 , . . .
fore the t-ips of the fibers ars~ torn Erom the heated dr~wing surface near thelr upper encls.
It has been found to be necessary to provide for a - proportionality or approxlmate:ly proportionality between the solidification ra~e of the polymer and the flbers' temperature.
Thus, if the solidificat:Lon ~s too rapid, the molten polymer is torn apart only as coarse fibers so that flakes rather than the desired fibers would be formed from molten material of high viscosity, whereas only thin filaments having bulblike roots could be pulled from molten polycondensates of low viscosity.
For this reason, the process of the invention is applied -~ primarily to polymerization products which have a low molecular weight and, correspondingly, a high melt index.
On the other hand, the use of highly crystalline high ` polymers, particularly of polycondensates of such polymers, is rendered difficult by the high crystallization rate. It has thus proved desirable to use such high polymers ln the form of copolymers or in polyblends together with other polymers so that the tendency to crystalli~e is reduced and the solidification range is increased. For instance, pure polyoxymethylene ~POM) when used alone results in thin and brittle Eibers but, in admixture with 10% by weight low density polyethylene, it can be .
used to produce a useful product having a catsklnlike feel or hand. An admixture oE polyamides Erom POM also improves the fiber-forming process. On the other hand, pure Polyamlde 6 (PA 63 when used alone results in thin fibers which look like . . :
cotton-wool. If this material is copolymerized with Polyamide 66 (PA 66) or with ethylene or is mlxed with 12% by weight poly-me~hylmethacrylate of low viscosity, a fabric-like textile plush . .
; ` 3 0 ; :, . . .
~,.
7 - :
... ,~,~ ,. . - ~
~: ` - , . . .
: ,. . . .
::. , ., . , . . , ~ . , . , ::
n be produc~cl. ~lix~lrcs oE PolyaolLde 6 (PA 6) with Polyamlde 11 (PA 11) or PA 12 or P~ 6.10 exhlblt a wlder sol:Ldlflcatlon range; in thcse cases, ~he .;econd component may be added in an amount ~Ip to 30% by ~eight. Other mixtures which have given favorable results comprlse saturated polyesters, such as poly-ethyleneterephthalate or polybutyleneterephthalate, together wlth Polyamlde 6, PA 11, PA 12 or copolyamides. The fiber-forming process and the quality of the product can be improved if such polyblends are addltionally cross-linked as they are processed.
; 10 The use of pure polypropylene (PP) having an MFI at 190/2 of 20 normally results in a fiber having a thickness of, e.g. 10 microns. The addition of Polyamide 12 reisult~ in increasingly ; thinner flbers until the proportlon of PA 12 is so large that a structure like that of cotton-wool is obtained.
: , :
Inorganlc substances, such as flllers and dyestuffs or additives have a high thermal conductivity, and when used in the , polymer layer accelerate solidification during the formation of fibers. In most cases, such fibers tear off sooner. In the `
process according to the invention, the use of such substances in a concentration up to 50% by weight is facilitated by the use ., . :
-~ of polymers having a low melt viscosity.
;~ ~An important feature of the process of the invention is that the polymer substrates are deflected by at least 5 and at most 90~ from their direction of travel along the drawing surface.
;~ :
The degree of deflection of the substrate is chosen mainly by consideration of the nature of the polymer and of the desired quality of the product. Where mainly linear polymers are used, a larger angle of deflection is preferred than with branched , . ~, polymers. Optimum results are to be expected if, in the , "
.~', ,, ~.
jl/~5 -8-f 8~l3 rroce~sing of polyoleflns (otller than low densLty polyethylene), the angles of deflection lie bctween 30 a~d 80 whereas ln the processing of low densLty polyethylene they slloul~l lie in a range between 10 and 60. Ill the process:Lng of saturat:ed linear polyesters, the selected angles lle wlthin the range of 50 a~d 80 and in the processing of cellulose acetate and cellulose acetate¦butyrate, this selected range if between 20 and 60.
Polyblends can be processed with good results if the angle of deflection, also known as ~he drawing angle, i9 at least 80~.
The polymer film is supplied to the fiber-forming region at a temperature which i.s above, and preferably considerably above its melting point; i.e., at a temperature of 10-200~C above the ~` melting point. This temperature melts the polymers closest to the melting zone.
Another feature is that, for example, a small soft mass of ,j polyamide in which there are wads o~ polyethylene or polyamide 6.6 ~1 which is compressed with polymethylmethacrylate, can be used in the invented process.
BRI~F DESCRIPTION OF THE DRAWING
Figure 1 is a magnified representation of the fiber drawing - process in which a single film has been applied;
, Figure 2 shows the fiber drawing process with two films each respectively representing one of the two polymer layers o~
thecomposite film; and Figure 3 shows the fiber drawing process with the application of three polymer layers.
DESCRIPTION OF PREFERRED EMBODIMENT
Figure 1 represents a heatable drum or drawing surface 10.
The drawing surface moves in the direction of the arrow 12. The ; 30 ~3 " ". , .
jl/lo _9_ / -~- . . . .
~ ly~ner f :i~.m 11 runs first throu~h a meltlng zone 13 in whicll it is mel~ed as is indlca~ed by ~lle arrows li~ and the dotLed line~
15. As was prcv;ously stated, no more than 2/3 of E:Llm 11 is per~itted to be melted. The un~elted portion of Eilin 11 ls substrate 16. The polymer passes througll thls ~one layerwise in a molten condition. The drawlng surface 10 ls heated above the melting po:Lnt of the polymer. The substrate 16 is not melted.
Next to the melting zone 13 ls the actual fiber formation ~one 17. At the beginning of this zone the fllm 11 shows a more solid consistency on the substrate 16 as the substrate is drawn away from the drawing surface 10 by the deflector 29 under simultaneous cooling. In the preferred embodiment, secondary cooling is used and is arranged as backside cooler 40, which acts to prevent the substrate 16 from completely melting and consequently breaking under the stress caused by drawing. By drawing away the substrate 16, the fibers 18 are formed on the proximate surface of substrate 16. These fibers are formed as a consequence of the temperature drop which resulted,as the molten polymer was torn away from the heat,ed drawing surface 10. By this means, individual torn points of the fibers 18 are formed on the drawing surface 10. After pulling away and deflecting the molten polymer and the substrate, a residue film 19 adheres upon the drawing surface 10. The deflector 29 is so constructed that it can simultaneou~ly provide for cooling of the residue film. Also a cooling apparatus operates in the directicn of arrow 39 directly inside ~h~ drawing angle between the drawn film and the drawing surface. Through the cooling as indicated by arrow 39, the nascent fibers 18 are ... .
', stabilized so that they form a continuing fiber coating on the ", substrate 16. The individual fibers 18 are firmly and durably :" :.
~;, 30 , ,,~
~ ~ 1 /J ~ - 1 o - - ~ ~
: . :: , . . ; . . . .. ,`, , .~ . ,",, . , . . ,., . . ~ ,......... .
- l~oun(l witll the substrate 16. The len~th and qucllity of ~he fibers 18 can be a:Ltered by adjusting the intensity of the coollngl by al~er:ing the def:Lecting angle, by challglllg the velocity of the drawing surface and by controlling the temperature of the drawing surface. Also c~ntributing to the quality and the length of the fibers 18 are the coolln~ system and the drawing tension.
Similarly, the depth of melting can be controlled, for example, by choosing the thickness of the layering. In order to obviate the problem of completely melting both the substrate and molten component, in practice one varies the depth of the layers which are ; passed through the melting æone.
Figure 2 shows two films, 20 and 21, which are present on the drawing surface 10. Films 20 and 21 may be different polymers ~ or they may be polymer isomer which have different melting points i or differerlt meltlng viscosities. As is shown by the dotted line 25 which illustrates the depth oE the melting, film 20 has com-petely melted in the melting zone 23, while there is stlll an ~, ~
unmelted residue of film 21, which is substrate 26. The melted ; polymer components are, for example, mixed with each other intensively through the influence of the shearing stress 22. In the fiber formation zone 27, a good union of both film polymers is achieved. Next, fibers 28 are formed. The properties of fibers 28 will be dependebt on how much of the lower film 21 is melted and, therefore, mi~ed wlth the molten polymer of the upper film 20.
Figure 3 depicts a third modification. Figure 3 shows the drawing surEace 10 with 3 polymer Eilms 30, 31 and 32, respe.ctively.
Three polymers, which could be different polymers, form miY~ed ~ibers because fllms 30 and 31 melt completely in the melting ' ~ zone while a part of the third fi.tm 32 is melted. The substrate , . ..
~,,, jl/Jo ,i: ; :
7~
is the unmeLted res-ldue of film 32. In the fiber formatlon zone 37, the mixed fibers 38 are drawn. Tlle mixed fibers 38 consist of a mixture of the polymers of f il7ns 30 and 31. By ad~usting the melting dep~h (see dotted line 35) one can achieve inclusion of a definLte part of the third polymer fllm 32.
Similarly, adj-lstments can be made which will preclude inclusion of any polymer of film 32 in the polymer mixture (of layers 30 and 31) which will form the fibers. Such a process makes it possible to utilize special physical properties, such as adhesive or binding properties, of the polymer of film 32, such special qualities can be adjusted to meet the unique requirements of utility for special cases of application. A cooler which is used for the production of the fiber nap is indicated through ` the arrow 39. By using this cooler, immediate stabilization of the nascent Eibers is assisted. The melting roller 10 can be ;`l replaced with another customary melting apparatus such as a heatable conveyor belt installation.
With the invented process, one can produce thermoplastic webs, substrates and sheets having fibrous surfaces; previously, this was not feasible. According to what was well-known in the prior art regarding the operation of processes of extrusions or spreading vent nozzles, blending could only be produced with difficulty if it could b~ produced at all.
The process of the invention is especially suitable Eor the production of new artlcles which could not be produced .. . .
feasibly by the prior art. Polymer webs, substrates or sheets -have always had a smooth glossy finish which was maximized by calenders which transformed the surfaces. According to the present invention, these films, sheets and webs can be produced ~. ;. .
'". ''' ~ :
o -12-economlcal:Ly with velour, plusll or pel~ ke surfaces. Further-..lore, these r~sults can be procluccd o~tt of one and the same meltable matcrlal :Ln ~n economical process wlthout the need of either any mater:ial in addltLon to the molten polymer component and the polymer snbstrate or more steps in ~he process.
Such a new mater:lal opens the previously-known film, sheets, and web materials to completely new possibilities. For example, this invention could be applied to decorated regions, pouched articles, floor, wall or celling overlays, for packaging, for outer clothing, for cars, power propelled vehicles, trailers, boat building, shoes and stuffed animals. Furthermore, numerous variations or after treatments can be made to the invented :~ , process such as stamping, shearing, embossing, friezing or printing.
This economical process of production by a systematic operation without the requirement of a non-polymeric material will have, for the seller, lmportant favorable eEfects on the price structure. This effect will, of course, be important for a great volume of sales. A further important modification is the independence of the products produced by the claimed invention from the fiber market. Furthermore, another advantage is that ~` the quality in form of the produc~s of the present invention can . ............. .
be determined by the operator ~f he makes simple adjustments.
Using the apparatus as shown in Figure 3, film 30 is polyamide 6 with a melting viscosity oE 2.1 to 3 b~, film 31 is polyethylene 190/2 from 10 to 300 g./10 minutes and Eilm 32 is polyamide 6 with a melting viscosity of 2.1 to 3.4. The thickness of each film is 50 microns. Films 30 and 31 are supported by film ' ,:j',' 32 which acts as a substrate. Films 30 and 31 encircle the ,.
:.
~ /J~ : -13- ~ ~
~awing surface 10 as f~lm 32 :i5 dra~/n. The me:Ltlng zone 17 is on the drawing surEace L0. Zone 17 :Lncludes the areas of the drawing surface ln wh:lch the temperature i.5 about 240C - a temperature wh:lch ls larger than the melting points of both polyamlde 6 and polyethy:lene 190/2.
Film 30 is completely melted. The temperature is also in excess of the meltlng point of polyethylene 190/2; film 31 completely melts. A part of the substrate - film 32 (Yolyamide 6) is melted. Because of the use of a backside cooler 40, film 32 melts only to a depth indicated by arrows 35. No more than 2/3 of film 32 is melted; melting more than 2/3 would risk breakage of the substrate because of drawing tension. ThereEore, at least a 20 micron thickness of film 32 must remain unmelted. The depth of melting can be controlled for example by regulating the amount of heat ~ransferred from the melting zone to the proximate solid film. Molten polymer still covers film 32. The deflector 29 guides film 32 and its covered surface away from the heated drawing surface. The nascent fibers are then stabilized by cooling - air which is blown in the direction oE arrow 39 from a cooler. The ;
fibers are strongly attached to the polyamide ~ substrate.
-~. Finally, the fibrous product is removed from the apparatus.
.. ..
.
" , .
. .
;' ' :~ .
~, 3 ', 30 , ~ ;, , ~, ,., ,, ~ , ..
~ 14-!~ ~'- . ! ; ' '
Claims (19)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for producing polymeric substrates having fibrous surfaces comprising the steps of:
(a) drawing a precursor polymeric film along and in contact with a drawing surface having a melting zone;
(b) heating the precursor polymeric film in the melting zone to melt the surface adjacent the drawing surface and yield an unmelted substrate covered with a film of molten polymeric component; and (c) deflecting the unmelted substrate covered with the film of molten polymeric component from the drawing surface while simultaneously cooling the molten component, whereby fibers are formed which are strongly bound to the surface of the substrate.
(a) drawing a precursor polymeric film along and in contact with a drawing surface having a melting zone;
(b) heating the precursor polymeric film in the melting zone to melt the surface adjacent the drawing surface and yield an unmelted substrate covered with a film of molten polymeric component; and (c) deflecting the unmelted substrate covered with the film of molten polymeric component from the drawing surface while simultaneously cooling the molten component, whereby fibers are formed which are strongly bound to the surface of the substrate.
2. A process as recited in Claim 1 wherein the precursor polymeric film is comprised of a single polymer or copolymer which is heated in the melting zone until as little as 1/3 of the film thickness remains unmelted as said substrate.
3. A process as recited in Claim 2 wherein the precursor polymeric film is at least 50 microns thick.
4. A process as recited in Claim 2 wherein the precursor polymeric film is 150 microns thick.
5. A process as recited in Claim 1 wherein the precursor polymeric film comprises a layer of polymer of lower melting point upon a layer of polymer of higher melting point arranged such that the layer of polymer of lower melting point is in contact with the drawing surface, and wherein the precursor polymeric film is heated in the melting zone until the polymer of lower melting point becomes a molten component and no more than 2/3 of the thickness of the polymer of higher melting point becomes a molten component, whereby the unmelted part of the polymer of higher melting point remains as said substrate.
6. A process as recited in Claim 5 in which the polymer of higher melting point has a thickness of at least 50 microns.
7. A process as recited in Claim 6 in which the polymer is 150 microns thick.
8. A process as recited in Claim 5 in which the polymer of lower melting point is in the form of particulate matter.
9. A process as recited in Claim 5 including cooling the side of the film remote from the drawing surface whereby complete melting of the polymer of higher melting point is precluded.
10. A process as recited in Claim 1 wherein the precursor polymeric film comprises a layer of polymer of lower melting viscosity upon a layer of polymer of higher melting viscosity arranged such that the layer of polymer of lower melting viscosity is in contact with the drawing surface, and wherein the precursor polymeric film is heated in the melting zone until the polymer of lower melting viscosity becomes a molten component and no more than 2/3 of the thickness of the polymer of high melting viscosity becomes a molten component, whereby the unmelted part of the polymer of higher melting viscosity remains as said substrate.
11. A process recited in Claim 1 wherein the precursor polymeric film comprises two or more different polymers, each with different melting points, deposited upon a polymeric substrate, and wherein said deposited polymers are melted in the melting zone.
12. A process as recited in Claim 11 in which up to 2/3 of the thickness of the polymeric substrate is also melted, while the unmelted polymeric substrate remains sufficiently strong to avoid tearing under drawing tension.
13. A process as recited in Claim 11 including cooling the side of the polymeric substrate remote from the drawing surface.
14. A process as recited in Claim 11 in which the deposited polymers are deposited simultaneously.
15. A process as recited in Claim 11 in which the deposited polymers are deposited successively.
16. A process as recited in Claims 12, 14 or 15, in which different colored polymers are deposited.
17. A process as recited in Claim 11 wherein the precursor polymeric film is formed by depositing a film at least 50 microns thick of polyamide 6 with a melting viscosity of 2.1 to 3.4 upon a film at least 50 microns thick of polyethylene having an MFI
of 190/2 from 10 to 300 g./10 minutes, and then depositing the polyamide 6 and polyethylene 190/2 films upon a film at least 50 microns thick of polyamide 6 with a melting viscosity of 2.1 to 3.4 whereby the polyethylene 190/2 film is between two polyamide 6 films, and wherein the precursor polymeric film is heated at a melting zone temperature of 240°C, whereby the polyamide 6 film which is most distant from the drawing surface is covered with a film of molten components after the 2 films closest to the melting zone are completely melted.
of 190/2 from 10 to 300 g./10 minutes, and then depositing the polyamide 6 and polyethylene 190/2 films upon a film at least 50 microns thick of polyamide 6 with a melting viscosity of 2.1 to 3.4 whereby the polyethylene 190/2 film is between two polyamide 6 films, and wherein the precursor polymeric film is heated at a melting zone temperature of 240°C, whereby the polyamide 6 film which is most distant from the drawing surface is covered with a film of molten components after the 2 films closest to the melting zone are completely melted.
18. A process as recited in Claim 17 in which no more than 2/3 of the thickness of the polyamide 6 film which is most distant from the drawing surface is also melted.
19. A process as recited in Claims 17 or 18 in which the thickness of each component film of the precursor polymeric film is 100 microns.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DEP2512772.4 | 1975-03-22 | ||
| DE19752512772 DE2512772A1 (en) | 1975-03-22 | 1975-03-22 | Thermoplastic webs with fibre pile - produced by partly fusing film and drawing off fibres and cooling them |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1087818A true CA1087818A (en) | 1980-10-21 |
Family
ID=5942187
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA248,472A Expired CA1087818A (en) | 1975-03-22 | 1976-03-22 | Method for the production of a polymer substrate with a fibrous surface |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JPS51114473A (en) |
| CA (1) | CA1087818A (en) |
| DE (1) | DE2512772A1 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5618583A (en) * | 1994-08-29 | 1997-04-08 | The Procter & Gamble Company | Sheet material having a fibrous surface and method of making the same |
| DE19538523A1 (en) * | 1995-10-06 | 1997-04-10 | Helmut Prof Dr Kaeufer | Biocompatible plastics, processes for their production and areas of application |
| DE102013109621B4 (en) * | 2012-11-19 | 2021-02-11 | Karlsruher Institut für Technologie | Process for producing a shaped body with a superhydrophobic surface and shaped body obtainable with this process and its use |
| DE102018004339A1 (en) | 2018-05-30 | 2019-12-05 | Karlsruher Institut für Technologie | Production process for the production of a shaped article with nanoprime, set for the production of a shaped article with nanopart and molded article with nanoprime |
-
1975
- 1975-03-22 DE DE19752512772 patent/DE2512772A1/en active Pending
-
1976
- 1976-03-10 JP JP2662176A patent/JPS51114473A/en active Pending
- 1976-03-22 CA CA248,472A patent/CA1087818A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| JPS51114473A (en) | 1976-10-08 |
| DE2512772A1 (en) | 1976-09-30 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4469543A (en) | Lamination of highly reinforced thermoplastic composites | |
| US5188778A (en) | Process for the surafce enhancement of articles of fibre reinforced plastics material | |
| US4044188A (en) | Stampable thermoplastic sheet reinforced with multilength fiber | |
| US5145626A (en) | Process for the continuous manufacture of thermomoldable thermoplastic composite materials | |
| JP3221749B2 (en) | Manufacturing method of composite products | |
| US4238266A (en) | Process of forming a glass fiber reinforced, stampable thermoplastic laminate | |
| US4258093A (en) | Molding nonwoven, needle punched fabrics into three dimensional shapes | |
| US4612238A (en) | Fiber reinforced multi-ply stampable thermoplastic sheet | |
| JP3068186B2 (en) | Fiber reinforced porous sheet | |
| US5407617A (en) | Method of forming latex-, PVC- and plasticizer-free foamed floor or wall coverings | |
| US4240857A (en) | Fiber reinforced multi-ply stampable thermoplastic sheet | |
| US4183889A (en) | Method for the production of a polymer substrate with a fibrous surface | |
| US4302269A (en) | Process of forming a fiber reinforced, stampable thermoplastic laminate | |
| US5154787A (en) | Method for making ceramic composite article | |
| CA1087818A (en) | Method for the production of a polymer substrate with a fibrous surface | |
| FR2625705A1 (en) | SHEET OF REINFORCED THERMOPLASTIC MATERIAL AND METHOD FOR PREPARING THE SAME | |
| US4000230A (en) | Process for producing sheeting having fibrous surface | |
| CA1132325A (en) | Fiber reinforced multi-ply stampable thermoplastic sheet | |
| US4065245A (en) | Apparatus for producing sheeting having a fibrous surface | |
| US5232771A (en) | Process for molding a fiberglass reinforced article | |
| CA1046220A (en) | Process for the production of pile surfaced articles from polyesters | |
| JPS62208914A (en) | Process for continuous manufacture of composite material sheet | |
| JPH04135743A (en) | Production of fiber composite sheet | |
| JP2646029B2 (en) | Molding materials and mixtures thereof | |
| JPH01308614A (en) | Continuous manufacture and device of heating moldable thermoplastic sheet reinforced |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |