CA1109383A - Stabilized fabrics - Google Patents
Stabilized fabricsInfo
- Publication number
- CA1109383A CA1109383A CA288,108A CA288108A CA1109383A CA 1109383 A CA1109383 A CA 1109383A CA 288108 A CA288108 A CA 288108A CA 1109383 A CA1109383 A CA 1109383A
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- Canada
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- layer
- fabric
- bonding
- web
- fibers
- Prior art date
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Abstract
Stabilized Fabrics Abstract of the Disclosure Stabilized fabrics include a woven, knitted or tufted fabric layer bonded to a stabilizing layer of staple or continuous fila-ment fibers by an air-permeable bonding layer of thermoplastic material. The bonding is carried out under heat and pressure suf-ficient to melt the bonding layer and have it penetrate into the fibers of both the fabric layer and the stabilizing layer.
Description
3~3 This invention relates to mult:i-ply textile webs or stabilized fabrics and particularly to ~abrics having certaln stabilizing structures bonded thereto to provide improved characteristics including dimensiona]
stability, breathability and improved seam strength. A process and apparatus for making the multi-ply textile webs are the subject of our copending Patent Application Serial Number 28~,107.
It is old in the art to stabilize certain fabrics by applying to the fabric a latex backing. While latex backing does stabilize such tabrics, it results in a product which lacks breathability, hot water washability, softness, and also is heavy and difficult to cllt and sew. Such latex sta-bilized fabrics, when used in upholstering, often require slip liners be-cause the rough surface of the latex backing catches on the padding.
Now in accordance with this invention there i5 provided a multi-ply textile web comprising a woven, knitted or tufted fabric layer, a sta-bilizing layer of staple fibers or continuous filaments, and an air-permeable bonding layer of thermoplastic material, wherein the bonding layer inter-connects the fabric layer and the stabilizing layer of staple fibers or continuous filaments by means of bonding zones, said bonding zones completely penetrating the fibers or filaments of the stabilizing layer and partially penetrating the fibers of the fabric layer.
The multi-ply textile web or stabilized fabric thus produced has improved dimensional stability, soft hand, high strength and seam slippage characteristics, high breathability, good drape and conformity, resistance to washing, improved durability and further is relatively easy to cut and sew.
The stabilized fabrlcs can be made by aligning the fabric so that the pattern or printed design is not distorted; advancing the fabric under tension to a bonding station; heating the thermoplastic netting or needle-punched film to its melt temperature; bonding the fabric, the melted netting or film, and the stabilizing web of staple or continuous filament fibers (or the fibers needle-punched into the netting or film) together under pressure sufficient a~3~3 to insure substantially com-plete penetration o~ the molten thcrmoplastic into the ~ibers of the sta~ilizing web or the needle-punched fibers and par-tial penetration into the fabric, and coo:ling the resulting composite struc-ture to effect hardening of the thermoplastic.
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~"d~ P~
~ ny woven, knittecl or tufted fabric can ~e st~bilized in ac cordance wlth this invention~ Typical fabr:ics that can be employed are Eabrics of cotton, linen, wool, silk, ju~e, or polypropylene, polyester, polyamide, rayon and acr~lic. The invention is partic-ularly advantageous for sta~ilizing loosely ~Joven fabrics. B~ the term "looselv woven fabric" is meant a fabric having a seam slip-page value of below 15 p~unds in both the rnachine and transver~e directions, as determined by the AsrrM D434 75 procedure. These fabrics can be stabilized to have a seam slippage value of at 10 least 25 pounds in both directions.
Any ther~oplastic netting or ~ilm material can be used in the practice of this invention. It is important, however, -that the stabili2ed fabric have breathability or air permeability.
Thus, the thermoplastic bonding layer mu~t have perforations or openings therethrough. A thermoplastic netting satlsfies this re-quire~;lent. However, a thermoplastic film can only be utilized if it is perforated, or if it is needle-punched to either a we~ of staple or continuous filament ~iber, to the fabric itself, or to both, the needle-punching providing the necessary air permeabil-20 ity. Typical thermoplastics from which said netting and filmmaterials can be made are polyethylene, polyvinyl chloriJe, amor-phous polyamides, thermoplaRtic polyurethanes, ethylene--vinyl acetate copolymers, ethylene-~aarylic acid copolymera, polyvinyli-dene chloride and its copolymers and a~rylic polymer~ and ~opolv-mers. Depending on the fabric to be ~tabil~zed, csrtain th~rmo-plastic materials will be more desirable than other~. For example, for stabili~ing polypropylene fabric~, it i~ de~irable that th~
~hermoplastic netting or ~ilm material have a ~o~taning point be-low about 130C. For othar ~abrics, ~u~h a~ cotton, wool, s~`lk, 30 linen, polyester, polyamide, rayon or acrylic, th~rmopla~tic n~t-ting or film materialg having so~ten~ng points up to a~out ~OO~C.
could ~e utilized, howe~r, it is pre~erable to u~e th~rm~plastic nettlng or film materLals having lower ~ofkening points. In gen~ ~
eral, it is des~ra~le t~at the netting ~e at lea~t 0,3 o~./sq. y~.
3~3 and the films be at least 1 mil in thickness to obtain the desired bonding.
Typical configurations of netting which can be used in the practice of this invention are shown by way of example in Figures 1 through 12. Pig-ure 1 shows in plan, a portion of an open network of thermoplastic material in sheet form, to an enlarged scale, comprising interwoven, spaced, parallel strands of circular section. Figure 2 shows in elevation the interwoven net-work of Pigure 1.
Figure 3 shows in plan, and Pigure ~ in elevation another open network of thermoplastic material in sheet form, to an enlarged scale, com- -prising spaced parallel strands of rectangular sections overlaying and made integral with similar strands at right angles thereto.
Pigure 5 shows in plan and Figure 6 shows in side elevation, another open network of thermoplastic material in sheet form, to an enlarged scale, comprising strands of rectangular section forming a network of squares with all the strands laying in one plane.
Figure 7 is a plan of a portion of an open network of a thermo-plastic material in sheet form, to an enlarged scale, comprising circular solid bosses connected by strands. Figure 8 is a sectional view of such bosses and aligned strands.
Pigure 9 shows in plan, and Pigure 10 in fragmentary perspective view, another open network of thermoplastic material of a type similar to that shown in Figures 7 and 8.
Pigure 11 shows in plan, and Figure 12 shows in side elevation, another open network of thermoplastic material in sheet form, to an enlarged scale, comprising a sheet or film having uniform size and uniformly spaced circular openings.
Pigure 13 is a schematic view illustrating the process and apparatus for making stabilized fabrics in accordance with the principles of this inven-tion.
Figure 1~ is a schematic view illustrating an alternative process and apparatus for making stabilized fabrics in accordance with the principles of this invention.
_ ~ _ ~ IG. 15 is a schematic view illustrat:incJ another al-terna-tive process ~nd apparatus for making stabilized fabrics in ac-cordance with th~ principles of this invention.
FIG. 16 is an en~arged cross~sectional view of a stabilized Eabric in accordance with the principles of this invention.
FIGS. 17A, 17B and 17C are enLarged cross-sectional views illustratlng a fabric layer, bonding layer and stabilizing layer before and a~ter need~e-punching, and the stabilized fabric re-sulting from the subsequent bonding.
FIGS. 18A, 18B and 18C are en:Larged cross-sectional view~
illustrating a fabric layer and bonding layer before and after needle punching, and the stabilized fabric resultiny from the subsequent bonding.
It wil] be readily apparent to those skilled in the art that innumerable other configurations of nettiny can be employed in the practice of this invention. The thermoplastic nets em-ployed in the practice of this invention can be formed in many ways, including molding, the laying of spaced strands or threads of desired cross-sections onto other similarly spaced strands or 20 threads arranged at a right angle to the first-mentioned spaced strands or threads and integrating the strands or threads at the crossing areas, punching holes or openings in sheets or films of thermoplastic material, or the weaving together of such strands or threads to form an open network. A preferred method of form-ing the nets is described in British Patent No. 914,489, pub-lished January 2, 1963.
In general, these thermoplastic nets will have up to ahout
stability, breathability and improved seam strength. A process and apparatus for making the multi-ply textile webs are the subject of our copending Patent Application Serial Number 28~,107.
It is old in the art to stabilize certain fabrics by applying to the fabric a latex backing. While latex backing does stabilize such tabrics, it results in a product which lacks breathability, hot water washability, softness, and also is heavy and difficult to cllt and sew. Such latex sta-bilized fabrics, when used in upholstering, often require slip liners be-cause the rough surface of the latex backing catches on the padding.
Now in accordance with this invention there i5 provided a multi-ply textile web comprising a woven, knitted or tufted fabric layer, a sta-bilizing layer of staple fibers or continuous filaments, and an air-permeable bonding layer of thermoplastic material, wherein the bonding layer inter-connects the fabric layer and the stabilizing layer of staple fibers or continuous filaments by means of bonding zones, said bonding zones completely penetrating the fibers or filaments of the stabilizing layer and partially penetrating the fibers of the fabric layer.
The multi-ply textile web or stabilized fabric thus produced has improved dimensional stability, soft hand, high strength and seam slippage characteristics, high breathability, good drape and conformity, resistance to washing, improved durability and further is relatively easy to cut and sew.
The stabilized fabrlcs can be made by aligning the fabric so that the pattern or printed design is not distorted; advancing the fabric under tension to a bonding station; heating the thermoplastic netting or needle-punched film to its melt temperature; bonding the fabric, the melted netting or film, and the stabilizing web of staple or continuous filament fibers (or the fibers needle-punched into the netting or film) together under pressure sufficient a~3~3 to insure substantially com-plete penetration o~ the molten thcrmoplastic into the ~ibers of the sta~ilizing web or the needle-punched fibers and par-tial penetration into the fabric, and coo:ling the resulting composite struc-ture to effect hardening of the thermoplastic.
- 2a -~X
~"d~ P~
~ ny woven, knittecl or tufted fabric can ~e st~bilized in ac cordance wlth this invention~ Typical fabr:ics that can be employed are Eabrics of cotton, linen, wool, silk, ju~e, or polypropylene, polyester, polyamide, rayon and acr~lic. The invention is partic-ularly advantageous for sta~ilizing loosely ~Joven fabrics. B~ the term "looselv woven fabric" is meant a fabric having a seam slip-page value of below 15 p~unds in both the rnachine and transver~e directions, as determined by the AsrrM D434 75 procedure. These fabrics can be stabilized to have a seam slippage value of at 10 least 25 pounds in both directions.
Any ther~oplastic netting or ~ilm material can be used in the practice of this invention. It is important, however, -that the stabili2ed fabric have breathability or air permeability.
Thus, the thermoplastic bonding layer mu~t have perforations or openings therethrough. A thermoplastic netting satlsfies this re-quire~;lent. However, a thermoplastic film can only be utilized if it is perforated, or if it is needle-punched to either a we~ of staple or continuous filament ~iber, to the fabric itself, or to both, the needle-punching providing the necessary air permeabil-20 ity. Typical thermoplastics from which said netting and filmmaterials can be made are polyethylene, polyvinyl chloriJe, amor-phous polyamides, thermoplaRtic polyurethanes, ethylene--vinyl acetate copolymers, ethylene-~aarylic acid copolymera, polyvinyli-dene chloride and its copolymers and a~rylic polymer~ and ~opolv-mers. Depending on the fabric to be ~tabil~zed, csrtain th~rmo-plastic materials will be more desirable than other~. For example, for stabili~ing polypropylene fabric~, it i~ de~irable that th~
~hermoplastic netting or ~ilm material have a ~o~taning point be-low about 130C. For othar ~abrics, ~u~h a~ cotton, wool, s~`lk, 30 linen, polyester, polyamide, rayon or acrylic, th~rmopla~tic n~t-ting or film materialg having so~ten~ng points up to a~out ~OO~C.
could ~e utilized, howe~r, it is pre~erable to u~e th~rm~plastic nettlng or film materLals having lower ~ofkening points. In gen~ ~
eral, it is des~ra~le t~at the netting ~e at lea~t 0,3 o~./sq. y~.
3~3 and the films be at least 1 mil in thickness to obtain the desired bonding.
Typical configurations of netting which can be used in the practice of this invention are shown by way of example in Figures 1 through 12. Pig-ure 1 shows in plan, a portion of an open network of thermoplastic material in sheet form, to an enlarged scale, comprising interwoven, spaced, parallel strands of circular section. Figure 2 shows in elevation the interwoven net-work of Pigure 1.
Figure 3 shows in plan, and Pigure ~ in elevation another open network of thermoplastic material in sheet form, to an enlarged scale, com- -prising spaced parallel strands of rectangular sections overlaying and made integral with similar strands at right angles thereto.
Pigure 5 shows in plan and Figure 6 shows in side elevation, another open network of thermoplastic material in sheet form, to an enlarged scale, comprising strands of rectangular section forming a network of squares with all the strands laying in one plane.
Figure 7 is a plan of a portion of an open network of a thermo-plastic material in sheet form, to an enlarged scale, comprising circular solid bosses connected by strands. Figure 8 is a sectional view of such bosses and aligned strands.
Pigure 9 shows in plan, and Pigure 10 in fragmentary perspective view, another open network of thermoplastic material of a type similar to that shown in Figures 7 and 8.
Pigure 11 shows in plan, and Figure 12 shows in side elevation, another open network of thermoplastic material in sheet form, to an enlarged scale, comprising a sheet or film having uniform size and uniformly spaced circular openings.
Pigure 13 is a schematic view illustrating the process and apparatus for making stabilized fabrics in accordance with the principles of this inven-tion.
Figure 1~ is a schematic view illustrating an alternative process and apparatus for making stabilized fabrics in accordance with the principles of this invention.
_ ~ _ ~ IG. 15 is a schematic view illustrat:incJ another al-terna-tive process ~nd apparatus for making stabilized fabrics in ac-cordance with th~ principles of this invention.
FIG. 16 is an en~arged cross~sectional view of a stabilized Eabric in accordance with the principles of this invention.
FIGS. 17A, 17B and 17C are enLarged cross-sectional views illustratlng a fabric layer, bonding layer and stabilizing layer before and a~ter need~e-punching, and the stabilized fabric re-sulting from the subsequent bonding.
FIGS. 18A, 18B and 18C are en:Larged cross-sectional view~
illustrating a fabric layer and bonding layer before and after needle punching, and the stabilized fabric resultiny from the subsequent bonding.
It wil] be readily apparent to those skilled in the art that innumerable other configurations of nettiny can be employed in the practice of this invention. The thermoplastic nets em-ployed in the practice of this invention can be formed in many ways, including molding, the laying of spaced strands or threads of desired cross-sections onto other similarly spaced strands or 20 threads arranged at a right angle to the first-mentioned spaced strands or threads and integrating the strands or threads at the crossing areas, punching holes or openings in sheets or films of thermoplastic material, or the weaving together of such strands or threads to form an open network. A preferred method of form-ing the nets is described in British Patent No. 914,489, pub-lished January 2, 1963.
In general, these thermoplastic nets will have up to ahout
2,000 openings per square inch, preferably from about 1~0 openinas per square inch to about 1,500 openings per square inch.
Where the netting or film is needled with staple fibers, the staple fihers are preferably from about 1 to about 20 denier and have a length of from about 1/2 to about 6 inches. Best re-sults are obtained when from about 0.3 oz./sq. yd. to about 2 oz./sq. yd. of staple fibers are ranaomly laid Otl the netting _ 5 _
Where the netting or film is needled with staple fibers, the staple fihers are preferably from about 1 to about 20 denier and have a length of from about 1/2 to about 6 inches. Best re-sults are obtained when from about 0.3 oz./sq. yd. to about 2 oz./sq. yd. of staple fibers are ranaomly laid Otl the netting _ 5 _
3~
,r filrn and neecllc-punchecl to an amount grealer thaJI ~5 pt~netra~
tions per square Lnch. If desired, contirluous fila~en-t fihers instead of staple ~ibers cou~d ~e needled to a netting or film -te obtain -the desired composite structure. Typical staple ibers which can be used in -~he practice o~ this invention are those o~
rayon, polye~ter~ polyamides, polyvillyl chloride, cotton, wool, silk, polypropylene and those acrylics with a shrlnkage tempera-ture above the softening point of the moplastic nettiny. Typical continuous filament fibers which can be utilized are nylon, poly-10 ester, and polypropylene.
Where the thermoplastic nettin~ or film is not needle-punched wikh staple or continuous filament flbers, but rather is used in combination with a separate web of staple or continuous filament fibers, such as a spun-bonded nonwoven, the web will preferably weigh from about .4 oz./sq. yd. to about 2 oz./sq. yd.
Typical fibers used in prepariny such ~ebs are those dascribed above.
The stabili~ed fabrics of this invention can be made by aligning the fabric; advancing the fabric under tension to a 20 bonding station; heating the thermoplastic netting or needle-punched film to its melt temperature bonding the fabric, the melted netting or film, and the stabilizing web of staple or con-tinuous filament fibers or the fibers needle-punched into the netting or film together under pressure suffi.cient to insure sub-stantially complete penetration of the molten thermoplastic into ~he fibers of the stabilizing web or the needle-punched fibers and partial penetration into the Eabric; and cooling the resultant composite structure to effeck hardening of the thermoplastic.
Where the process :is continuous, the fabric can be aligned by 30 passing it through a conventional fabric straightener, which may either be automatic, manual, or ~oth~ Fabric straigh.teners are well known in the art and need not b~ described hexe~ The fabric can be advanced under tensio~ wikh th.e use of a tenter, such as a pin or clamp tenter, wh ch trans~7ersely stretche~ the fabric and -- & --, 3~
places it under tension before it i.3 heat~cl~ rrh~ fabri( is heated so that the melted thermoplastic netting or Eilm will not solidi~y upon initial contact witll the fabric. In genexal, the ~ahrlc can be heated by passing it beneath a heater or by passing -the fabrlc and the netting or needle-punched film or netting over a heated roll. It may be desirable to use a fluoropoly~er coated heating roll or a release film to prevent the t~ermoplastic from sticking to the roll. If the fabric is to be maintained under tension while heating, the heated roll can be fitted with pins on its 10 periphery which catch the fabric as it leaves the tenter and main--tain it under tension. Alternativel~, helts on the periphery of the heated roll can sex~e the same purpose as the pins. Stlll another method is by using a blanket to hold the fabric in ten-sion against the roll. Still other means will be ohvious to those skilled in the art. The fabric, the melted netting or film, and the stabilizing web of staple or continuous filament fibers or the stabilizing fiber~ needle-punched into the netting or film are bonded together under pressure sufficient to insure substantially complete penetration of the m~olten thermoplastic into the fibers 20 of the stabilizing web or into the stahilizing needle-punched fibers and partial penetration into the fabric by several methods.
One of the eas-est means for exerting pressure on the fabric, netting or film ana stabilizing web is with a nip roll, whereby the COTnposite fabric structure passes between the nip of the heated roll and an adjacent roll. If desired, the adjacent nip roll can be cooled by some known means, such as water cooling.
It will he o~vious to those skilled in the art that the cooling step can be conducted separately from the bonding step~ such as by using an air knife directed on the fahric.
In general, the heating of the thermoplastic netting will be carried out at a témperature in th~ range of from about 80C. to 240C., preferably about 100C. to 220C., most preferably about 120C. to 200C. The r0~uired time of heating will vary inversely with the temperature and will be in the range of from a~out seconcl to 60 seconds/ preEarab].y ~ to 30 seconds, an~l most preferably 3 to :l.5 seconds. The pressure requirec~ to insure sub stantially complete penetrati~n of the molten plastic into the fibers oE -the sta~ ing web and partial penetration into the fabric will be in a range of from about 1 to 100 lbs. per linear inch, preferably 10 to 90 :lbs. per linear inch, mos-t preferably 40 to 80 lbs. psr linear in~h.
The equipment or apparatus used in carrying out khe pro-cess of this invention includes means for aligning the fabric, 10 such as a fabric straigh~ener, neans for placin~ the ~abric under tension, such as a tenter, means for honding the ahric with the thermoplastic netting or film and stabi~izing we~ or ~ibers, such as a heated roll, ~eans for applving pressure to the composite structure to cause substantially complete penetration of the molten plastic into the stabilizing web or fibers and partial - penetration in~o the fabric, and means for cooling the composite structure, such as a cooled nip roll.
A typlcal apparatus for stabilizing fabric in accordance . with this .invention is shown in FIG. 13. As i:llustrated in FIG.
20 13, the fabric 16 is drawn from a fabri.c supply roll through a fabric strai~htener 18 to align the fabric and onto a pin tenter 19 which places the fabric under tension. As the fabric 16 ad-vances, it is engaged by khe pins 20 on a heated drum 21 which : maintains tension on the fabric 16. The netting supply roll 22 supplies the netting or film 23 (which has been needle-punched with staple or continuous filament fibers) between the fabric 16 and the heated roll 21. In those cases where a separate stabil-izing web of staple or cohtinuous filament fibers i.s used, a web supply roll 24 advances the stabilizing web 25 onto the netting 30 23 (which does not have staple or continuous fi.lament ~iber needled thereto~ and then. around the heated roll 21. After pas.s-ing at least 180 aroun~ the heat~d roll 21, or a suffici.ent distance to melt the netting or film~ the fabri.c 16, melted ~ netting or film 23 and stabili.zing we~ of staple or continuous , .
.
~ibers 25 pass between th0 nip of chilled ro'Ll 26 ancl heated roll 21, insuring penetration of the me:Lted ~hermoplastic in-to the fabric structure as previous~y descrIbed. The struc-ture then passes at least 12n around the chill rol'L 26 which harde~s the thermoplastic. T~e thus stabilized fabric 27 passes over idler rolls 28 and .is ta~en up on roll 29.
Referring to ~IG. 14, ther~ is shown alternative apparatus for manufacturing stabilized fabrics in accordance with thi~ in-vention. Fabric 30 is drawn from a fabric ~upply roll 31 and 10 passes through a fabric straightener 32 which straightens the bow and bias of the fabric so that it is properly aligned as it ad-vances onto a pin ten~er 33 which places the fabric under trans-verse tension. The pin tenter 33 is preferably a split pin tenter which allows one set of pins on one side of the fabxic to be advanced at a different rate rom the other set of pins on the other side oE the fabric~ Thus, if all of the bias is not re-moved from the fabric by the fabric straightener 32, an operator can control the speed of one set of pins relative to the other to remove any re~ai~ing bias in th~ fabric. The ~abric 30 ad-20 vances under tension beneath a heater 34, which he-ats the ~abrïc 30 so that when it comes into contact with the melted thermo-plastic netting or film, the thermoplastic will not solidify upon contact. The fabric 30 is lifted off the pins o~ the pin tenter 33 by a strip roll 36 which urges it against a heated drum 37.
A supply roll 38 of thermoplastic netting 35 and a supply roll 39 of a stabilizing web 40 of staple or continuous filament fibers is provided. The n~tting 35 and stabilizing web 40 advance over a pair of bowed rolls 41 which keep the materials ~rinkle-free.
The netting 3S and stabilizing web 40 then pass between a heated 30 nip roll 43 and the heated drum 37 to preheat the thermoplastic netting. As the thermop~astic n~tting 35 and the stabilizing web 40 advan~e about the periphery of the drum 37, which is enclosed within an insulating hood 44 to help r~tain the drum heat, the th~rmoplastic netting ~egins to melt. At the point where it _ g _ , reaches tha strip rol:L 36 and com~s into contac-t with the fahric 30, the thermoplastic~ nettiny is completely melted. The ~abric 30, melted netting 3~ and stabiliziny weh 40 continue around the heated drum 37 to a bonding station where pressure is applied to the materials by a roll 46 to bond the materlals into a unitary composite struc~ure. The temperature of drum 37 and the pressure at the bonding station between roll 46 and drurn 37 mus-t be suffi-cient to cause substantially complete penetrati.on of the melted thermopla~stic 3~ into the fibers o~ the ~kabillzing web 40 and 10 partial penetra~ion o~ ~he melted thermoplastic into the ~abric 30. The roll 46 is desirably rubber covered to protect the sur-face texture of the fabric 30. The roll is also desirably water-cooled to cool the stabili~ed fabric and solidify the molten thermoplastic netting. The stabilized structure then advances around a second water-cooled roll 47 which ~urther completes the cooling action, and then is wound on a take up roll 48.
While the above-described embodiments work satisfactorily for certain fabrics, such as cotton, xayon and polye0ter, cer-tain other heat-sensitive materials, most notably pol~propylene, 20 may encounter shrinkage due to the closenass of the temperature of the heated drum and the melting temperature of the fabric it-self. With cotton, polyamide, polyester, or rayon, or any non-thermoplastic or cellulosic fiber, the temperature of the drum and the melting temperature of the thermoplastic netting, will not usually adversely affect the fabric and shrinkage is not a prob-lem. EIowever, with thermoplastic fabrics which have a low melting temperature, such as polypropylene which melts at approximately 160C., shrinkage is a problem and ~are must be taken to avoid melting and shrinkage of the fabric. Accordingly, another embodi-30 ment which maintains the width of the fahric without subjectingit to prolonged high temperature is particularly suitable for such heat-sensitive fabri~s as polypropylene. The following embodiment may also be desi~able for any fabrics including those that have a substantial portion of thermoplastic fiber contained therein as ~ ¢~3~3 well as those that have no thermop~astic Elber therein.
Referring now to ~IG. 15, there is shown a supply roll 51 tllat advanc~s a abric 52 into and through a f~hric straighener 53 a~ previously described~ The fabric S2 then advances onto a relatively short ~plit pin tenter 55 which allows the operakor to take care of any bias that may not have been corrected within the fabric straightener ~3. The fabric 52 then advances onto a pin tenter 54 ~hiclh maintains the ~abri~ under trans~erse tension.
The abric 5~ then advances past a heater 56, which heats the 10 bottom of the Eabric S2. ~he fabric 52 then advances ~enea-th a heated dr~ S7 which is positioned between the pins oE each side of -the tenter 54. A supply rol~ 60 oE khermoplastic nettiny 5S
and a supp~y xoll 65 of a stabilizing web 59 i5 pro~idea. The netting 58 and web ~9 advance over a pair o bowed rolls 66 be-tween the nip of a heated roll 61 and heated drum 57 and continue about the rotating heated drum. A hood ~9 may be positioned over the drum 57. The nettirlg S8 is substantially completely melted as it reaches a bon~ing station~ where the fabric 52 is urged against the netting S8 and web 59 by a roll ~2 which is prefer-~0 ably rubber-covered and water-cooled. The temperature of the drum 57 and the dwell time of the netting 58 thereon, ancl the pressure at the bonding station between roll 62 ~d drum 57 are selected to sufficiently melt the thermoplastic netting 58 and cause substantially complete penetration of the meIt~d thermo--plastic into the fibers of the ~tabilizing web 59 and partial penetration of the melted thermoplastic into the fabric 52. The stabili~ed fabric structur~ is maintained under tension during bonding and continues to be maintained under ~ransver~e tension as it continues along the tenter 54 through a cooling section 63 30 which may have air blowers or fans or the like to cool the stabil-i~ed fabric str~cture to ~olidify the thermoplastic. It i5 to be noted that the fabric 52 is mainta~ned under tension during the entire op~ratio~ lncluding hea~ing, bonding and ~ooling so that little or no s~r~lkag~ ~zn oc~ur. A~er t~e stabili~ed fa~ric J~ 3~ ~
,tructure is cool~d, it i~ wound on a t.ake-up roll 64. While -thls apparatus and ~rooess have be~n described as bei.ng pa:rkicula:rly advantageous for -thermoplas~ic fabrics, it, o~ cour~e, can also be utilized on non thermoplastic Eabrics, such a8 cotton, linen and rayon.
When the netting of FIG. 7 or 9 is utilized as the bonding layer, the pressure and temperature of the preheatincJ roll~ such as ~3 or ~l in FIGS l4 and l~ respectively, can be adjusted such that the netting is preheated sufficiently ~so that upon initial lO contact with the heated drum, the interconnecting bars oE the netting melt and brea~, leaving the bosses or spots o~ bonding material intact. When you have suf~icient preheat on th.e heated roller, the bars ~substantially instantaneously meIt and break upon contact with the heated drum, thus avoiding any shrinking or dePor-mation of netting as it is heat~d by the drum. This provides for uniform distribution oE the bonding material over the entire fab-ric width.
In any of the above-described embodiments, it may be desir-able to steam the fabric~ prior to advancement thereof onto the 20 pin tenter. This is particularly desirable for hygroscopic fa~-rics, such as fabrics made of cellulosic ibers, to facilitate removal of any wrinkles or creases hy th~ subse~uent tentering operation While the abo~e-described apparatus and p.rocesses in FIGS.
13, 14 and 15 have primarily described a three-part s~stem wherain a ~abric is bonded by heat and pressure to a stabilizing web by means of a thermoplastic netting, the pr~casses and apparatus could also be utili~ed in a two-part system wherein a fabric is bonded to a single composite layar which includes a thermopla~tic 30 film or netting havi~g staple or c~ntinuous ~ilament ~ibers needle-punched thereto, or a the~moplastic netting which has ai.r-lai.d and bonded thereto stap~ or continuous ilament ~ibe.rs.
In such a two-~art system, inst~ad of two supply rolls, suoh a~
2~ and 24, being utill~ed, only on~ supply roll would ~upply cuch a single composite layer~ i~cludincJ bo~h the }~)onding material and the stahilizing fibers, koward the heated dn~ to be boncled to the fabric.
Referring to FIG. 16, there is shown a stabilized fabric made in accordance with the principles oE this invention. The stabilized fa~ric i~cludes a wov~n fahric :layer 71 h~ing warp fibers 72 and fi~l fibers 730 A stahilizincJ layer of stap:Le or continuous ilament fibers is designa~ed as 74 The fahric layer 71 is bonded to the stabilizing layer 74 hy a thermoplastic bond-10 ing layer or netting such as shown in FI~S. 1-1~, which, upon melting, Eorms spo~s or areas of bonding material 76 which pene-~txate substantially completely into the stabiliæing layer 74 and partialLy into the fabric layer 71.
When the bonding layer of the stabilized fahric ïs a th~r-moplastic netting .such as shown in FIGS~ 7 and 9, the int~connect-iny bars of the netting break upon melting, leaving disc~ete spots or areas of bonding material surrounded by open spaces. The ther-moplastic netting sh~wn in FIGS. 1, 3, 5 and 11 will provide, upon melting, areas of bonding naterial having open spaces therebetween.
20 With any of these bonding materials, the openings are provided to allow the fibers of the stabilizing layer to be unhonded to the fabric in some spots and to he bonded together by the melted thermoplastic layer in other ~pots. Thus, the~stabilized fabric structure will have breathability due to the openings in the thermoplastic layer and will have a soft hand and flexibility due to the areas where the stabilizing layer of fabrics are not bonded to the fabric itse~f.
It is nec~ssary that the bondlng material 76 penetrate sub-; stantially completely into the stabilizing layer to provide the 30 desired dimensional stability to the fabric and to ~old the fibersof th~ stabiJ.i~ing layer together. It is equally important that open spaces such as 77 be provided between the bonding material 76 to provide breathability of th~ s~abili~ed fabric, as well as flexibility and soft hand, which is desirea. The thermoplastic - .
.,~
material 76 bonds the ~ibers oE the stabil.i~iny l~er 7~ to-gether, as well as bonding the fibers of the stabilizing layer 7A
to the fabric layer 71.
~ .~hile FIG. 16 illustrates a stabilized fabric made b~y sta-biliziny a woven fabric 71, a similar structure is obtained when stabilizing knitted or tufted fabrics.
Referring to FIG. 11, there .is showm in 17A a fabric layer generally designated as 81, a stabilizing layer designated as 8 and an in~ermediate bondiny layer generally design~ted as 83.
10 FIG. 17B shows the three layers 81, 8~ and 83 ater being needle-punched together, illustrating the fibers 84 which are transported from the fabric layer 81 by the needle--punching to interlock and entangle the bonding layer 83 and stabilizing layer 82. In FIG.
17C, the structure of 17B is shown after bondin~, where the bond-ing layer 83 is melted to provide a plurality o~ bond areas 86 which penetrate substantially completely through the stabilizing layer 82 to bond the filaments thereof together and to bond the filaments of the stabilizing layer to the fabric ~1.
In FIG. 18~, there is shown a fabric layer generally desig-20 nated as 91, which is stabilized by needle-punching and bonding to a bonding layer 92 o~ netting or fil~.. After needle-punching, the structure is sho~n in FIG. 13B wherein fibers 93 of the fab-ric 91 protrude into and through the bonding layer 92 to interlock and entangle with the bonding layer. The needle~~unching trans ports part of the ~ace yarn of the fabric through the netting to produce a stabilizing web o~ fibers on the back side of the bond-ing layar 92. ~fter bonding, the structure is shbwn in FIG. 18C
wherein the protruding fibers 93 are bonded by the melted bonding layer 92 which forms bond areas 9S which penetrate substantially 30 completaly through the protruding ibers 93 to bond the fibers together and to bond such ibers to the abric 91 to provide the neces:sary di~ensional stability. Between the hond areas 95 are open spaces 9~ where th~ protrudi~ needle-punched fi~ers 93 are not bonded to the fabric 91 to provi.d~ breath~bi.li.ty and soft hand.
In making stabilize~ fabrics as described in Figures 17 ancl 18, the needle-p~mching operation could take place either in line prior to the tenter, or off-line in a separate operation. The needle-punched material would then be advanced onto a tenter, heated so that l:he thermoplastic material melts, and subjected to pressure to bond the structure as previously described. If desired, the apparatus shown in Figure 15 could be utilized to make such a structure. The heater section 56 would have to be of sufficient length and temperature to melt the thermoplastic netting or film, and the heated struc-ture could then either pass through a pair of cold nip rolls, or could pass lb between drum 57 and roll 62 as shown in Figure 15, to bond the materials to-gether.
In order to make flame-retardant stabilized fabrics, flame-retarding fiber such as polyvinyl chloride fiber, modacrylic fiber, NOh~X fiber (trade-mark of E.I. duPont de Nemours ~ Company), or other flame-retardant fibers, can be used in place of the staple or continuous filament fiber which is needle-punched to the thermoplastic netting in a two-part system. If a three-part system is used, the stabilizing web of staple or continuous filaments can be replaced with staple or continuous filament fibers that are flame-retardant.
Another embodiment of a flame-retardant, stabilized fabric can be made by needle-punching a thermoplastic netting, a layer of aluminum foil, and a stabilizing web together, and then subsequently bonding such a structure to a fabric as previously described. Alternatively, the netting, aluminum foil, and stabilizing web could be needle-punched directly to the fabric and then bonded together. This will provide a fabric having sufficient flame-retardancy to meet the National Bureau of Standards cigarette test.
Stabilized fabrics made in accordance with this invention exhibit the following properties: good dimensional stability, improved seam fatigue strength and seam slippage ~seam fatigue strength is a dynamic test of seam strength and seam slippage is ~ statlc tes-t oL ~eam ~tron~-th), brea-thahility, soft ~land~ and high tensile strength. Additionally, better coverage i5 often obtained with the stabiliz~d fabrics because the nip pressure utiliæed in bondiny spreads out the lndividual yarn bund]es -to improve the coverage of the individual fibers in the fabric, without adversely affecting the surface texture. Additionally/
the stabilizad fabrics have resistance to washing slnce the struc-ture is not loosened or affected by hot water washing as is latex backing. Further~ore, because of the resistance to problems with lO hot water washing, dyeing can be accomplished after the fabrics are stabiliæed without any dificulties. Dyeing operations which are carried out ater latex bonding, however, are very difficult because the latex often breaks down in the dye bath. Additional advantages are that the stabilized fabric is easier to cut and sew than latex-backed fabrics. This is because the latex backing is non-uniform and is also sticky and is difficult to feed through sewing or other processing machines. Adclitionally, sewing needles pick up a ~art of the latex backing and gum up, necessitating frequent cleaning or replacement. Moreover, the stabilized struc-20 tures made in accordance with this invention are significantly lighter in weight than conventional latex-backect fahrics - in the range of ~0% to 50% lighter, thereby resulting in a savincJs in shipping and providing easier handling. Additionally the energy and water requirements o the subject process are significantly less than the conventiona~ latex coating process, resulting in substantial savings.
The following examples will serve to illustrate this inven-tion.
Example 1 This example illustrates the stabilization of a Jac~uard woven upholstery fabric prepared from polypropylene yarns by bond-ing to it a high density polyethylene netting needled with a thin web of polypropylene staple fibe~s.
The looscly woven fabric has an 86 warp count of 260 denier continuous filament yarn and a 16 fill count of 2,6~0 denier bul}ced continuous filament polypropylene yarn. This fab~ic shows an original seam sliopaye value of 5.6 lbs. in the maciline dir~c-tion and 6.8 lbs. in the transverse direction as measured bv the ASTM D434-75 procedure. The fabric is aligned to make the fill-ing yarns uniformly perpendicular to the machine direction and is placed under tension using a tenter. High density polyethylene nettin~ weighing 0.8 o~./sq. yd. having 13~ 12-mil bosses per lO square inch which has been modified by needle-punchin~ into it a thin web (1.0 oz./sq. yd.) of 3-denier 1.5 inch polyproPylene staple fibers with 300 penetrations per inch, is laid on top of the fabric. This composite is passed around a 16-inch diameter roll heated to 143C. The needled thermoplastic netting is ad-jacent to the heated roll and separated from it by a ylass fabric release film. A blanket on the outside of the composite structure applied about l p s.i. pressure to hold the composite against the hot roll and maintain the tension. The contact time on the roll is 30 seconds. The laminate then passes through khe nip of a 20 heated roll and an adj~c~nt cool roll which exerts a pressure of 23 lbs. per linear inch. The laminate passes about hal way around the cool roll before tension on it is released. The sta-bilized fabric so produced has a seam slippage value of 70 pounds in the machine direction and 44 pounds in the transverse direc-tion and a soft, smooth back facing.
EXample 2 This example illustratas the process of stabili~ing the fab-ric described in Example l using a polyvinyl chloride film needled with polyester staple fihers.
The fabric and procedure of Example l i5 employed except that the stabili~ing backing is formed from a polyvinyl chIoride film 2 mils thick and having a. 6 o~ ./sq. yrd. of 2 denier, 3 inch polyester staple fi~ers attached to it by needling with 30a pen-etrations per inch. The resulting product has a ~eam slippage ,.
value of 55 poun-ls in the maahine direction and ~5 pounds in the transverse direction.
Example 3 This eY.ample illustr`ates the stahilization o~ the fahric described in Example l using an oriented foamed thermoplastic polyurethane netting needled with polypropylene stap]e fibers.
The fahric employed in Example l is aligned and tentered as in Example l, and oriented, foamed thermoplastic po~yurethane ne-t~
- ting having a weight of 0.9 02./sq. yd., which has been modified 10 by needle-punching into it a thin web (l.0 oz./sq. yd.) of 3 clenier 1.5 inch polypropylene staple fibers with 300 penetrations per inch is laid on top of it. This composite is passed 180 around a fluoropolymer coated 8 inch diameter roll heated to 1~6C. and having pins on the periphery which penetrate the ~abric and main-tain it under tension. A 6.3 second dwell time is employed, fol-lowed by passing the laminate through the nip formed with an ad-jacent water-cooled 8 inch, polished, silicon rubber ~Shore A
hardness of 55) coated rol~ with a nip pressure of 45pounds per linear inch. The fabric so treated has a seam slippage value of 20 65 pounds in the machine direction and 50 pounds in the transverse direction.
EXample 4 This example illustrates the stabilization of the fabric described in Example l using an amorphous copolyamide netting needled with cross-lappad carded cotton.
The fahric and procedure as described in Example l are em-ployed, except that an amorphous ~opolyamide netting 0.5 oz.-/sq.
yd. in weight~ consisting of intersecting continuous ilaments 3 mils thick in a grid pattern and needled with 0.8 oz./sq. yd. of cross-lapped carded cotton with 30q penetrations per inch is used as the needled thermoplastic netting and the hot roll tem-perature is 120C. The seam slippage values of the resulting stabilized product are 31 pounds in the machine direction and 36 pounds in the transverse direction.
., , , . ~ .
.
~ 7~ 3 Ex ~ 5 This example illustrates ~he s~abilization of the fabric described in Example l using a ~igh density polyethylene nettlny and a thin layer of random ~aid po~ypropylene staple fibers.
The fabric and procedure of Rxample 1 are used except that the high c1ensity polyethylene netting i5 modified by random laying a 0.5 oz./sq. yd. web of 3 denier l.5 inch polypropylene staple fibers on i~ as the abric and netting approach the hot roll, the staple fibe~ web thus being supported by the nettiny lO and coming into contact with the heated roll. The resulting stabilized fabric has seam slippage values of 37 pounds and 34 pounds in the machine and transverse clirections respectively.
Example 6 This example illustrates the stabilization of a loosely woven upholstery fabric using a high density polyethylene netting and a random laid web of rayon staple fibers.
A loosely woven upholstery fabric 10 oz./sq. yd. in weight with an 8 x 8 yarn count prepared from 2,600 denier bulked con tinuous filament polypropylene yarn and with an original seam 20 slippage value in each direction of less than lO pounds is stabil-ized using an oriented high density polyethylene net 0.8 oz./sq.
yd. in weight and having l,050 bosses/in.2, 4 mils in thickness.
The method of Example 3 is employed, except that a random laid web of rayon staple fibers l.0 oz./sq. yd. in weight is laid on the high density polyethylene netting. During contact with the heated roll and subsequent pressure treatment the plastic netting melts, penetrating both the upholstery fabric and the rayon web, binding the two together, thus increasing the bulk and improving the han~l and softness of the fabric as well as the dimensional stability.
30 The seam slippage values of the resulting stabilized fabric are 37 pounds and 50 pounds in the machine and transverse directions respectively.
Example 7 This example illustrates the stabilization of the upholstery .
3~3 fabric described in exa~ple 6, using an oriented h-igh density polyethylene net and a web of continuous filament polyester.
The upholstery ~'abric, plastic nettlng and procedure employed in Example 6 are used, except that a continuous filament polyester web weighing 0.6 oz./sq. yd. ls substituted for the rayon staple web. The resulting treat-ed fabric has considerably improved dimensional sta'bility, increased bu]k, softness and strength compared with the untreated fabric. It has a seam strength of 47 pounds and 42 pounds in the machine and transverse directions respectively.
xample 8 This example illustrates the stabilization of the upholstery fabric described in Example 6 using an oriented high density polyethylene netting and a web of continuous filament nylon fibers.
The upholstery fabric, plastic netting and procedure'employed in Example 6 are used, except that a continuous filament nylon web weighing 0.6 oz./sq. yd. is substituted for the continuous filament polyester web. The seam slippage values for the resulting stabilized fabric are 43 pounds and 4 pounds in the machine and transverse directions respectively.
Example 9 This example illustrates the stabilization of a polypropylene up-holstery fabric using oriented high density polyethylene netting and a web of staple nylon fibers.
An upholstery fabric woven from 3,600 denier bulk con~inuous fil-ament polypropylene yarn, 4.9 oz./sq. yd. in weight, having a 10 x 6, warp by fill count per inch, is stabilized with a combination of a 0.64 oz./sq. yd.
oriented, high density, polyethylene ne~ting, and 1.0 oz./sq. yd. web of 3 denierJ 2 inch staple nylon fibers. The original upholstery fabric has a seam slippage value of less than 10 pounds in each direction and a grab tensile strength of 100 p.s.i. in the machine direction and 45 p.s.i. in the transverse direction. The fabric is passed through a web straightening device to establish proper alignment 3~
~f pattern, then cJn to a pin tenter where it is dra~ to the full standard upholstery Eabric width o~ 56 inches. ~rom the ten-ter the fabric passes immed.iately on to a 4 fo~t diameter fluoropoly-mer coated drum which is heated to a surface temperature of 150C.
To maintain the full width o.~ the abric and to resist shrinkaye and distortion, the fahric is retaine~ by a line of pins around the circumference at each edge of the heated cylinder. At the point where the fabric makes contact with the heated drum the layer of thermopla.stic netting (of flat, 4 mil thic~ hexagonal lO bosses, which measure 16 mils across a flat surface and are evenly distributed at a density of 900 bosses p.s.i., connected to each other by thin strips of oriented thermoplastic between each of the six sides of the hexagonal, as shown in FIGS. 9 and lO of the drawings), and the layer of nylon web are joined to the fabric and the 3 layer laminate travels around the drum with the weh against the hot surface and with the oriented netting be-tween the fiber web and the upholstery fabric, the composite being in con-act with 3/4 of the circumference of the drum, at a rate of 60 ft./min. The dwell time in contact with the hot roll is 9.8 sec-20 onds. The laminate then passes through a nip formed by an 8 inchdiameter water-cooled steel roll pressing against the heated drum with hydraulic pressure of 18 lbsO/linear inch. The fabric then moves around the cooled roll to the wind-up. The resulting sta-bilized fabric has a tensile strangth of 150 lbs./in. in the machine direction and 105 lbs./in. in the transverse direction and seam slippage values of 28 pounds and 35 pounds in the ma-chine and transverse directions respectively.
Example lO
This example illustrates stabilization of a tufted fabric 30 as well as the use of the alternative apparatus for manufacturing stabilized fabr.ics shown in FIG. 14.
A tufted fabric, weighing 10~5 o~./sq. yd. and comprised of 0.11 inch pile of 1.5 denier rayon on a 48 x 30 count woven cotton is stabilized using a combination of spun bonded continuous 3~3 ~ilament nylon with an orientecl high clensity polyethy1ene nettin~J
weight 0.~ oz./sq. yd. and having 121 bosses per square inch, about 4 mils thic~. (Hercules ~elnet PA-218).
Using the apparatus shown in FIG. 14, the fabric is aligned as in previous examples and lifted from the tenter so as to place its back side towarcls the heated drum 37 at the point of contact between rolls 36 and 4~ where the stabilizing material is ~oncled to the fabric. The stabilizing material which i6 a 0.6 oz./sq.
yd. spun bonded nylon weh 40, and the netting 35, pass over roll 10 43 which is heated to a surface temperature of 260~F., and, after 1 second dwell on roll 43, passes through the nip at 60 pouncls per linear inch and onto the hot drum 37 which ls at 385F. After 5 seconds dwell on the hot drum 37, the netting is completely melted and is supported on the spun bonded nylon web. The melted net then contacts the fabric at roll 36. The fabric and stabiliæing material continue around the hot ~rum for 1 second and a pressure of 80 lbs./linear inch is applied by roll 46 which has a steel surface and is internally cooled by water. The stabilized struc-ture then advances around a second wa~er-cooled roll 47 to the 20 take-up roll 48.
The resulting stabiliæed fabric was improved from a con-dition o nearly zero resistance to loss of tufts to a condition of complete retention of tufts after the most stringent dyeing conditions.
Example 11 This example illustrates stabilization o~ a knit fabric produced from polyester spun yarn using a combination of spun bonded continuous filament nylon with an oriented high density polyethylene net. The knit fabric weighing 10.5 o~.~sq. yd. had 30 an elastic recovery of less than 75~ in 5 minutes after elonga-tion, before stabilizing. The high density polyethylene ne~, ~eighLng 0.7 oz./sq. yd., has 910 hosses per square inch which are approximate~y 4 mils thick. The spun bonded nylon is ~.4 oz./sq. yd.
, :
3~ 3 The apparatus as in FIG. 1~ was used exactly as in Example lO. The stabilï~ed fabric product has sicJnificantly improved di~
mensional stability, the elastic recovery heing over 85~ ln 5 minutes after lS~ elongation.
Example 12 This example illustrates the stabiliz.ation of the upholstery fabric described in Example 9, using an oriented high density polyethylene net and a web of staple modacr~lic fiber.
The upholstery fabric, plastic netting and procedure employed lO in Example 9 are used, except that a needle-punched staple web of modacrylic fiber weiyhing l.0 oz./sq. yd. i5 substituted for the nylon staple web. The modacrylic web is of 3 denier, 2.5 inch fibers which were needle-punched 150 penetrations per square inch onto the plastic netting. The composite of modacrylic fibers and plastic netting was supplied to the stabilizing apparatus as one web. The resulting stabilized fabric has a tensile strength of 145 lbs./in. machine direction and 98 lbs./in. transverse direc-tion and seam slippage values of 30 and 33 pounds in the machine and transverse directions respectively.
Example 13 This example illustrates the stabilization and flame retar-dance improvement of upholstery fabric using oriented high density polyethylene netting in combination with aluminum foil and poly-ester staple web.
Aluminum foil, 0.35 mil thick, was plied with a l.0 o~./s~.
yd. web of polyester staple fiber, 3 denier, 1.5 inch length, and needle-punched to the e~tent of 25 penetrations per square inch.
The oil composite so produced was then laminated to the upholstery fabric as in Example 9. The procedure as in Example 9 was fol-30 lowed with the exceptions ~1) that the drum s~rface temperature was at 180C., ~2) the plastic netting was 0.8 o~./sq. yd., having 99 bosses per square inch o approximately 12 mil thickness, and ~3) the aluminum foil staple web composite was used in place of the staple nylon we~.
The stabili~e~l fahric product had seam slippage o~ 40 and 31 pounds in the machihe ~nd transverse directions re~pectively, and recei~ed a ratirlg of Class A by the Federal Standard PFF6-74, Cigarette Ignition Test.
Exa~ple 14 This example illustrates stahilization of a fabric by an al-ternative procedure of needle-punching the fabric together with a thermoplas~ic netting and a stabilizing layer~ and then applying heat and pressure to bond the loose-needled fibers of the ~abric 10 and the stabilizing layer into a dimensionally stable structure.
A woven fabric of nylon yarn, having a yarn count of 1 1X9, warp X fill, anc~ a weight of 11 oz./sq. ycl., is plied with a bond-ing layer oE thermoplastic netting and a stabilizing layer of spun bonded nylon, and the combination is needle-punched together -to form a composite structure. The netting and stabiliæing layer are positioned at the back of the fabric and the needles penetrate into the face side of the fabric and through the back so as to entangle the netting and stahilizing layer among the fibers at the back of the fabric. A needle penetration of 250 per sq. in., 20 at 5/8 inch dept}i, is used. The thermoplastic netting is high density polyethylene weighing 0.8 oz.~sq. yd., having 130 12-mil bosses per square inch. The stahilizing layer is 0.4 oz./sq. yd.
spun bonded nylon.
After needle-punching, the composite structure, which is formed, is supplied as a single component to the apparatus as in Example 9 and thermally bonded. The procedure and bonding condi-tions are the same as in ~xample 9, except that in this case, the fabric which enters the web straightening device has the ~onding and stabilizing layers already in place. After the heatiny, 30 pressing, and cooling as in Example 9, ~he profluct has seam slip-page values of 30 pounds and 32 pounds in the machine and trans-verse dire~tions, respectivelyO
In all o~ the preceding axamples, the bonding material was observed to h~ve penetrated substantially ~om~letely into the stabflizing layer and partially into ~he fabric layer.
- 2~ -
,r filrn and neecllc-punchecl to an amount grealer thaJI ~5 pt~netra~
tions per square Lnch. If desired, contirluous fila~en-t fihers instead of staple ~ibers cou~d ~e needled to a netting or film -te obtain -the desired composite structure. Typical staple ibers which can be used in -~he practice o~ this invention are those o~
rayon, polye~ter~ polyamides, polyvillyl chloride, cotton, wool, silk, polypropylene and those acrylics with a shrlnkage tempera-ture above the softening point of the moplastic nettiny. Typical continuous filament fibers which can be utilized are nylon, poly-10 ester, and polypropylene.
Where the thermoplastic nettin~ or film is not needle-punched wikh staple or continuous filament flbers, but rather is used in combination with a separate web of staple or continuous filament fibers, such as a spun-bonded nonwoven, the web will preferably weigh from about .4 oz./sq. yd. to about 2 oz./sq. yd.
Typical fibers used in prepariny such ~ebs are those dascribed above.
The stabili~ed fabrics of this invention can be made by aligning the fabric; advancing the fabric under tension to a 20 bonding station; heating the thermoplastic netting or needle-punched film to its melt temperature bonding the fabric, the melted netting or film, and the stabilizing web of staple or con-tinuous filament fibers or the fibers needle-punched into the netting or film together under pressure suffi.cient to insure sub-stantially complete penetration of the molten thermoplastic into ~he fibers of the stabilizing web or the needle-punched fibers and partial penetration into the Eabric; and cooling the resultant composite structure to effeck hardening of the thermoplastic.
Where the process :is continuous, the fabric can be aligned by 30 passing it through a conventional fabric straightener, which may either be automatic, manual, or ~oth~ Fabric straigh.teners are well known in the art and need not b~ described hexe~ The fabric can be advanced under tensio~ wikh th.e use of a tenter, such as a pin or clamp tenter, wh ch trans~7ersely stretche~ the fabric and -- & --, 3~
places it under tension before it i.3 heat~cl~ rrh~ fabri( is heated so that the melted thermoplastic netting or Eilm will not solidi~y upon initial contact witll the fabric. In genexal, the ~ahrlc can be heated by passing it beneath a heater or by passing -the fabrlc and the netting or needle-punched film or netting over a heated roll. It may be desirable to use a fluoropoly~er coated heating roll or a release film to prevent the t~ermoplastic from sticking to the roll. If the fabric is to be maintained under tension while heating, the heated roll can be fitted with pins on its 10 periphery which catch the fabric as it leaves the tenter and main--tain it under tension. Alternativel~, helts on the periphery of the heated roll can sex~e the same purpose as the pins. Stlll another method is by using a blanket to hold the fabric in ten-sion against the roll. Still other means will be ohvious to those skilled in the art. The fabric, the melted netting or film, and the stabilizing web of staple or continuous filament fibers or the stabilizing fiber~ needle-punched into the netting or film are bonded together under pressure sufficient to insure substantially complete penetration of the m~olten thermoplastic into the fibers 20 of the stabilizing web or into the stahilizing needle-punched fibers and partial penetration into the fabric by several methods.
One of the eas-est means for exerting pressure on the fabric, netting or film ana stabilizing web is with a nip roll, whereby the COTnposite fabric structure passes between the nip of the heated roll and an adjacent roll. If desired, the adjacent nip roll can be cooled by some known means, such as water cooling.
It will he o~vious to those skilled in the art that the cooling step can be conducted separately from the bonding step~ such as by using an air knife directed on the fahric.
In general, the heating of the thermoplastic netting will be carried out at a témperature in th~ range of from about 80C. to 240C., preferably about 100C. to 220C., most preferably about 120C. to 200C. The r0~uired time of heating will vary inversely with the temperature and will be in the range of from a~out seconcl to 60 seconds/ preEarab].y ~ to 30 seconds, an~l most preferably 3 to :l.5 seconds. The pressure requirec~ to insure sub stantially complete penetrati~n of the molten plastic into the fibers oE -the sta~ ing web and partial penetration into the fabric will be in a range of from about 1 to 100 lbs. per linear inch, preferably 10 to 90 :lbs. per linear inch, mos-t preferably 40 to 80 lbs. psr linear in~h.
The equipment or apparatus used in carrying out khe pro-cess of this invention includes means for aligning the fabric, 10 such as a fabric straigh~ener, neans for placin~ the ~abric under tension, such as a tenter, means for honding the ahric with the thermoplastic netting or film and stabi~izing we~ or ~ibers, such as a heated roll, ~eans for applving pressure to the composite structure to cause substantially complete penetration of the molten plastic into the stabilizing web or fibers and partial - penetration in~o the fabric, and means for cooling the composite structure, such as a cooled nip roll.
A typlcal apparatus for stabilizing fabric in accordance . with this .invention is shown in FIG. 13. As i:llustrated in FIG.
20 13, the fabric 16 is drawn from a fabri.c supply roll through a fabric strai~htener 18 to align the fabric and onto a pin tenter 19 which places the fabric under tension. As the fabric 16 ad-vances, it is engaged by khe pins 20 on a heated drum 21 which : maintains tension on the fabric 16. The netting supply roll 22 supplies the netting or film 23 (which has been needle-punched with staple or continuous filament fibers) between the fabric 16 and the heated roll 21. In those cases where a separate stabil-izing web of staple or cohtinuous filament fibers i.s used, a web supply roll 24 advances the stabilizing web 25 onto the netting 30 23 (which does not have staple or continuous fi.lament ~iber needled thereto~ and then. around the heated roll 21. After pas.s-ing at least 180 aroun~ the heat~d roll 21, or a suffici.ent distance to melt the netting or film~ the fabri.c 16, melted ~ netting or film 23 and stabili.zing we~ of staple or continuous , .
.
~ibers 25 pass between th0 nip of chilled ro'Ll 26 ancl heated roll 21, insuring penetration of the me:Lted ~hermoplastic in-to the fabric structure as previous~y descrIbed. The struc-ture then passes at least 12n around the chill rol'L 26 which harde~s the thermoplastic. T~e thus stabilized fabric 27 passes over idler rolls 28 and .is ta~en up on roll 29.
Referring to ~IG. 14, ther~ is shown alternative apparatus for manufacturing stabilized fabrics in accordance with thi~ in-vention. Fabric 30 is drawn from a fabric ~upply roll 31 and 10 passes through a fabric straightener 32 which straightens the bow and bias of the fabric so that it is properly aligned as it ad-vances onto a pin ten~er 33 which places the fabric under trans-verse tension. The pin tenter 33 is preferably a split pin tenter which allows one set of pins on one side of the fabxic to be advanced at a different rate rom the other set of pins on the other side oE the fabric~ Thus, if all of the bias is not re-moved from the fabric by the fabric straightener 32, an operator can control the speed of one set of pins relative to the other to remove any re~ai~ing bias in th~ fabric. The ~abric 30 ad-20 vances under tension beneath a heater 34, which he-ats the ~abrïc 30 so that when it comes into contact with the melted thermo-plastic netting or film, the thermoplastic will not solidify upon contact. The fabric 30 is lifted off the pins o~ the pin tenter 33 by a strip roll 36 which urges it against a heated drum 37.
A supply roll 38 of thermoplastic netting 35 and a supply roll 39 of a stabilizing web 40 of staple or continuous filament fibers is provided. The n~tting 35 and stabilizing web 40 advance over a pair of bowed rolls 41 which keep the materials ~rinkle-free.
The netting 3S and stabilizing web 40 then pass between a heated 30 nip roll 43 and the heated drum 37 to preheat the thermoplastic netting. As the thermop~astic n~tting 35 and the stabilizing web 40 advan~e about the periphery of the drum 37, which is enclosed within an insulating hood 44 to help r~tain the drum heat, the th~rmoplastic netting ~egins to melt. At the point where it _ g _ , reaches tha strip rol:L 36 and com~s into contac-t with the fahric 30, the thermoplastic~ nettiny is completely melted. The ~abric 30, melted netting 3~ and stabiliziny weh 40 continue around the heated drum 37 to a bonding station where pressure is applied to the materials by a roll 46 to bond the materlals into a unitary composite struc~ure. The temperature of drum 37 and the pressure at the bonding station between roll 46 and drurn 37 mus-t be suffi-cient to cause substantially complete penetrati.on of the melted thermopla~stic 3~ into the fibers o~ the ~kabillzing web 40 and 10 partial penetra~ion o~ ~he melted thermoplastic into the ~abric 30. The roll 46 is desirably rubber covered to protect the sur-face texture of the fabric 30. The roll is also desirably water-cooled to cool the stabili~ed fabric and solidify the molten thermoplastic netting. The stabilized structure then advances around a second water-cooled roll 47 which ~urther completes the cooling action, and then is wound on a take up roll 48.
While the above-described embodiments work satisfactorily for certain fabrics, such as cotton, xayon and polye0ter, cer-tain other heat-sensitive materials, most notably pol~propylene, 20 may encounter shrinkage due to the closenass of the temperature of the heated drum and the melting temperature of the fabric it-self. With cotton, polyamide, polyester, or rayon, or any non-thermoplastic or cellulosic fiber, the temperature of the drum and the melting temperature of the thermoplastic netting, will not usually adversely affect the fabric and shrinkage is not a prob-lem. EIowever, with thermoplastic fabrics which have a low melting temperature, such as polypropylene which melts at approximately 160C., shrinkage is a problem and ~are must be taken to avoid melting and shrinkage of the fabric. Accordingly, another embodi-30 ment which maintains the width of the fahric without subjectingit to prolonged high temperature is particularly suitable for such heat-sensitive fabri~s as polypropylene. The following embodiment may also be desi~able for any fabrics including those that have a substantial portion of thermoplastic fiber contained therein as ~ ¢~3~3 well as those that have no thermop~astic Elber therein.
Referring now to ~IG. 15, there is shown a supply roll 51 tllat advanc~s a abric 52 into and through a f~hric straighener 53 a~ previously described~ The fabric S2 then advances onto a relatively short ~plit pin tenter 55 which allows the operakor to take care of any bias that may not have been corrected within the fabric straightener ~3. The fabric 52 then advances onto a pin tenter 54 ~hiclh maintains the ~abri~ under trans~erse tension.
The abric 5~ then advances past a heater 56, which heats the 10 bottom of the Eabric S2. ~he fabric 52 then advances ~enea-th a heated dr~ S7 which is positioned between the pins oE each side of -the tenter 54. A supply rol~ 60 oE khermoplastic nettiny 5S
and a supp~y xoll 65 of a stabilizing web 59 i5 pro~idea. The netting 58 and web ~9 advance over a pair o bowed rolls 66 be-tween the nip of a heated roll 61 and heated drum 57 and continue about the rotating heated drum. A hood ~9 may be positioned over the drum 57. The nettirlg S8 is substantially completely melted as it reaches a bon~ing station~ where the fabric 52 is urged against the netting S8 and web 59 by a roll ~2 which is prefer-~0 ably rubber-covered and water-cooled. The temperature of the drum 57 and the dwell time of the netting 58 thereon, ancl the pressure at the bonding station between roll 62 ~d drum 57 are selected to sufficiently melt the thermoplastic netting 58 and cause substantially complete penetration of the meIt~d thermo--plastic into the fibers of the ~tabilizing web 59 and partial penetration of the melted thermoplastic into the fabric 52. The stabili~ed fabric structur~ is maintained under tension during bonding and continues to be maintained under ~ransver~e tension as it continues along the tenter 54 through a cooling section 63 30 which may have air blowers or fans or the like to cool the stabil-i~ed fabric str~cture to ~olidify the thermoplastic. It i5 to be noted that the fabric 52 is mainta~ned under tension during the entire op~ratio~ lncluding hea~ing, bonding and ~ooling so that little or no s~r~lkag~ ~zn oc~ur. A~er t~e stabili~ed fa~ric J~ 3~ ~
,tructure is cool~d, it i~ wound on a t.ake-up roll 64. While -thls apparatus and ~rooess have be~n described as bei.ng pa:rkicula:rly advantageous for -thermoplas~ic fabrics, it, o~ cour~e, can also be utilized on non thermoplastic Eabrics, such a8 cotton, linen and rayon.
When the netting of FIG. 7 or 9 is utilized as the bonding layer, the pressure and temperature of the preheatincJ roll~ such as ~3 or ~l in FIGS l4 and l~ respectively, can be adjusted such that the netting is preheated sufficiently ~so that upon initial lO contact with the heated drum, the interconnecting bars oE the netting melt and brea~, leaving the bosses or spots o~ bonding material intact. When you have suf~icient preheat on th.e heated roller, the bars ~substantially instantaneously meIt and break upon contact with the heated drum, thus avoiding any shrinking or dePor-mation of netting as it is heat~d by the drum. This provides for uniform distribution oE the bonding material over the entire fab-ric width.
In any of the above-described embodiments, it may be desir-able to steam the fabric~ prior to advancement thereof onto the 20 pin tenter. This is particularly desirable for hygroscopic fa~-rics, such as fabrics made of cellulosic ibers, to facilitate removal of any wrinkles or creases hy th~ subse~uent tentering operation While the abo~e-described apparatus and p.rocesses in FIGS.
13, 14 and 15 have primarily described a three-part s~stem wherain a ~abric is bonded by heat and pressure to a stabilizing web by means of a thermoplastic netting, the pr~casses and apparatus could also be utili~ed in a two-part system wherein a fabric is bonded to a single composite layar which includes a thermopla~tic 30 film or netting havi~g staple or c~ntinuous ~ilament ~ibers needle-punched thereto, or a the~moplastic netting which has ai.r-lai.d and bonded thereto stap~ or continuous ilament ~ibe.rs.
In such a two-~art system, inst~ad of two supply rolls, suoh a~
2~ and 24, being utill~ed, only on~ supply roll would ~upply cuch a single composite layer~ i~cludincJ bo~h the }~)onding material and the stahilizing fibers, koward the heated dn~ to be boncled to the fabric.
Referring to FIG. 16, there is shown a stabilized fabric made in accordance with the principles oE this invention. The stabilized fa~ric i~cludes a wov~n fahric :layer 71 h~ing warp fibers 72 and fi~l fibers 730 A stahilizincJ layer of stap:Le or continuous ilament fibers is designa~ed as 74 The fahric layer 71 is bonded to the stabilizing layer 74 hy a thermoplastic bond-10 ing layer or netting such as shown in FI~S. 1-1~, which, upon melting, Eorms spo~s or areas of bonding material 76 which pene-~txate substantially completely into the stabiliæing layer 74 and partialLy into the fabric layer 71.
When the bonding layer of the stabilized fahric ïs a th~r-moplastic netting .such as shown in FIGS~ 7 and 9, the int~connect-iny bars of the netting break upon melting, leaving disc~ete spots or areas of bonding material surrounded by open spaces. The ther-moplastic netting sh~wn in FIGS. 1, 3, 5 and 11 will provide, upon melting, areas of bonding naterial having open spaces therebetween.
20 With any of these bonding materials, the openings are provided to allow the fibers of the stabilizing layer to be unhonded to the fabric in some spots and to he bonded together by the melted thermoplastic layer in other ~pots. Thus, the~stabilized fabric structure will have breathability due to the openings in the thermoplastic layer and will have a soft hand and flexibility due to the areas where the stabilizing layer of fabrics are not bonded to the fabric itse~f.
It is nec~ssary that the bondlng material 76 penetrate sub-; stantially completely into the stabilizing layer to provide the 30 desired dimensional stability to the fabric and to ~old the fibersof th~ stabiJ.i~ing layer together. It is equally important that open spaces such as 77 be provided between the bonding material 76 to provide breathability of th~ s~abili~ed fabric, as well as flexibility and soft hand, which is desirea. The thermoplastic - .
.,~
material 76 bonds the ~ibers oE the stabil.i~iny l~er 7~ to-gether, as well as bonding the fibers of the stabilizing layer 7A
to the fabric layer 71.
~ .~hile FIG. 16 illustrates a stabilized fabric made b~y sta-biliziny a woven fabric 71, a similar structure is obtained when stabilizing knitted or tufted fabrics.
Referring to FIG. 11, there .is showm in 17A a fabric layer generally designated as 81, a stabilizing layer designated as 8 and an in~ermediate bondiny layer generally design~ted as 83.
10 FIG. 17B shows the three layers 81, 8~ and 83 ater being needle-punched together, illustrating the fibers 84 which are transported from the fabric layer 81 by the needle--punching to interlock and entangle the bonding layer 83 and stabilizing layer 82. In FIG.
17C, the structure of 17B is shown after bondin~, where the bond-ing layer 83 is melted to provide a plurality o~ bond areas 86 which penetrate substantially completely through the stabilizing layer 82 to bond the filaments thereof together and to bond the filaments of the stabilizing layer to the fabric ~1.
In FIG. 18~, there is shown a fabric layer generally desig-20 nated as 91, which is stabilized by needle-punching and bonding to a bonding layer 92 o~ netting or fil~.. After needle-punching, the structure is sho~n in FIG. 13B wherein fibers 93 of the fab-ric 91 protrude into and through the bonding layer 92 to interlock and entangle with the bonding layer. The needle~~unching trans ports part of the ~ace yarn of the fabric through the netting to produce a stabilizing web o~ fibers on the back side of the bond-ing layar 92. ~fter bonding, the structure is shbwn in FIG. 18C
wherein the protruding fibers 93 are bonded by the melted bonding layer 92 which forms bond areas 9S which penetrate substantially 30 completaly through the protruding ibers 93 to bond the fibers together and to bond such ibers to the abric 91 to provide the neces:sary di~ensional stability. Between the hond areas 95 are open spaces 9~ where th~ protrudi~ needle-punched fi~ers 93 are not bonded to the fabric 91 to provi.d~ breath~bi.li.ty and soft hand.
In making stabilize~ fabrics as described in Figures 17 ancl 18, the needle-p~mching operation could take place either in line prior to the tenter, or off-line in a separate operation. The needle-punched material would then be advanced onto a tenter, heated so that l:he thermoplastic material melts, and subjected to pressure to bond the structure as previously described. If desired, the apparatus shown in Figure 15 could be utilized to make such a structure. The heater section 56 would have to be of sufficient length and temperature to melt the thermoplastic netting or film, and the heated struc-ture could then either pass through a pair of cold nip rolls, or could pass lb between drum 57 and roll 62 as shown in Figure 15, to bond the materials to-gether.
In order to make flame-retardant stabilized fabrics, flame-retarding fiber such as polyvinyl chloride fiber, modacrylic fiber, NOh~X fiber (trade-mark of E.I. duPont de Nemours ~ Company), or other flame-retardant fibers, can be used in place of the staple or continuous filament fiber which is needle-punched to the thermoplastic netting in a two-part system. If a three-part system is used, the stabilizing web of staple or continuous filaments can be replaced with staple or continuous filament fibers that are flame-retardant.
Another embodiment of a flame-retardant, stabilized fabric can be made by needle-punching a thermoplastic netting, a layer of aluminum foil, and a stabilizing web together, and then subsequently bonding such a structure to a fabric as previously described. Alternatively, the netting, aluminum foil, and stabilizing web could be needle-punched directly to the fabric and then bonded together. This will provide a fabric having sufficient flame-retardancy to meet the National Bureau of Standards cigarette test.
Stabilized fabrics made in accordance with this invention exhibit the following properties: good dimensional stability, improved seam fatigue strength and seam slippage ~seam fatigue strength is a dynamic test of seam strength and seam slippage is ~ statlc tes-t oL ~eam ~tron~-th), brea-thahility, soft ~land~ and high tensile strength. Additionally, better coverage i5 often obtained with the stabiliz~d fabrics because the nip pressure utiliæed in bondiny spreads out the lndividual yarn bund]es -to improve the coverage of the individual fibers in the fabric, without adversely affecting the surface texture. Additionally/
the stabilizad fabrics have resistance to washing slnce the struc-ture is not loosened or affected by hot water washing as is latex backing. Further~ore, because of the resistance to problems with lO hot water washing, dyeing can be accomplished after the fabrics are stabiliæed without any dificulties. Dyeing operations which are carried out ater latex bonding, however, are very difficult because the latex often breaks down in the dye bath. Additional advantages are that the stabilized fabric is easier to cut and sew than latex-backed fabrics. This is because the latex backing is non-uniform and is also sticky and is difficult to feed through sewing or other processing machines. Adclitionally, sewing needles pick up a ~art of the latex backing and gum up, necessitating frequent cleaning or replacement. Moreover, the stabilized struc-20 tures made in accordance with this invention are significantly lighter in weight than conventional latex-backect fahrics - in the range of ~0% to 50% lighter, thereby resulting in a savincJs in shipping and providing easier handling. Additionally the energy and water requirements o the subject process are significantly less than the conventiona~ latex coating process, resulting in substantial savings.
The following examples will serve to illustrate this inven-tion.
Example 1 This example illustrates the stabilization of a Jac~uard woven upholstery fabric prepared from polypropylene yarns by bond-ing to it a high density polyethylene netting needled with a thin web of polypropylene staple fibe~s.
The looscly woven fabric has an 86 warp count of 260 denier continuous filament yarn and a 16 fill count of 2,6~0 denier bul}ced continuous filament polypropylene yarn. This fab~ic shows an original seam sliopaye value of 5.6 lbs. in the maciline dir~c-tion and 6.8 lbs. in the transverse direction as measured bv the ASTM D434-75 procedure. The fabric is aligned to make the fill-ing yarns uniformly perpendicular to the machine direction and is placed under tension using a tenter. High density polyethylene nettin~ weighing 0.8 o~./sq. yd. having 13~ 12-mil bosses per lO square inch which has been modified by needle-punchin~ into it a thin web (1.0 oz./sq. yd.) of 3-denier 1.5 inch polyproPylene staple fibers with 300 penetrations per inch, is laid on top of the fabric. This composite is passed around a 16-inch diameter roll heated to 143C. The needled thermoplastic netting is ad-jacent to the heated roll and separated from it by a ylass fabric release film. A blanket on the outside of the composite structure applied about l p s.i. pressure to hold the composite against the hot roll and maintain the tension. The contact time on the roll is 30 seconds. The laminate then passes through khe nip of a 20 heated roll and an adj~c~nt cool roll which exerts a pressure of 23 lbs. per linear inch. The laminate passes about hal way around the cool roll before tension on it is released. The sta-bilized fabric so produced has a seam slippage value of 70 pounds in the machine direction and 44 pounds in the transverse direc-tion and a soft, smooth back facing.
EXample 2 This example illustratas the process of stabili~ing the fab-ric described in Example l using a polyvinyl chloride film needled with polyester staple fihers.
The fabric and procedure of Example l i5 employed except that the stabili~ing backing is formed from a polyvinyl chIoride film 2 mils thick and having a. 6 o~ ./sq. yrd. of 2 denier, 3 inch polyester staple fi~ers attached to it by needling with 30a pen-etrations per inch. The resulting product has a ~eam slippage ,.
value of 55 poun-ls in the maahine direction and ~5 pounds in the transverse direction.
Example 3 This eY.ample illustr`ates the stahilization o~ the fahric described in Example l using an oriented foamed thermoplastic polyurethane netting needled with polypropylene stap]e fibers.
The fahric employed in Example l is aligned and tentered as in Example l, and oriented, foamed thermoplastic po~yurethane ne-t~
- ting having a weight of 0.9 02./sq. yd., which has been modified 10 by needle-punching into it a thin web (l.0 oz./sq. yd.) of 3 clenier 1.5 inch polypropylene staple fibers with 300 penetrations per inch is laid on top of it. This composite is passed 180 around a fluoropolymer coated 8 inch diameter roll heated to 1~6C. and having pins on the periphery which penetrate the ~abric and main-tain it under tension. A 6.3 second dwell time is employed, fol-lowed by passing the laminate through the nip formed with an ad-jacent water-cooled 8 inch, polished, silicon rubber ~Shore A
hardness of 55) coated rol~ with a nip pressure of 45pounds per linear inch. The fabric so treated has a seam slippage value of 20 65 pounds in the machine direction and 50 pounds in the transverse direction.
EXample 4 This example illustrates the stabilization of the fabric described in Example l using an amorphous copolyamide netting needled with cross-lappad carded cotton.
The fahric and procedure as described in Example l are em-ployed, except that an amorphous ~opolyamide netting 0.5 oz.-/sq.
yd. in weight~ consisting of intersecting continuous ilaments 3 mils thick in a grid pattern and needled with 0.8 oz./sq. yd. of cross-lapped carded cotton with 30q penetrations per inch is used as the needled thermoplastic netting and the hot roll tem-perature is 120C. The seam slippage values of the resulting stabilized product are 31 pounds in the machine direction and 36 pounds in the transverse direction.
., , , . ~ .
.
~ 7~ 3 Ex ~ 5 This example illustrates ~he s~abilization of the fabric described in Example l using a ~igh density polyethylene nettlny and a thin layer of random ~aid po~ypropylene staple fibers.
The fabric and procedure of Rxample 1 are used except that the high c1ensity polyethylene netting i5 modified by random laying a 0.5 oz./sq. yd. web of 3 denier l.5 inch polypropylene staple fibers on i~ as the abric and netting approach the hot roll, the staple fibe~ web thus being supported by the nettiny lO and coming into contact with the heated roll. The resulting stabilized fabric has seam slippage values of 37 pounds and 34 pounds in the machine and transverse clirections respectively.
Example 6 This example illustrates the stabilization of a loosely woven upholstery fabric using a high density polyethylene netting and a random laid web of rayon staple fibers.
A loosely woven upholstery fabric 10 oz./sq. yd. in weight with an 8 x 8 yarn count prepared from 2,600 denier bulked con tinuous filament polypropylene yarn and with an original seam 20 slippage value in each direction of less than lO pounds is stabil-ized using an oriented high density polyethylene net 0.8 oz./sq.
yd. in weight and having l,050 bosses/in.2, 4 mils in thickness.
The method of Example 3 is employed, except that a random laid web of rayon staple fibers l.0 oz./sq. yd. in weight is laid on the high density polyethylene netting. During contact with the heated roll and subsequent pressure treatment the plastic netting melts, penetrating both the upholstery fabric and the rayon web, binding the two together, thus increasing the bulk and improving the han~l and softness of the fabric as well as the dimensional stability.
30 The seam slippage values of the resulting stabilized fabric are 37 pounds and 50 pounds in the machine and transverse directions respectively.
Example 7 This example illustrates the stabilization of the upholstery .
3~3 fabric described in exa~ple 6, using an oriented h-igh density polyethylene net and a web of continuous filament polyester.
The upholstery ~'abric, plastic nettlng and procedure employed in Example 6 are used, except that a continuous filament polyester web weighing 0.6 oz./sq. yd. ls substituted for the rayon staple web. The resulting treat-ed fabric has considerably improved dimensional sta'bility, increased bu]k, softness and strength compared with the untreated fabric. It has a seam strength of 47 pounds and 42 pounds in the machine and transverse directions respectively.
xample 8 This example illustrates the stabilization of the upholstery fabric described in Example 6 using an oriented high density polyethylene netting and a web of continuous filament nylon fibers.
The upholstery fabric, plastic netting and procedure'employed in Example 6 are used, except that a continuous filament nylon web weighing 0.6 oz./sq. yd. is substituted for the continuous filament polyester web. The seam slippage values for the resulting stabilized fabric are 43 pounds and 4 pounds in the machine and transverse directions respectively.
Example 9 This example illustrates the stabilization of a polypropylene up-holstery fabric using oriented high density polyethylene netting and a web of staple nylon fibers.
An upholstery fabric woven from 3,600 denier bulk con~inuous fil-ament polypropylene yarn, 4.9 oz./sq. yd. in weight, having a 10 x 6, warp by fill count per inch, is stabilized with a combination of a 0.64 oz./sq. yd.
oriented, high density, polyethylene ne~ting, and 1.0 oz./sq. yd. web of 3 denierJ 2 inch staple nylon fibers. The original upholstery fabric has a seam slippage value of less than 10 pounds in each direction and a grab tensile strength of 100 p.s.i. in the machine direction and 45 p.s.i. in the transverse direction. The fabric is passed through a web straightening device to establish proper alignment 3~
~f pattern, then cJn to a pin tenter where it is dra~ to the full standard upholstery Eabric width o~ 56 inches. ~rom the ten-ter the fabric passes immed.iately on to a 4 fo~t diameter fluoropoly-mer coated drum which is heated to a surface temperature of 150C.
To maintain the full width o.~ the abric and to resist shrinkaye and distortion, the fahric is retaine~ by a line of pins around the circumference at each edge of the heated cylinder. At the point where the fabric makes contact with the heated drum the layer of thermopla.stic netting (of flat, 4 mil thic~ hexagonal lO bosses, which measure 16 mils across a flat surface and are evenly distributed at a density of 900 bosses p.s.i., connected to each other by thin strips of oriented thermoplastic between each of the six sides of the hexagonal, as shown in FIGS. 9 and lO of the drawings), and the layer of nylon web are joined to the fabric and the 3 layer laminate travels around the drum with the weh against the hot surface and with the oriented netting be-tween the fiber web and the upholstery fabric, the composite being in con-act with 3/4 of the circumference of the drum, at a rate of 60 ft./min. The dwell time in contact with the hot roll is 9.8 sec-20 onds. The laminate then passes through a nip formed by an 8 inchdiameter water-cooled steel roll pressing against the heated drum with hydraulic pressure of 18 lbsO/linear inch. The fabric then moves around the cooled roll to the wind-up. The resulting sta-bilized fabric has a tensile strangth of 150 lbs./in. in the machine direction and 105 lbs./in. in the transverse direction and seam slippage values of 28 pounds and 35 pounds in the ma-chine and transverse directions respectively.
Example lO
This example illustrates stabilization of a tufted fabric 30 as well as the use of the alternative apparatus for manufacturing stabilized fabr.ics shown in FIG. 14.
A tufted fabric, weighing 10~5 o~./sq. yd. and comprised of 0.11 inch pile of 1.5 denier rayon on a 48 x 30 count woven cotton is stabilized using a combination of spun bonded continuous 3~3 ~ilament nylon with an orientecl high clensity polyethy1ene nettin~J
weight 0.~ oz./sq. yd. and having 121 bosses per square inch, about 4 mils thic~. (Hercules ~elnet PA-218).
Using the apparatus shown in FIG. 14, the fabric is aligned as in previous examples and lifted from the tenter so as to place its back side towarcls the heated drum 37 at the point of contact between rolls 36 and 4~ where the stabilizing material is ~oncled to the fabric. The stabilizing material which i6 a 0.6 oz./sq.
yd. spun bonded nylon weh 40, and the netting 35, pass over roll 10 43 which is heated to a surface temperature of 260~F., and, after 1 second dwell on roll 43, passes through the nip at 60 pouncls per linear inch and onto the hot drum 37 which ls at 385F. After 5 seconds dwell on the hot drum 37, the netting is completely melted and is supported on the spun bonded nylon web. The melted net then contacts the fabric at roll 36. The fabric and stabiliæing material continue around the hot ~rum for 1 second and a pressure of 80 lbs./linear inch is applied by roll 46 which has a steel surface and is internally cooled by water. The stabilized struc-ture then advances around a second wa~er-cooled roll 47 to the 20 take-up roll 48.
The resulting stabiliæed fabric was improved from a con-dition o nearly zero resistance to loss of tufts to a condition of complete retention of tufts after the most stringent dyeing conditions.
Example 11 This example illustrates stabilization o~ a knit fabric produced from polyester spun yarn using a combination of spun bonded continuous filament nylon with an oriented high density polyethylene net. The knit fabric weighing 10.5 o~.~sq. yd. had 30 an elastic recovery of less than 75~ in 5 minutes after elonga-tion, before stabilizing. The high density polyethylene ne~, ~eighLng 0.7 oz./sq. yd., has 910 hosses per square inch which are approximate~y 4 mils thick. The spun bonded nylon is ~.4 oz./sq. yd.
, :
3~ 3 The apparatus as in FIG. 1~ was used exactly as in Example lO. The stabilï~ed fabric product has sicJnificantly improved di~
mensional stability, the elastic recovery heing over 85~ ln 5 minutes after lS~ elongation.
Example 12 This example illustrates the stabiliz.ation of the upholstery fabric described in Example 9, using an oriented high density polyethylene net and a web of staple modacr~lic fiber.
The upholstery fabric, plastic netting and procedure employed lO in Example 9 are used, except that a needle-punched staple web of modacrylic fiber weiyhing l.0 oz./sq. yd. i5 substituted for the nylon staple web. The modacrylic web is of 3 denier, 2.5 inch fibers which were needle-punched 150 penetrations per square inch onto the plastic netting. The composite of modacrylic fibers and plastic netting was supplied to the stabilizing apparatus as one web. The resulting stabilized fabric has a tensile strength of 145 lbs./in. machine direction and 98 lbs./in. transverse direc-tion and seam slippage values of 30 and 33 pounds in the machine and transverse directions respectively.
Example 13 This example illustrates the stabilization and flame retar-dance improvement of upholstery fabric using oriented high density polyethylene netting in combination with aluminum foil and poly-ester staple web.
Aluminum foil, 0.35 mil thick, was plied with a l.0 o~./s~.
yd. web of polyester staple fiber, 3 denier, 1.5 inch length, and needle-punched to the e~tent of 25 penetrations per square inch.
The oil composite so produced was then laminated to the upholstery fabric as in Example 9. The procedure as in Example 9 was fol-30 lowed with the exceptions ~1) that the drum s~rface temperature was at 180C., ~2) the plastic netting was 0.8 o~./sq. yd., having 99 bosses per square inch o approximately 12 mil thickness, and ~3) the aluminum foil staple web composite was used in place of the staple nylon we~.
The stabili~e~l fahric product had seam slippage o~ 40 and 31 pounds in the machihe ~nd transverse directions re~pectively, and recei~ed a ratirlg of Class A by the Federal Standard PFF6-74, Cigarette Ignition Test.
Exa~ple 14 This example illustrates stahilization of a fabric by an al-ternative procedure of needle-punching the fabric together with a thermoplas~ic netting and a stabilizing layer~ and then applying heat and pressure to bond the loose-needled fibers of the ~abric 10 and the stabilizing layer into a dimensionally stable structure.
A woven fabric of nylon yarn, having a yarn count of 1 1X9, warp X fill, anc~ a weight of 11 oz./sq. ycl., is plied with a bond-ing layer oE thermoplastic netting and a stabilizing layer of spun bonded nylon, and the combination is needle-punched together -to form a composite structure. The netting and stabiliæing layer are positioned at the back of the fabric and the needles penetrate into the face side of the fabric and through the back so as to entangle the netting and stahilizing layer among the fibers at the back of the fabric. A needle penetration of 250 per sq. in., 20 at 5/8 inch dept}i, is used. The thermoplastic netting is high density polyethylene weighing 0.8 oz.~sq. yd., having 130 12-mil bosses per square inch. The stahilizing layer is 0.4 oz./sq. yd.
spun bonded nylon.
After needle-punching, the composite structure, which is formed, is supplied as a single component to the apparatus as in Example 9 and thermally bonded. The procedure and bonding condi-tions are the same as in ~xample 9, except that in this case, the fabric which enters the web straightening device has the ~onding and stabilizing layers already in place. After the heatiny, 30 pressing, and cooling as in Example 9, ~he profluct has seam slip-page values of 30 pounds and 32 pounds in the machine and trans-verse dire~tions, respectivelyO
In all o~ the preceding axamples, the bonding material was observed to h~ve penetrated substantially ~om~letely into the stabflizing layer and partially into ~he fabric layer.
- 2~ -
Claims (18)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A multi-ply textile web comprising a woven, knitted or tufted fabric layer, a stabilizing layer of staple fibers or continuous filaments, and an air-permeable bonding layer of thermoplastic material, wherein the bonding layer interconnects the fabric layer and the stabilizing layer of staple fibers or continuous filaments by means of bonding zones, said bonding zones completely penetrating the fibers or filaments of the stabilizing layer and partially penetrating the fibers of the fabric layer.
2. A multi-ply textile web as claimed in claim 1 in which the layer of staple fibers or continuous filaments is needle-punched to the other two layers.
3. A multi-ply textile web as claimed in claim 1 or 2 wherein the air-permeable bonding layer is a plurality of discrete spots of bonding material in a substantially uniform pattern.
4. A multi-ply textile web as claimed in claim 1 further characterized in that the layer of thermoplastic material, a layer of aluminum foil and the stabilizing layer of staple fibers or filaments are needle-punched together and are then bonded to the fabric layer.
5. A multi-ply textile web as claimed in claim 1 further characterized in that the layer of thermoplastic material, a layer of aluminum foil and the stabilizing layer of staple fibers or filaments are needle-punched to the fabric layer and then bonded together.
6. A multi-ply textile web as claimed in claim 4 or 5 wherein the air-permeable bonding layer is a plurality of discrete spots of bonding material in a substantially uniform pattern.
7. A multi-ply textile web as claimed in claim 1 wherein said fabric layer is fabricated from continuous filament polypropylene yarn and is stabilized by bonding with an oriented, high density polyethylene netting needled with a loose web of polypropylene staple fibers.
8. A multi-ply textile web as claimed in claim 1 wherein said bonding layer is a thermoplastic netting and wherein said stabilizing layer is a web of spun bonded staple fiber.
9. A multi-ply textile web as claimed in claim l wherein said stabil-izing layer and bonding layer comprise a unitary composite structure of a thermoplastic netting or film having a web of staple or continuous filament fibers needle-punched thereto.
10. A multi-ply textile web as claimed in claim 1 wherein said stabil-izing layer and bonding layer comprise a unitary composite structure of a thermoplastic netting having a web of staple or continuous filament fibers bonded thereto.
11. A multi-ply textile web as claimed in claim 1 wherein the staple or continuous filament fibers of said stabilizing layer are flame retardant.
12. A multi-ply textile web as claimed in claim 9 wherein said unitary composite structure includes a layer of aluminum foil interposed between and needle-punched to said thermoplastic netting or film and said web of staple or continuous filament fibers.
13. A multi-ply textile web as claimed in claim 1 wherein said fabric layer is a woven fabric.
14. A multi-ply textile web as claimed in claim l wherein said fabric layer is a knitted fabric.
15. A multi-ply textile web as claimed in claim l wherein said fabric layer is a tufted fabric.
16. A multi-ply textile web as claimed in claim 1 wherein said bonding layer and said stabilizing layer are needle-punched to said fabric layer prior to bonding.
17. A multi-ply textile web as claimed in claim 16 including a layer of aluminum foil interposed between said bonding layer and said stabilizing layer.
18. A multi-ply textile web as claimed in claim 1 wherein said stabil-izing layer and said bonding layer have interposed therebetween a layer of aluminum foil, and said three layers are needle-punched together to form a unitary composite structure prior to bonding to said fabric layer.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US73283276A | 1976-10-15 | 1976-10-15 | |
| US732,832 | 1976-10-15 | ||
| US05/826,489 US4159360A (en) | 1976-10-15 | 1977-08-17 | Stabilized fabrics |
| US826,489 | 1977-08-17 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1109383A true CA1109383A (en) | 1981-09-22 |
Family
ID=27112464
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA288,108A Expired CA1109383A (en) | 1976-10-15 | 1977-10-04 | Stabilized fabrics |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA1109383A (en) |
| IT (1) | IT1087960B (en) |
-
1977
- 1977-10-04 CA CA288,108A patent/CA1109383A/en not_active Expired
- 1977-10-14 IT IT2863777A patent/IT1087960B/en active
Also Published As
| Publication number | Publication date |
|---|---|
| IT1087960B (en) | 1985-06-04 |
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| MKEX | Expiry |