CA2302345C - Process for producing sheet-like formations by using a mixture of fibers and foamable material as well as foamable material - Google Patents
Process for producing sheet-like formations by using a mixture of fibers and foamable material as well as foamable material Download PDFInfo
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- CA2302345C CA2302345C CA002302345A CA2302345A CA2302345C CA 2302345 C CA2302345 C CA 2302345C CA 002302345 A CA002302345 A CA 002302345A CA 2302345 A CA2302345 A CA 2302345A CA 2302345 C CA2302345 C CA 2302345C
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- Prior art keywords
- fibers
- foamed
- foamable material
- foamable
- fiber
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Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
- D04H1/68—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions the bonding agent being applied in the form of foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C44/0446—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by increasing the density locally by compressing part of the foam while still in the mould
Abstract
The invention relates to a method for the production of flat structures using foamable material and fibers with a high fineness coefficient. The foamable material is applied by spinning or is foamed totally or partially thereafter on the flat structure by applying energy. Fibers with a fineness coefficient greater than 50 are used. A considerable enlargement of the active surface is achieved by using foamed or post-foamed fibers. This leads to a reduction in bonding agent or binding fiber consumption and in thickness. A
reduction in material consumption and costs is also achieved.
Insulation values are improved while emissions are reduced.
reduction in material consumption and costs is also achieved.
Insulation values are improved while emissions are reduced.
Description
kcv sY : z-~~~.- ~~ : ~ ~> : t oE~~ : cc i ~r~~ r:cNt~ sMAwr ~ t~ i conk .._. ., '"'1 2545,/ ~7 ~ 13 B
PrOCe~ly for producing sheet-like formations by us~_ng a mixture of fib~:rs and foamable material as well ae foamable material The ir.~rention cencern~ a pxocese for producing sheet-like torrnat:~ons by using a mixture of fibers and foamabie material which ~.s fC~amed by adding energy and to e~ foamable material for pxc>ducirig these sheet-like formations, Nonuvov~:n yabrics, mats, insulating and cushioning elements made of fibers, natural. fibers, wand woal, straw, plant stalks and the: like are known in a variety of forms:
with mechanical bonding by needling, stitching, binding or plaiting, with bonding by thermobon,dir~g, with bonding by an adhesive which is applied by dipping, pouring or spraying on, with bonding by an adhesive which is applied by special mixers or gluing machines or else blow lines, the latter techniques only be:lng applicable in the case of short fibers of up to about 2f~ mm .
Also known are foam materials and foam composites in which a foam represents the matrix in which fibers, knitted or laid fabxics are integrated for reinforcing puxposes.
The proc.ucts and processes ment~,onad above have a. number of reetricticns and disadvantages. RmQng the moat serious are:
RCV F3Y : 2-24- O : 12 : 1 2P!11 : CC; I TT E;CM--~ SMART & B I GGAR : # ~3 1 i v~. v ~ -J Vt' n L-~ .~~ IL:..~~,TL ~ ' ~J
Ne8dli11g, stitching or ple,iting inevitably leads to an increane in density. As a result, the insulating properties and th~a cushioning properties are greatly reduced. Higher den~sit~r also means at the same time higher raw material consum~~tion;
~'hermox~onding with single- or bi-component polymer fiyaers has proven very successful for many application areas. However, polymer fibers are expensive and not very ecological, since considerable amounts of process energy are required in the eyrthaeris, with high emissions as a consequence. To avoid this, t;lends of natural fibers and polyfier fibers are used wherever there ft3 no need for pure polymer fibers to be used.
However, even in the cane of fiber blends, the proportion of polymer fibers is usually no lowex than 25%, otton even over 50~r;
Dipping and spraying predominantly takes place with elastomers, secondly with thermosetting materiala~ and, for certain application areas, also with mineral binders.
I~owever, the consumption of binders is high. The density ie likewise high. High material consumption means high costs.
High do~.~sity means low thermal insulation.
According to the prior art, subs~,anc~es used as binders, for example polymer fiber~$, are fully spun or extruded over their cross sEaction~ impregnating or spraying compositions are applied with full coverage, predaminarifi,ly full wett3ny arid encapsu~.axyon, and then cured.in a variety of ways.
Tt is kr:~.own to produce insulating materials from natural fibers. Since, with few exceptions, natural fibers do not havQ high resilience and nonwovan fabrics made of natural fibers therefore have poor shape retention, they disintegrate RCb fY' = 2-'?4- O : 12 = 1 LPM : CC I'f'f ECM-. SN1=ART ~ 13 f GGAR : # 4 ~r and lot;;e a can~iderable part of their insulating affect over time. To~prevent this, generally l5% more brittle polymer fibexa are mixed in as "supporting fiber~a". Subjecting the nonwove:n fabrics made of natural and supporting fibers to a heat tt-eatrnent, thereby making the polymer fibers begin to melt, G:chieves the effect that the polymer fibers fuse togeths~r at their erossing points (thermobonding). xhi.s brings about a three~dimensional composite structure, toy which the su~~porting effect of the polymer fibers is enhanced. Full palymex~fiberB are used.for this purpose, ire, other words fibers of which the entixe cross sectis~n consists of a polymer or of two pol~rmers in the case of so-called bi-component fibers.
JP-A-44 028 534 discloses a method for producing compound parts wtzich are formCd of reinforcing fibers and foamed resin as matrix. The foaming ~akes place subsequently and serves for better yenetration o.f the reinforcing fibers. The compound parts produced ir. such a manner have a high compression with !~omogen~aous structure. Almost no air inclusionr~ remain between the fib~ars. The gas created during the foaming does not remain in the ~:ompound part, but escapes through a gap in the formation. According to this state of the axt, a homogeneous halohed~.~al connection from fib~r to fiber is vbtai.ned and therefo~:e compound parts with a high compression.
Accordic>,g to U.S. Patent No. 5,264,~.~3 a filling is provided whioh ccrasists of inflammable fibers with natural fibers. Such loose fillings are used, for example, far thermal jackets.
The i.nva<ntion is based on the object of providing a process for producing sheet-like formations which is distznguis3hed by the following a,dvantager~
PrOCe~ly for producing sheet-like formations by us~_ng a mixture of fib~:rs and foamable material as well ae foamable material The ir.~rention cencern~ a pxocese for producing sheet-like torrnat:~ons by using a mixture of fibers and foamabie material which ~.s fC~amed by adding energy and to e~ foamable material for pxc>ducirig these sheet-like formations, Nonuvov~:n yabrics, mats, insulating and cushioning elements made of fibers, natural. fibers, wand woal, straw, plant stalks and the: like are known in a variety of forms:
with mechanical bonding by needling, stitching, binding or plaiting, with bonding by thermobon,dir~g, with bonding by an adhesive which is applied by dipping, pouring or spraying on, with bonding by an adhesive which is applied by special mixers or gluing machines or else blow lines, the latter techniques only be:lng applicable in the case of short fibers of up to about 2f~ mm .
Also known are foam materials and foam composites in which a foam represents the matrix in which fibers, knitted or laid fabxics are integrated for reinforcing puxposes.
The proc.ucts and processes ment~,onad above have a. number of reetricticns and disadvantages. RmQng the moat serious are:
RCV F3Y : 2-24- O : 12 : 1 2P!11 : CC; I TT E;CM--~ SMART & B I GGAR : # ~3 1 i v~. v ~ -J Vt' n L-~ .~~ IL:..~~,TL ~ ' ~J
Ne8dli11g, stitching or ple,iting inevitably leads to an increane in density. As a result, the insulating properties and th~a cushioning properties are greatly reduced. Higher den~sit~r also means at the same time higher raw material consum~~tion;
~'hermox~onding with single- or bi-component polymer fiyaers has proven very successful for many application areas. However, polymer fibers are expensive and not very ecological, since considerable amounts of process energy are required in the eyrthaeris, with high emissions as a consequence. To avoid this, t;lends of natural fibers and polyfier fibers are used wherever there ft3 no need for pure polymer fibers to be used.
However, even in the cane of fiber blends, the proportion of polymer fibers is usually no lowex than 25%, otton even over 50~r;
Dipping and spraying predominantly takes place with elastomers, secondly with thermosetting materiala~ and, for certain application areas, also with mineral binders.
I~owever, the consumption of binders is high. The density ie likewise high. High material consumption means high costs.
High do~.~sity means low thermal insulation.
According to the prior art, subs~,anc~es used as binders, for example polymer fiber~$, are fully spun or extruded over their cross sEaction~ impregnating or spraying compositions are applied with full coverage, predaminarifi,ly full wett3ny arid encapsu~.axyon, and then cured.in a variety of ways.
Tt is kr:~.own to produce insulating materials from natural fibers. Since, with few exceptions, natural fibers do not havQ high resilience and nonwovan fabrics made of natural fibers therefore have poor shape retention, they disintegrate RCb fY' = 2-'?4- O : 12 = 1 LPM : CC I'f'f ECM-. SN1=ART ~ 13 f GGAR : # 4 ~r and lot;;e a can~iderable part of their insulating affect over time. To~prevent this, generally l5% more brittle polymer fibexa are mixed in as "supporting fiber~a". Subjecting the nonwove:n fabrics made of natural and supporting fibers to a heat tt-eatrnent, thereby making the polymer fibers begin to melt, G:chieves the effect that the polymer fibers fuse togeths~r at their erossing points (thermobonding). xhi.s brings about a three~dimensional composite structure, toy which the su~~porting effect of the polymer fibers is enhanced. Full palymex~fiberB are used.for this purpose, ire, other words fibers of which the entixe cross sectis~n consists of a polymer or of two pol~rmers in the case of so-called bi-component fibers.
JP-A-44 028 534 discloses a method for producing compound parts wtzich are formCd of reinforcing fibers and foamed resin as matrix. The foaming ~akes place subsequently and serves for better yenetration o.f the reinforcing fibers. The compound parts produced ir. such a manner have a high compression with !~omogen~aous structure. Almost no air inclusionr~ remain between the fib~ars. The gas created during the foaming does not remain in the ~:ompound part, but escapes through a gap in the formation. According to this state of the axt, a homogeneous halohed~.~al connection from fib~r to fiber is vbtai.ned and therefo~:e compound parts with a high compression.
Accordic>,g to U.S. Patent No. 5,264,~.~3 a filling is provided whioh ccrasists of inflammable fibers with natural fibers. Such loose fillings are used, for example, far thermal jackets.
The i.nva<ntion is based on the object of providing a process for producing sheet-like formations which is distznguis3hed by the following a,dvantager~
RC\' BY : 2-'~4- 0 : 1:3 : l 1 F'M : CC: I '1"f L:CM~ Shf.~lR7' & B I (:C:AR :
# 5 a LW LvVV I ' LL: IW ~.nY' V'J-~ t i ~ J
Lowering densities to the greatest extent, in order to save weight and' consequently material. The lower the density, the better the insulating effect of insulating materials. The lower the weight, the lower the fuel co:~.sumption in the case of vehj.cies and consequently the lawer the emissions. Low weight generally allso means a reduction of aostm.
Retention of high strength values in spite of lowering the density' .
Lowering to the greatest extent pos~lible the binder consumption requzred Lor holding components together. Binders are almost always considerably more expensive than, for example, fibrous or fiber-'containing natural substances.
economical binder eonsumptior~ therefore lowers coats. Since most binders are synthetically produced, economical binder consumption can also play a part in reducing emiss~.ons.
This abject is achieved according to the invention by a proces$ for producing sheet-like formations using a mixture of fibers ~~nd foamable material which is foamed by adding energy, whereby the fibers are conzzected partially with each other to a, apati~~l network with low density, whereby the polymexs contains=.d therein freely expand without cvunterpressure and foamed c7r foam~ble material i$ introduced into the fibexs in drip sh~~pe and by expansion of the foam bodies the natural fibers :>.re glued with each other in a junction point manner and supg~orted from within.
zn a dei~elopment of the invention, the foamable or the entirely or partially foamed material is formed of synthetic fibers. The foamabZe or entireJ.y or partly foamed material is advantageously used in the form of filaments or rovings.
# 5 a LW LvVV I ' LL: IW ~.nY' V'J-~ t i ~ J
Lowering densities to the greatest extent, in order to save weight and' consequently material. The lower the density, the better the insulating effect of insulating materials. The lower the weight, the lower the fuel co:~.sumption in the case of vehj.cies and consequently the lawer the emissions. Low weight generally allso means a reduction of aostm.
Retention of high strength values in spite of lowering the density' .
Lowering to the greatest extent pos~lible the binder consumption requzred Lor holding components together. Binders are almost always considerably more expensive than, for example, fibrous or fiber-'containing natural substances.
economical binder eonsumptior~ therefore lowers coats. Since most binders are synthetically produced, economical binder consumption can also play a part in reducing emiss~.ons.
This abject is achieved according to the invention by a proces$ for producing sheet-like formations using a mixture of fibers ~~nd foamable material which is foamed by adding energy, whereby the fibers are conzzected partially with each other to a, apati~~l network with low density, whereby the polymexs contains=.d therein freely expand without cvunterpressure and foamed c7r foam~ble material i$ introduced into the fibexs in drip sh~~pe and by expansion of the foam bodies the natural fibers :>.re glued with each other in a junction point manner and supg~orted from within.
zn a dei~elopment of the invention, the foamable or the entirely or partially foamed material is formed of synthetic fibers. The foamabZe or entireJ.y or partly foamed material is advantageously used in the form of filaments or rovings.
gy : '?-24- 0 : 1'? : 1 1PM : CC: I TT L:CM-~ SMAKT & B I GEAR : # E4 'J A~ ' L O ~ L ~ 'v V 1 ~ r L i I,~. ~ 1 V ' V 'J 1 L '~
Further advantageous embodiments of the method accord~.ng to the iw;rentivn axe shown in the further subclaims.
The ums of foamed or subsequently expandable fibers achieves a great :Lnerease in the effective surface area. This xesults in a redo<~tion of the binder ox binding fiber consumption as well as of I:he density, Material consumption and costs are reduced. The insulating values are improved. Emissions are lowered.
The ex~randing of the binding fibers or binders in some other form i~~ to take place in a variety of wayls:
Blowing agent may be incorporated in the melt before spinning of the fibers, said agent being activated only subsequently by introducing a greater amount of energy than is reauired for creating the melt. Therefore, initially as unfoamed full fiber/bristle is produced, which is then made to expand by introducing energy only after creating a nonwoven or woven fabxic or some othex sheet-like formation, However, the melt may also k~e Chemically or mechanically foamed :~efore spinning, s~o that an already foamed fiber emerge~a from the spinneret, The foaming may also take place by arranging in the spinneret a hollow needle through which air/gas is blown, preferably in a pulsating manner, into the fiber/bristle being produced, in ordex tc~ create an alternation of expanded and nonexpaaded filament:/bristle segments, in order in this way to make the foam-liJ~:e structure of th~ fibers/bristles retain ite ahs,pe better.
Further advantageous embodiments of the method accord~.ng to the iw;rentivn axe shown in the further subclaims.
The ums of foamed or subsequently expandable fibers achieves a great :Lnerease in the effective surface area. This xesults in a redo<~tion of the binder ox binding fiber consumption as well as of I:he density, Material consumption and costs are reduced. The insulating values are improved. Emissions are lowered.
The ex~randing of the binding fibers or binders in some other form i~~ to take place in a variety of wayls:
Blowing agent may be incorporated in the melt before spinning of the fibers, said agent being activated only subsequently by introducing a greater amount of energy than is reauired for creating the melt. Therefore, initially as unfoamed full fiber/bristle is produced, which is then made to expand by introducing energy only after creating a nonwoven or woven fabxic or some othex sheet-like formation, However, the melt may also k~e Chemically or mechanically foamed :~efore spinning, s~o that an already foamed fiber emerge~a from the spinneret, The foaming may also take place by arranging in the spinneret a hollow needle through which air/gas is blown, preferably in a pulsating manner, into the fiber/bristle being produced, in ordex tc~ create an alternation of expanded and nonexpaaded filament:/bristle segments, in order in this way to make the foam-liJ~:e structure of th~ fibers/bristles retain ite ahs,pe better.
SMART & 13 I GGAR : # 7 RCV BY : 2-24'- C3 : 12 : 12PM : CC IT'I' EL'1~1--JV-~L. ..JVV i'LVl ~.,~ IY~"VVTL t ' The f~aam-Like structure may also be created by spinning hollow fi7.aments~ in a known way, which are then tran,sv~rsely fused at predetlsrm.ined interva:~s for enclosing the air in chambers.
The cont~ and material-saving effects of expansion far the gurpos~: of producing sheet-like formations can be further enhanc~ad by the foamed or still to be expanded binder not being need over the full suxtace area, with full or substa,itial coverage or encapsulation, but in a punctitorm manner ax over part of the surface area, referred to hereafter as °paxtial".
Expedient developments of the invention are presented ir. the remaining subclaims.
Thd invention ie explained using a number of example 1st example:
Polymer fibers which have already been foamed during spinning or which are subsequently foamed are used. They combine low density, low raw material consumption and low emissions with a greater effective surface area. according to the invention, in this way insulating materials of still lower density can be created than when using full polymer fib~xs. A lower density means, ;zowever, an improvement in the insulating values. The ~aupport,eng and recovery functions of the polymers are likewise enhanced by the foaming.
subseque~ntzy expandable fibers in. particular offer a large number c'f technical possibilities, on account of the internal pressurE: created during expansion. 'his can be used in many ways.
The cont~ and material-saving effects of expansion far the gurpos~: of producing sheet-like formations can be further enhanc~ad by the foamed or still to be expanded binder not being need over the full suxtace area, with full or substa,itial coverage or encapsulation, but in a punctitorm manner ax over part of the surface area, referred to hereafter as °paxtial".
Expedient developments of the invention are presented ir. the remaining subclaims.
Thd invention ie explained using a number of example 1st example:
Polymer fibers which have already been foamed during spinning or which are subsequently foamed are used. They combine low density, low raw material consumption and low emissions with a greater effective surface area. according to the invention, in this way insulating materials of still lower density can be created than when using full polymer fib~xs. A lower density means, ;zowever, an improvement in the insulating values. The ~aupport,eng and recovery functions of the polymers are likewise enhanced by the foaming.
subseque~ntzy expandable fibers in. particular offer a large number c'f technical possibilities, on account of the internal pressurE: created during expansion. 'his can be used in many ways.
~- gy : 2 -24- 0 : 12 : 1 "P~1 : CC 1 T'1' EC41-i SM ART Ke B I GGAR : # 8 ' i L4'LT' r-VVV i'LVI Yi IIL'IJSiTL I ' V
If the laid fabric or the polymers contained therein is or are allowed to expand freely, in other words without counteupressure, this loads overall to an increase in volume of the laid fabric and consequently to a reduction of th~
density beyond the extent naturally obtained. For the produet:ion of insulating materials, this offers the advantage of obtaining lower nanwoven densities than is possible accord~.ng to the prior art with fiber blends, and consequently better insulating values.
yf, on the other hand, the heigk~..t/volume of the laid fabric is restricted, for example by a double-band press, the expanding pressm;e created has the effect that the fibers press more firmly against one az:other at their crossing points. A more sheet-:.ike bond is created than in the case of free expansion, and consequently a greater strength of the bend.
Foamed or subsequently expandable fibera/bristles/ rovings and the liu:e may also be compression-molded. In the case of blends with polymer fibers, in this case the plastification must f3.rstly take place by supplying energy and then the press mo~.dinc; must take place in a cold mold. In this way, moldings with zc~nally differing compaction can be produced, for example a high~.y compacted outer zo:~e with likewise highly or more highly compacted ribs, ridges; embos~aments etc. lying in betweer:, while the remainder of the laid fabric remains uncamp~.cted or compacted to a small extent. In the case of combina.tians with thermosetting materials in the not yet crvsslinked state, the compression moldzng takes place in a hot mold.
2nd example:
To obtain good reco~rery pxaperties in the case of cushioning materials made of natural fibers, the expandab7.e polymer or KCV BY : 2 -?4- 0 : 1 ~ : 12PM : CC: 17"1' EC,h1-~ Sb1A12T & B I GGAR ; # 9 rw L'1' ...J'nV I LVi III 1. 'v VTL I ' natural.-substance derivative blends or else elastic natural eube~ar~ces,(latex? do not necessarily require a fibrous struct~.ire, since tensile and flexural stxesses scarcely occur ir_ thib~ application. Mere it is sufficient if the natural fibers are supported from the inside by small elastic foam bodies and obtain their forces of xecovery from these, In such a~~plication eases, it is intended to introduce between the f'ix~ers mechanically or reactively foamed elastomers, thermoe.lal~tic materials or polymers, or such materials which can be subsequently expanded. They bring about at the same time a punctiform bonding o~ the Fibers at the points at which they pass through foamed or expandable droplets, beads yr comparable formations as well as resilient support from the inside. This embodiment is technically easier to implement, requires smaller amounts of polymers, elastomers etc. and is adequate for cushioning tasks or fox achieving shape retentio:~.
3rd exa'~nple:
The possibilities of e~tample 1 and example 2 can additionally be combir..ed with one another in many ways.
If long natural fibers are used, the use of foam droplets instead of foamed or expandable fibers is the lower-cost and more ecological variant. It, however, a higher transverse tensil~ strength and possibly flexural strength are also required, small amounts of foamed or expandable fiibera may also be mix~d in with the natural fibers, ire order to bring about a spatial crosslinkage by thermobonding to supplement the resilient properties of the small foam bodies yn the form of drop~.ets or beads.
Taking t;hia. idea a stage further, extremely lightweight and nevertheless high-strength composites can be produced from _g-i ttCV BY : 2--'?4- O : r'? : 1'.?f'M ; CC l'I'T rC~9--~ SMART Xz B ~ (:.i.:AR :
#1.0 . ",. , ~-, fi.ber~~, preferably natural f;bere, as the matrix, foamed or expanf,abhe polymer fibers ~or forming a spatial network fused by therrnobondin3, as well a.a small foam bod::.es in between for expar~~:~ng and supporting the entire system from the inside. A
system of this kind would be analogous to a certain extent with the bony f xamework of a bore at the neck of the femur, which comprises a n~twork of bone platelets with cavities lying ir, between. Tn this case, the cavities predominate. As the bo.~e proved, thin network produces an extremely high degree of strength in spite of the low bone mass. A melding produc~:d in this way could, in terms of voi.ume, consist primar:Wy of air. Long raturai fibers and foamed polymer fibers would form the spatial network. The small fcam bodies additionally introduced would, by expansion of the entire system, not only additionally ~~educe the deneity~but also adhesi~,~ely i~ond the natural fibers together additionally in a nodal ~ca.~ner.
~ith example;
On they basis of the possibi.l.ities menti,cned i.n examples 1 to 3, the production of high-strength, extreme~.y lightweight composite materials, for example vehicle body parts, is possib.e. A laid fabric with the expa~ndalale Gcmpanente mentioned, in fiber and,~or droplet form, rauld, fox example, be placed into the outer panel of a car door arid ~xpanded there. T~h~s expanding pressure would cause the expandable components of the laid fabric to enter into a solid bond with the she;a metal by :incipient melting o, foaming, with or without priming, depending an the nature of tr~$ m~ltable material.. The cyst~m analogous to the neck of a bone, cited in exam~~le 3,. Gompxising a spatially arrar~geci system of long fibers connected to one another by nodes with ~.arge c~avitie$
in betweeh and punctiform support and adhesive bonding by emal7. foam bodies, together with the outr~r panel of a door ~g_ RCS' F3Y ~ "? -~>4 - 0 : 12 : 1 a3Pb1 : CC I'I"f ECM-> I, . ~ SMART & B I GGAR
: # 11 i L i ' ~. ~T ' L V V V I ' L T i L', resultl~ in particularly low weight and partzcularZy high flexurf~l rigidity. The spatial network of long fzbers with the nodal connections described would, in contrast with comparable priar-art moldings3, result in significantly greater strength with much lower weight. Prior-art moldings do nat have such networks as yet, According to the prior art, the densit~~ is still used for providing moldings of this kind with their strength.
Hy analogy, moldings for door linings for examp7.e, can also be produced by the activated polymer fibers and/or small foam bodies fusing or Foaming with the decorative surface and producing the composite structure. The expanding pressure can in this case also be used as the deforming pressure.
_~p_
If the laid fabric or the polymers contained therein is or are allowed to expand freely, in other words without counteupressure, this loads overall to an increase in volume of the laid fabric and consequently to a reduction of th~
density beyond the extent naturally obtained. For the produet:ion of insulating materials, this offers the advantage of obtaining lower nanwoven densities than is possible accord~.ng to the prior art with fiber blends, and consequently better insulating values.
yf, on the other hand, the heigk~..t/volume of the laid fabric is restricted, for example by a double-band press, the expanding pressm;e created has the effect that the fibers press more firmly against one az:other at their crossing points. A more sheet-:.ike bond is created than in the case of free expansion, and consequently a greater strength of the bend.
Foamed or subsequently expandable fibera/bristles/ rovings and the liu:e may also be compression-molded. In the case of blends with polymer fibers, in this case the plastification must f3.rstly take place by supplying energy and then the press mo~.dinc; must take place in a cold mold. In this way, moldings with zc~nally differing compaction can be produced, for example a high~.y compacted outer zo:~e with likewise highly or more highly compacted ribs, ridges; embos~aments etc. lying in betweer:, while the remainder of the laid fabric remains uncamp~.cted or compacted to a small extent. In the case of combina.tians with thermosetting materials in the not yet crvsslinked state, the compression moldzng takes place in a hot mold.
2nd example:
To obtain good reco~rery pxaperties in the case of cushioning materials made of natural fibers, the expandab7.e polymer or KCV BY : 2 -?4- 0 : 1 ~ : 12PM : CC: 17"1' EC,h1-~ Sb1A12T & B I GGAR ; # 9 rw L'1' ...J'nV I LVi III 1. 'v VTL I ' natural.-substance derivative blends or else elastic natural eube~ar~ces,(latex? do not necessarily require a fibrous struct~.ire, since tensile and flexural stxesses scarcely occur ir_ thib~ application. Mere it is sufficient if the natural fibers are supported from the inside by small elastic foam bodies and obtain their forces of xecovery from these, In such a~~plication eases, it is intended to introduce between the f'ix~ers mechanically or reactively foamed elastomers, thermoe.lal~tic materials or polymers, or such materials which can be subsequently expanded. They bring about at the same time a punctiform bonding o~ the Fibers at the points at which they pass through foamed or expandable droplets, beads yr comparable formations as well as resilient support from the inside. This embodiment is technically easier to implement, requires smaller amounts of polymers, elastomers etc. and is adequate for cushioning tasks or fox achieving shape retentio:~.
3rd exa'~nple:
The possibilities of e~tample 1 and example 2 can additionally be combir..ed with one another in many ways.
If long natural fibers are used, the use of foam droplets instead of foamed or expandable fibers is the lower-cost and more ecological variant. It, however, a higher transverse tensil~ strength and possibly flexural strength are also required, small amounts of foamed or expandable fiibera may also be mix~d in with the natural fibers, ire order to bring about a spatial crosslinkage by thermobonding to supplement the resilient properties of the small foam bodies yn the form of drop~.ets or beads.
Taking t;hia. idea a stage further, extremely lightweight and nevertheless high-strength composites can be produced from _g-i ttCV BY : 2--'?4- O : r'? : 1'.?f'M ; CC l'I'T rC~9--~ SMART Xz B ~ (:.i.:AR :
#1.0 . ",. , ~-, fi.ber~~, preferably natural f;bere, as the matrix, foamed or expanf,abhe polymer fibers ~or forming a spatial network fused by therrnobondin3, as well a.a small foam bod::.es in between for expar~~:~ng and supporting the entire system from the inside. A
system of this kind would be analogous to a certain extent with the bony f xamework of a bore at the neck of the femur, which comprises a n~twork of bone platelets with cavities lying ir, between. Tn this case, the cavities predominate. As the bo.~e proved, thin network produces an extremely high degree of strength in spite of the low bone mass. A melding produc~:d in this way could, in terms of voi.ume, consist primar:Wy of air. Long raturai fibers and foamed polymer fibers would form the spatial network. The small fcam bodies additionally introduced would, by expansion of the entire system, not only additionally ~~educe the deneity~but also adhesi~,~ely i~ond the natural fibers together additionally in a nodal ~ca.~ner.
~ith example;
On they basis of the possibi.l.ities menti,cned i.n examples 1 to 3, the production of high-strength, extreme~.y lightweight composite materials, for example vehicle body parts, is possib.e. A laid fabric with the expa~ndalale Gcmpanente mentioned, in fiber and,~or droplet form, rauld, fox example, be placed into the outer panel of a car door arid ~xpanded there. T~h~s expanding pressure would cause the expandable components of the laid fabric to enter into a solid bond with the she;a metal by :incipient melting o, foaming, with or without priming, depending an the nature of tr~$ m~ltable material.. The cyst~m analogous to the neck of a bone, cited in exam~~le 3,. Gompxising a spatially arrar~geci system of long fibers connected to one another by nodes with ~.arge c~avitie$
in betweeh and punctiform support and adhesive bonding by emal7. foam bodies, together with the outr~r panel of a door ~g_ RCS' F3Y ~ "? -~>4 - 0 : 12 : 1 a3Pb1 : CC I'I"f ECM-> I, . ~ SMART & B I GGAR
: # 11 i L i ' ~. ~T ' L V V V I ' L T i L', resultl~ in particularly low weight and partzcularZy high flexurf~l rigidity. The spatial network of long fzbers with the nodal connections described would, in contrast with comparable priar-art moldings3, result in significantly greater strength with much lower weight. Prior-art moldings do nat have such networks as yet, According to the prior art, the densit~~ is still used for providing moldings of this kind with their strength.
Hy analogy, moldings for door linings for examp7.e, can also be produced by the activated polymer fibers and/or small foam bodies fusing or Foaming with the decorative surface and producing the composite structure. The expanding pressure can in this case also be used as the deforming pressure.
_~p_
Claims (19)
1. A process for producing sheet-like formations using a mixture of fibers and foamable material being foamed by the addition of energy, characterized in that the fibers are partially connected with each other to a spatial network with low density, whereby the polymers contained therein freely expand without counterpressure and the foamed or foamable material is introduced into the fibers in drip shape and by expansion of the foam bodies the fibers are glued with each other in a junction point manner and supported from within.
2. The process according to claim 1, characterized in that the foamable or the entirely or partly foamed material is formed by at least one of synthetic fibers and man-made fibers.
3. The process as claimed in any one of claims 1 or 2, characterized in that the foamable or entirely or partly foamed material is used in the form of filaments or rovings.
4. The process as claimed in any one of claims 1 to 3, characterized in that the foamed or subsequently foamable material is combined with nonfoamable materials of high strength and high elesticity as an enclosing covering in the melt bath.
5. The process as claimed in claim 4, characterized in that the combination of expanded or expandable material with firm, high-strength and elastic material is created as a covering or cross-sectional segment by coextrusion.
6. The process according to any one of claims 1 to 5, characterized in that the different fiber types are mixed with each other.
7. The process as claimed in any one of claims 1 to 6, characterized in that the droplets of the foamed or foamable material are introduced between the fibers during the formation of the spatial network.
8. The process as claimed in any one of claims 1 to 7, characterized in that the fiber material is bonded together at the crossing points or points of contact by expansion and/or thermobonding.
9. The process as claimed in any one of claims 1 to 8, characterized in that small amounts of foamed or expandable fibers are mixed in with the natural fibers and a spatial crosslinkage takes place by thermobonding.
10. The process as claimed in any one of claims 1 to 9, characterized in that fibers with a slenderness ratio of greater than 50 are used.
11. The process as claimed in any one of claims 1 to 10, characterized in that the different types of fiber are blended with one another.
12. The process as claimed in any one of claims 1 to 11, characterized in that the fiber material is shaped to form the laid fabric.
13. The process as claimed in any one of claims 1 to 12, characterized in that, in the case of combinations with thermosetting materials in the not yet crosslinked state, the compression molding is carried out in a hot mold.
14. The process as claimed in any one of claims 1 to 13, characterized in that, in the case of blends with polymer fibers, the plastification takes place by supplying energy and subsequently press molding is carried out in a cold mold.
15. The process as claimed in any one of claims 13 and 14, characterized in that moldings with zonally differing compaction are produced.
16. A foamable material for producing sheet-like formations using fibers according to any one of claims 1 to 15, characterized by hollow fibers, the cavity of which is interrupted by cross walls or constrictions.
17. The foamable material as claimed in claim 16, characterized in that a hollow needle is arranged in the spinneret for foaming.
18. The foamable material as claimed in claim 17, characterized in that when the hollow needle is actuated, gas is blown in, in a pulsating manner, through the hollow needle during extrusion.
19. The foamable material as claimed in any one of claims 16 to 18, characterized in that the hollow fibers are divided into chambers at predetermined intervals by transverse fusing.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE19737013.6 | 1997-08-26 | ||
| DE19737013A DE19737013A1 (en) | 1997-08-26 | 1997-08-26 | Process for the production of flat structures and foamable material for the production of flat structures |
| PCT/DE1998/001765 WO1999010579A2 (en) | 1997-08-26 | 1998-06-29 | Method for the production of flat structures and foamable material for the production of said structures |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2302345A1 CA2302345A1 (en) | 1999-03-04 |
| CA2302345C true CA2302345C (en) | 2004-10-19 |
Family
ID=7840138
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002302345A Expired - Fee Related CA2302345C (en) | 1997-08-26 | 1998-06-29 | Process for producing sheet-like formations by using a mixture of fibers and foamable material as well as foamable material |
Country Status (7)
| Country | Link |
|---|---|
| EP (1) | EP1007313B1 (en) |
| AT (1) | ATE204802T1 (en) |
| AU (1) | AU8971898A (en) |
| CA (1) | CA2302345C (en) |
| DE (2) | DE19737013A1 (en) |
| ES (1) | ES2163292T3 (en) |
| WO (1) | WO1999010579A2 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ITMI20042159A1 (en) * | 2004-11-11 | 2005-02-11 | Sapsa Bedding S R L | PROCEDURE FOR THE MANUFACTURE OF AN ARTICLE IN LATEX FOAM AND ITS ARTICLE IN LATEX FOAM |
Family Cites Families (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB993966A (en) * | 1960-12-23 | 1965-06-02 | W E Rawson Ltd | Method of and apparatus for bonding fibrous material |
| JPS495743B1 (en) * | 1965-10-21 | 1974-02-08 | ||
| GB1141549A (en) * | 1966-06-23 | 1969-01-29 | Du Pont | Cushioning structure |
| US3760046A (en) * | 1967-08-04 | 1973-09-18 | Avisun Corp | Process for producing a composite yarn which is bulky, slip-resistant and of high strength |
| DE1685180A1 (en) * | 1968-02-03 | 1971-09-02 | Heinrich Haeussling Fa | Non-woven fabric |
| DE1710622A1 (en) * | 1968-03-12 | 1971-07-08 | Girmes Werke Ag | Process for the production of spun hollow threads or fibers and device for carrying out the process |
| NL7317678A (en) * | 1973-12-27 | 1975-07-01 | Aku Goodrich Chem Ind | PROCESS FOR THE MANUFACTURE OF M IMPREGNATED NON-WOVEN FLIES, AS WELL AS THE FLIES THEREFORE OBTAINED AND THE OBJECTS THEREOF. |
| ATE4863T1 (en) * | 1980-09-15 | 1983-10-15 | Firma Carl Freudenberg | FILTER PACK. |
| EP0159427B1 (en) * | 1982-10-22 | 1988-06-29 | Chisso Corporation | Non-woven fabric |
| EP0117458A3 (en) * | 1983-02-26 | 1988-01-13 | Firma Carl Freudenberg | Method of making voluminous fibrous textile fabrics |
| US4626390A (en) * | 1985-01-03 | 1986-12-02 | Allied Corporation | Self-crimped foamed fibers |
| US4758466A (en) * | 1987-05-05 | 1988-07-19 | Personal Products Company | Foam-fiber composite and process |
| DE3918360A1 (en) * | 1988-06-11 | 1990-02-08 | Bundesrep Deutschland | Spinneret and process for producing filamentous compartmented hollow fibres |
| JPH0428534A (en) * | 1990-05-25 | 1992-01-31 | Teijin Ltd | Manufacture of fiber reinforced composite molded form and intermediate blank used in the manufacture |
| US5384193A (en) * | 1990-07-19 | 1995-01-24 | The Dow Chemical Company | Stabilized and carbonaceous expanded fibers |
| JPH06212502A (en) * | 1992-12-25 | 1994-08-02 | Furekishiii Kk | Cushioning material for brassiere cup |
| ATE185733T1 (en) * | 1993-11-29 | 1999-11-15 | Greiner & Soehne C A | MOLDED PART MADE OF PLASTIC FOAM AND METHOD AND DEVICE FOR THE PRODUCTION THEREOF |
-
1997
- 1997-08-26 DE DE19737013A patent/DE19737013A1/en not_active Withdrawn
-
1998
- 1998-06-29 DE DE59801340T patent/DE59801340D1/en not_active Expired - Fee Related
- 1998-06-29 AT AT98941238T patent/ATE204802T1/en not_active IP Right Cessation
- 1998-06-29 AU AU89718/98A patent/AU8971898A/en not_active Abandoned
- 1998-06-29 WO PCT/DE1998/001765 patent/WO1999010579A2/en active IP Right Grant
- 1998-06-29 CA CA002302345A patent/CA2302345C/en not_active Expired - Fee Related
- 1998-06-29 ES ES98941238T patent/ES2163292T3/en not_active Expired - Lifetime
- 1998-06-29 EP EP98941238A patent/EP1007313B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| EP1007313B1 (en) | 2001-08-29 |
| WO1999010579A2 (en) | 1999-03-04 |
| EP1007313A2 (en) | 2000-06-14 |
| CA2302345A1 (en) | 1999-03-04 |
| DE59801340D1 (en) | 2001-10-04 |
| AU8971898A (en) | 1999-03-16 |
| ES2163292T3 (en) | 2002-01-16 |
| DE19737013A1 (en) | 1999-03-04 |
| ATE204802T1 (en) | 2001-09-15 |
| WO1999010579A3 (en) | 1999-06-10 |
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| EEER | Examination request | ||
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Effective date: 20080630 |