CS214516B1 - Method of making the non-woven textile with the form memory - Google Patents

Description

The invention relates to a process for the production of a stage whose nonwovens having stitched pre-cut and velor face and thermoplastic fiber interlayer are thermally plasticized lfl at the melting point of thermoplastic fibers in the interlayer and patterned from the velor face of the tread or molding , by spot or line strengthening of the pressure product and the pattern roller or fitting.

The nonwoven fabric has my shape memory and is suitable for interior furnishing © in the mold

- utility or decorative items for insulation molded, shaped ijalúnické (toast for furniture, technical nonwovens type spevnenýeh geotextllií, mellaračných filters 0 shape memory molded fabric for insulation and cover auto interior _of mobile phones, ships, rail cars letadiel and shaped at the same time patterned parts and the like.

A fabric with a shape memory is understood to be a sheet-like structure that can not only be shaped but retains the acquired shape.

The technology of shaping in textile industry has already its tradition. It can be used for plastic patterning and surface shaping, or for the production of textile extrusions using a prioro shaping method.

By surface-forming is meant the formation of facing and / or backing plastic patterns, wherein the textured patterned fabric practically remains a two-dimensional fabric. In contrast, spatial shaping is understood to be the formation of three-dimensional moldings.

The production of textile moldings by spatial shaping is known in the textile industry in the Specialized assortment, e.g. for textured car mats, soundproofing and heat-insulating textile ceilings, shoe uppers and the like, according to different methods. The first method is carried out by impregnating 8 pre-condensates of synthetic resins and slightly following crosslinking while forming with a hot molding tool. The second method is carried out by forming or superimposing the thermoplastic film or thermoplastic fibrous layer on the back of the fabric and subsequent shaping at the plastification temperature of the thermoplastic fibers with a cold forming tool. The third method is carried out by returning a synergistic blend of thermoplastic and non-thermoplastic fraction in the form of powder, flakes or fibers or coarse fibers 8 by subsequent thermoforming with a cold forming tool.

From the above overview, we can see that the apoobies of the priming process consist solely of physicochemical processes which give very good results, <

however, they also have disadvantages. For example, in the prior art use of thermo molds, one of the disadvantages is a lightly high need of up to 50% by weight, impossibility to use for face patterning, and therefore the need to apply only to the back of the textile product.

In spite of this, the production of plastically patterned nonwoven fabrics provokes more physico-mechanical processes and only sporadically chemical processes of surface shaping.

Plastically patterned needlepunch fabrics have been manufactured since 1969 according to patents. Sommer on needling machines with specially designed grids and with a new type of needling needle, which will fit in essence - three kinds of lion-patterned needled fabric, with a grooved structure, looking. . cord-like, with velor structure, irradiating loop velcro and hollow knot and simple pattern effects, especially thick.plastic knobs or simple straightheat patterns. . '

However, the disadvantage of this type of plastic patterning has ceased e.g. high meanders, the more robust machine construction and lower performance compared to the production of plain needled fabrics, as well as the resulting impact on product price, energy consumption and the like. «

Besides mchanických Preparation of patterned fabrics needled e and ^p, however ECENT vyvdali ^e 'and ^e alší.e principles used up lieenrýchh ^ ^ a fabric especially using mrežkovej, plastic or colored patterned fabric layer to the cheek storing the pattern thread ^ h as a priastov loosely laid loops, patterns and the like. on the fleece, by sliding the fibers into the underlying precipitating layer, which, upon shock precipitation, forms spaced loops, studs or geometric patterns at the casting.

Also known are methods of flattening patterning theoretically. all kinds of non-woven iertilií, for example. termoppastev's use and bikomponentov.s shape Steam • ou as vJ.áíkl.en, fiber ^ units, "Foli ^ · ^d isperzií or plastomers. All known manner in the iejio areas are only partially pobiteíné for plastic patterned Lica platform shaped head of 'The reason that the fibers and fiber structures shape bunch of technicians are focused' production with very close ^t i ^r rovo and coloristic 'with * timentnou track. Foil, dispersion. and the plasmids in turn are merely auxiliary textile raw materials which help to form the lion layer but do not look.

However, the method of making the shape memory nonwoven fabric of the invention solves many of the problems and drawbacks of the plastically patterned iertiles.

The results of the verification shall confer advantages,. which are achieved by a process according to the invention, of a shape memory nonwoven and of plastics. patterned on the base of the epichelet, predetermined from the face velor layer formed during the adherence of synthetic but natural staple fibers and a self-interlining of 'thermplaetic fibers' at a low melting point, characterized by: The layered inscribed pre-separation is plasticized by heat at the melting point level of the slaughtered fibers of the throat waist layer and farther at this temperature. from the face of the face of the skin plastically. Patterns and, at the same time, according to the pattern, flat, spot or Siarove is reinforced by negative engraving on rollers or on the fitting and the resulting plastic pattern of textile tread or molding and fixed by cooling to room temperature ·

In order for the production process according to the invention to be carried out correctly, it is necessary that the melting point of the fibers of the facing superficial layer is at least 20 ° C higher than the melting point of the fibers of the thermoplastic interlayer used.

Jale j reverses to each other as needed and connects by padding, overflowing by dancing or bonding to achieve the desired properties and color of the finished product *

The plastic patterning of the textile molding e can be carried out in one operation in a large-scale molding from the large face of the product ·

Laboratory experiments have shown that if on a thermoplastic morning, e.g., polyethylene fibers, is laminated in the morning from colored fibers without a melting point, or with a melting point of at least 20 ° C than the polyethylene self-bonding web used, then starting on a conventional needling machine. piercing even the bundles of colored fibers through the thermoplastic web, a new face pattern layer is formed on its outer side which covers the thermoplastic web and which thus gets to the center of the workpiece. nonwoven J fabric and shape fit · An additional layer of fibrous web, interwoven, foil, and the like can be attached to the pre-piece and and with the help of needling, overlapping or bonding to give the final nonwoven and shape fit ·

By melting the fabric layer thus produced above the melting point of the thermoplastic fibers used, the thermoplastic web melts, flows between the fibers and anchors the roots of the pile fibers into a spatially arranged melt grating.

By suitable regulation of the described thermoprocess, essentially a thermoplastic melt interlayer impregnation takes place, which provides chemical reinforcement of the nonwoven core layer at the level of impregnation with the aqueous dispersions of the film forming polymers · The face pattern layer ei retains the textile character and acquires a high level of mechanical properties

By appropriately controlling the mass fraction of the thermoplastic wound in the nonwoven product within the range of 15 to 50% by weight, the plastic patterning or preator shaping capability is achieved with the desired formation of the plastic pattern 8 by a permanent shape memory.

The prepared nonwoven fabric according to the invention may also be used as a smooth product reinforced by interlayer impregnation and without further impregnation with aqueous dispersions. If desired, a suitable backing can be provided, e.g. · According to the product orientation and permeability or water permeability requirements · The aiming of the product made according to the invention can be from light weights with good permeability for filter materials, wallpapers, upholstery, carpeting and moldings, soundproofing textile cassettes and the like.

The essence of the invention has been experimentally verified in needlepunched and interlaced fabrics.

It was pre-punched by layering a 400 to 500 g / m wound of 17 dtex colored polypropylene staple onto 150 g / m gray polyethylene morning spun directly under the cod.

Needle was transferred with needles 15 x 18 x 32 x 3.5 RB from polypropylene fleece side and thereafter 0 60 stitches / cm ² with stitching depth of 15 mm · Above polyerylene wound a colored covering hair pile emerges from the stitched fiber bundles. in the next procedure considered the face, patterning layer ·

This was previously used as a basic shape memory article and as a face layer for the construction of the finished nonwoven fabric.

In the first experiment ea, on the reverse side of the forehead, another polypropylene morning weight of 400-500 g / m ² was added by needle-punching. The needle-punching was carried out under the conditions of the forepart, but with 150 vpi breeding / cm ² The facial pile layer of the new product still thickened and completely covered the polyethylene fiber layer. The new product was further processed in a laboratory oven at 130 to 140 ° C for 5 to 10 minutes, thereby inter-layered impregnation with a polyethylene melt and thereby chemical reinforcement of the felt. After cooling, the product was evaluated against a similar prepared polypropylene mildew but without incorporated polyethylene j / fibrous layer, and whose chemical reinforcement was predominantly by one-sided impregnation to 20% by weight of the aqueous dispersion of butylacrylate-vinyl acetate copolymer. Drying was carried out at 130-140 ° C for 10 min.

The comparative evaluation hurts the following results:

Binder dry matter Weight g / · ² thickness mm Oder-loss CSN 80 0816 g / m ² % g / в ² % The β ΪΕ felt layer according to the invention, interlayer ivΕ melt impregnation 150 12.37 1222 7.06 56.0 4.58 Plases without PE layer, impregnation with butyl acrylate / vinyl acetate dispersion 210 17.20 1220 7.01 59.3 4.86

From the obtained results of the first attempt to see that the loss of the fiber golded. The dry matter content of the polyethylene binder was up to -5% less than that of the butyl acrylate vinyl acetate copolymer.

In a second experiment, the formation of the plastic patterns by surface shaping on a needled felt produced according to the invention in the first experiment was verified. Predmtná vplchovaná .pleť-treated in a ^p a ^{b l} and plowing ^the rnej auši.arni at 130 to 140 ^{- -} ° C for ⁵ to 10 moderate aa. patterned on a knitted mat by the pressure of a cold-patterning tool according to the conventional known surface-molding technology. - The result was evaluated on - anchored the hair with a peeling - as well as on the percentage of deformation, compress the load !! and recreation of the plastic pattern with parmment, shape memory. * \.

thickness Density-t ^g / · ² % % Retareácla%. Od.r-loss grams /. ² ' % N-isomerized felt according to the invention 7.65 1196 30.96 16.92 5, $ 75 ^ 56.30 4.70 Patterned felt according to the invention 7.30 1193 27.98 15.71 6,510 51.33 4.30

From the results obtained, it can be seen that the plastically patterned felt produced according to the invention, after sheet forming, exhibits generally better yolk properties.

V'tre ^the om ^p Okuse was ovarená olooo ^{p and t} ereo toaroratoínosť plate ^- v ^ ^y otonoj according to the judgment of the patterned aúčairnom plastcckom cheeks. The experiment was then predddalo prepared ^E from ^P rocedure ^fo r the first ^p okU8 wherein proddiolo contained 200 ^{- g} / m ^{2 p} OLYA ^{yl Star} of the new l & nitoj pad ^yl and 400-5 °° ^g / mr colored polypropylene ^ ltaovej vláÍtoiitoj the type ^ . Aalst - process the two preddielo navvrtvili to each henna hair side down, and the connection of the two needling prevailed away from the backing layer and the polypropylene ej miožstoom 15 ^ ⁰ in the collection / cm ² and a puncture hfokou ¹⁸ mm.

The product was subsequently treated in a laboratory drier at 130 to 140 ° C for 5 to 10 minutes and hot-formed by a button, a cold or a warm molding tool on the surface of the fitting that comes into contact with the liner. pista was engraved negative of plastic patterns. When the hot knits are pressed into the molding, the molding agent first came into contact with the molding agent and, after fully pressing, the plastic molding of the textile molding. The shape and pattern were made by cooling the molding.

The shape memory was predominated by gilding the shape deformation of the molding produced according to the invention, without molding - impregnated with a dispersion of a thermoplastic butyl acrylate vinyl acetate dispersion, as well as a commercially available interlining 1000 g / m 2 layer. * polyethylene wound knocked out. right under the jet. The results obtained were! as follow: _

Fiber content of the product Used component for shape memory and as a binder Used heat Deformation. shape in% - po 1 ' 10 ' . 60 ' 48h 8 ⁰⁰ g / m ² polypropylene yarn no Copolymer-B-yl-acrylate-vinyl acetate. Coating 30, 8% - in the dry matter. dry 24.6 24.6 34.0 92.8 650 g / m * polypropylene j staple Spunbonded polyethylene fleece, cased on fabric back. . Weight ¹ 000 ^g / m ² wet / vapor / 24.6 24.6 24.6 25.0 600-800 g / m ² polypropylene staple Spunbonded polyethylene fleece and mounted in a fabric according to the invention. 'Moisture ^{400 g} / m ² dry 24.6. 24.6 24.6 25.0

It can be seen from the comparison that the shaped molding produced according to the invention at the cost-effective embroidery of only 400 g / m @ 2 of thermoplastic binder based. Polyethylene gives practically the same excellent shape memory values as commonly known technologies using up to 1000 g / m 2 of polyethylene fleece. Polypropylene felt alone impregnated with dispersion. of the thermoplastic exhibits only slight shape steam.

The particular processes for producing a memory-shaped knitted fabric according to the invention are described in Examples 1 to 8.

Example 1

For the production of a plastically patterned needlepunching flooring, a fineness of color polypropylene staple fiber is prepared for this material. 50 * parts 17 d-tet, 20 parts 30 children and 30 parts 70 children · Cut length - 90. áž 130 mm ·

The grains are waved, unified and milled to 400 g / m @ 2 in a conventional spinning process, then layered onto a gray polyethylene fleece spun directly below the nozzle at a moisture level.

150 to ‘200 g / m @ 2 and stabs from the side of the polypropylene layer with a 15x18x32x3.5RB needle and a number of 60 to 70 punctures with a 15 mm puncture depth. / This product is considered--to be delayed. .

Parallel for those iatých-primionok prepared the same polypropylene web, but Boz polyethylene layer, which is on the back naivratví prsddiele'a needling combined with the istýn · ^P om the needles, the number of 150 punches / cm ^2, and ^h for ^hours íbkou vpic ¹⁸ as.

• f ·. .

A laminated needle-punched nonwoven fabric is obtained which, if necessary, is treated with a scoop or a heavy-duty backing coat or coating.^{0 g}/ m² and vision, field^- required.the weight and stiffness of production^tou. The plate was dried and plas ticks at a temperature of ‘130 0 to 140 ° C until the polyethylene temoliasic layer is melted and is immediately hot-patterned with a cold forming tool according to a known method.

The formed plastic pattern on the nonwoven - that is, is fixed to room temperature. The finished product ca is trimmed, finished and finished, - packed and dispatched.

Example 2

For the production of so-called. calibrated skins with minimum fluctuations and rakes - for knitted mats of warm PVC flooring, wallpaper and the like. A smooth or patterned cheek is prepared by spinning from - 100% wool or carpet types of textile fibers, or slightly blends with the fibers of the secondary textiles. aicrovine according to Example 1.

The prepared preform aa plasticizes at 130-140 ° C - and - immediately hot is pressed between the smooth and cold rolls of the embossing calender, set at a nip of a half value, such as the thickness of the plastic plate. If desired, the plastic patterned product is obtained by pressing the roller medium of the patterned calender at a pressure of 2 [mu] m.

The compacted felt and the smooth or patterned cheeks formed were allowed to cool to room temperature by cooling. The finished product - aa adjusts as in example 1.ý '.X

Example 3.

For the production of plastically patterned textile interleaves and a handled maid

Λ prepare in advance by laminating a 250 g / M non-woven polypropylene web;] staple fibers 17 a - dise vise on a 100 g / m temppsstic nonwoven web of polyethylene fibers cut directly under the nozzle. The webs are needle punched according to Example 1.

In parallel, a 130 g / m ² fleece was prepared from 70 clays of high-shrinkage polyvinyl chlorofibre and 30 clays of polypropylene staple in wool titers. The fleeces are just pierced.

The web and the fleece are joined in parallel. series. The stacks of strings on the interlocking machine are known in the art. nezráftavýM ⁸

The resulting entanglement is subsequently precipitated and at the same time plasticized on the precipitator by a direct рагу temperature of 150-180 ° C and a pressure of 6-10 kp / cm ² .

The embossed tangles and hot laces next to the patterning calender and the rowed bows and and transversely, geometrically, or otherwise, the fertile shapes are formed into the redesigned images of Example 1.

Example 4

For the production of green amelioration and similar textile filters or geotextiles • Shape memory is made by returning and blending textile fibers from secondary raw materials with a fineness of 3.0 to 30 dtex, mainly on a cheaper and synthetic basis · Blends eg 70 parts of chopped waste with a clarity of 3.0 to 6 dtex and a 30-prong polypropylene-based filament yarn and a fineness of 17 dtex · A blended fleece weighing, for example, · 200 g / m ² is layered on a gray polyethylene fleece m, stitched from the side of the fleece with a number of SO to 90 inserts / cm with a depth of puncture of 13 to 15 mm · Prepared pre-cut is subsequently plasticized at a temperature of 130 to 140 ° C until melting polyethylene J layer and cooling ·

For amelioration filters, it is confoketonized by embossing onto strips of desired hole, plasticized again by heating and shaped into a mellor tube as necessary. A second possible method is the combination of plaetification, subsequent pipe shaping and final welding using a thermoplastic nonwoven component according to known technologies.

For the manufacture of soundproofing and heat-insulating spatially shaped views, shaped sofa parts, seating and linen furniture products, technical moldings and the like, the preparation proceeds as in Example 1, except that a colored polypropylene staple of up to 30 dtex is used with possible blending of 10 to 90 parts of loose fibers only from secondary textile raw materials · Pre-prepared by layering the web from the above-mentioned mixture of fibers of 250 to 400 g / m 2 on a polythylene fleece spun directly under a nozzle of 150 to 200 g / m, followed by needling from the side of the change web of 80 to 90 sprays / cm ² with a puncture depth of 13 to 15 mm · additionally provided with a hardening spray or coating preferably based on dispersion based on thermoplastic polymer to 15 to 25% by weight · In dry matter, further dried, plastic ific is polyethylene at the melting point new j fiber layers and molded by pressing a cold punching tool into desired molding · Molding is fixed by cooling · Molding is cut, ready, packed and shipped ·

Príkledó

For y-fabrication. molded moldings for car, boat, and non-ellers and poles are prepared by a needlepunch according to Example 1 ' -buttons containing ethylene fibers spun directly under the nozzle. cm ² and with an insertion depth of 13 to 15 mm. Subsequently, two layers are applied on top of each other with a pile of hair and side-joints with a side of 150 needles / cm

and insertion depth 18 mm ·

Rripravená nonwoven fabric with shape ^- pamaíou Aalen J is plasticized at the temperature ^T o ^p en and ^{the pickle} of women half ^the lénovýc ^s e ^{h vrβticv,} Dep * at ¹³⁰ to ¹⁴⁰ ° C, to take place okladná mee ^d ^^^^ impregnating the core network fabrics with a polyethylene melt, forming spatially. of an ordered melt grid * - The treated nonwoven fabric is cooled, cut, or chopped on a sheet for molding *

Prepared fertile parts - are plasticized by moist or dry heat and pressed immediately! into the mold by pressure according to known technology. Fixation of the shape in the molding is carried out by it. cooling to room temperature. The molding is - subsequently - - trimmed, - co-infected, packaged and shipped. .

Example 7

For the production of - spatially / molded and at the same time plastically patterned moldings - in one - the description process proceeds in the production technology of the preform and the whole nonwoven fabric with the shape memory including the plasticizing and shaping according to example 6. contact with the face-layer of the molding, and which is opaited with a negative of the plastic vxor to be shown on the Hen side of the molding *.

Molding - molding takes place in two phases. In the first stage, by pressing the molding tool 4, it is drawn into the farm - a plasticized textile product, and - the molding of the second phase is formed by pressing the molding tool into the mold, the molding of the plastic patterns on the molding side is pressed. packaging pretoete PRFI .When ^the Ia ^d of ^1, and 6 *

Example 8

For the production of a spatially shaped stitch-bonded loop texttlií pre - furnishing e.g. * rSznych transport lroltrtedkbv was prepared preddielo no layering - web 200-300 ^g / m ² of ^ woven polypropylene staple kobercársketa ^ty pe of the termoolasticW y ⁱⁿ NO 400 - - 600 g / m ² of The webs are stitched under a nozzle. The webs are stitched according to an example with a depth of 15-18 mm.

At the same time aa prepares interwoven or knitted ferro patterned loop or velor face of staple or filament yarn of carpet type according to known technologies ·

The part aa on the one hand does not melt thermally according to known technology and joins by laminating the patterned face layer and pressing it between the calender rolls into a non-woven fabric final product with a slow shape ·

The nonwoven fabric having an interwoven or knitted patterned face with a shape memory and then plasticized by dry or moist heat is spatially shaped into the desired molding and adjusted according to Example 1.

The finished molding in the case of wet heat plasticization permeated air and water · In the case of dry heat plasticization, the degree of melting of the polyethylene fiber layer may make it impermeable to air and water,

Claims (4)

1 »A method of producing a nonwoven fabric and a plastically patterned face on a needlepunched backing substrate consisting of a facing high-velocity layer formed during the needling of synthetic or natural staple fibers and an interconnecting interlayer. Low-melting thermoplastic fibers comprising 15 to 50% by weight of the mass of the nonwoven product, characterized in that the layered needlepunched part is plasticized by heat at the melting point of the thermoplastic interlayer fibers used and at a high temperature and at the velor side face at the same time Depending on the pattern used, it is solidified, point or line, by pressure-engraved negative on the cylinder or on the fitting, and the resulting pattern of the textile tread or molding is fixed by cooling to room temperature. Method according to Claim 1, characterized in that the melting point of the facial velor layer is at least 20 ° C higher than the melting point of the thermoplastic intermediate layer used. 3. The production method according to claim 1, characterized in that the preforms are further layered on top of each other and bonded by spilling, sawing or bonding. Production method according to claim 1, characterized in that the plastic patterning of the textile molding has been carried out in one operation with the a priori shaping of the velor face of the article.