DE1635606A1 - Process for the production of products which can be used as solid cushioning material - Google Patents

Description

EI DU PONT DB NEMORS AND COMPANY 10th and Market Streets, Wilmington, Delaware 19 898, V.St.A ₁

Process for the production of as coarse upholstery material

usable products

The invention relates to a method for the production of resistant ,, compacted products made from fully expanded, randomly arranged, micro-cell-shaped thread material.

Upholstery fabrics, especially carpet underlays, have to be subjected to high loads withstand while retaining some compressibility, they must have a high initial resistance to tf.ie have compression, and they must be proportionate thin, usually about 0.63 to 1.90 µm thick. Furthermore, such substances must also be used without the permanent influence of an external body To be constant in strength.

Attempts to use compacted upholstery material made of fleece from mikrozallenförroigen Threads according to the usual heat bonding process

to manufacture

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• How they are used to manufacture non-woven fabrics from dense, fibrous thermoplastic materials are used, were not satisfactory. The self-tie lead often microscopic structural changes in the cell walls of the cellular material, which reduces its impermeability to gases, leading to the loss of blowing agents local heat treatments in which parts of the inflated padding melts, leads to cutting or tearing of the material due to its low density.

Ylieae made from puffed up microcellular filaments are far too puffy and easy to bend around each other permit. Such products are soft because of the volume of gas compressed at the crosshairs when first a load is brought into effect, is extremely small in comparison to the total volume of the fleece

The inventive method allows the production of coarse cushioning material from micro-sell-shaped threads that can be calibrated, is particularly suitable for carpet underlay, but also used for the production of cushioning acting containers or cushion intermediate layers for products port in Iran are easily damaged. Furthermore, the products manufactured according to the invention are very good thermal insulation materials that can be used in the walls of cooling systems, apartments or in winter clothing, etc.

109813/16

ORIGINAL

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the like can be used. As a result of their low Density and their water resistance - they are also suitable for Devices that rely on buoyancy in the water.

The method according to the invention for the production of products which can be used as coarse upholstery material is characterized in that a random fiber fleece or random fiber fleece made of completely inflated, randomly arranged, closed-cell, micro-cell-shaped thread material, preferably with planar-oriented plastic cell walls, in which a normally solid binding agent is used on the thread material thermoplastic adhesive is deposited, which can be activated at a temperature below the melting temperature of the plastic from which the threads are made, heated to a temperature below the melting temperature of the plastic which is sufficient to activate the adhesive, by compression, preferably between rollers and / or belts, compressed and cooled under compression for the purpose of deactivating the adhesive and stabilizing the fleece in compressed'Zustande, the volume of the thread material being at least 40 $> the volume of the compressed fleece. "_

In a preferred embodiment, the method is thereby characterized in that a fleece made of ultra-micro-cell conveying

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BATH ORIGINAL

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migen padengut, the closed cells of which contain 6 to 40 g non-thermosetting blowing agent per 100 g plastic, is heated to such an extent that the padding is completely inflated = the drawing represents a Plieesdiagrannn of this preferred embodiment of the method according to the invention.

The compression of the fleece can be between a product and an outer barrier layer, so that a protective layer is formed around the product, or it can be between Surfaces are made, at least one of which is deeply engraved 1st, so that a compacted fleece is formed, embossed with a raised pattern of intersecting lines.

According to another embodiment of the invention, a knitted, non-woven, tightly woven or net-like textile material, a foam foil, a metal foil or a coherent plastic foil is used during activation of the adhesive ait brought into contact with the fleece and firmly bonded to the fleece surface by compression together with the fleece.

According to a particularly preferred embodiment, this is The volume of the thread material is at least 80 # the volume of the compacted web.

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A method for production is also within the scope of the invention of three-dimensional molded bodies, what is achieved thereby is that you can put the procedural steps in a form carries out "

Micro-cell-shaped thread material is a homogeneously ver ~ to understand schaustes plastic material in thread form. the Lines of foam are vial-curled, and at least the majority of them is completely made of thin, filmartdgen, foldable Walls enclosed made of a film-forming thermoplastic Are made of high molecular weight plastic. Fully inflated threads have a volume of at least about 95 # dos maximum volume that without stretching the cell walls is achievable.

Suitable micro-cell-shaped threads should have densities in the completely inflated state in the range from about 0.005 to 0.05 g / cm2. | flattened filaments are usually in the range of about 0.25 to 6.35 mm; however, diameters between 1.27 and 2.54 mm are preferred. The usable in the invention raikrozellenförmigen threads are ausθerdem be collapsible, so that by a from the outside exerted pressure load substantial deformation materialize "this is requirement gentigen the threads in general, when have the thickness that it in the fully inflated state au t, under a

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load of 0.70 kg / cm, based on the area calculated from the thread length and the original thread diameter, reduced by at least $ 10 if the load is applied for 1 second, and if the thickness immediately after the load has ceased increases by at least $ _{50 »9,} preferably by 100 # of the value by which it had previously decreased.

Particularly advantageous microcellular threads are the ultra-microcellular threads described in US Pat. No. 3,227,664. Ultra-microcell-shaped threads have cell walls less than about 2μ thick, in which the plastic is in a crystalline state and has a uniplanar orientation and a uniform texture, as described in the patent mentioned. The last two properties give the threads a surprisingly high strength m * and make their cell walls particularly impermeable to most gases.

The predominance of closed cells is determined with the pale eye or microscopically. One can see the content of the closed Determine cells but also by the gas displacement method, which Remington and Pariser in "Rubber World", May 1958, page 261, is described, the 3e method eo is modified, that is at the lowest possible pressure differences is working"

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A non-penetrative blowing agent is a gas that duroh xlie cell walls penetrate so long that it is practical inside is held back all the time. .

Breathable blowing agents have at room temperature (i.e. between about 15 and 40 ° C) vapor pressures of at least 50 mm Hg and are contained in the cells in such an amount that that the internal partial pressure is at least 50 mm Hg. Preferredö Breathable blowing agents have at atmospheric pressure Boiling points less than about 25 C.

The rate of penetration of a blowing agent through a given plastic decreases with the diffusivity and the Solubility too. Therefore should. Connections «which are considered through Incapable blowing agents are considered so large Molecules exhibit as it is still with the required vapor pressure is compatible, and they should not dissolve in the plastic g. Preferably those are incapable of penetration Bloat compounds whose molecules have other chemical bonds than those of the plastic forming the cells β, and their molecules also have a low dipole moment and show a very low atorapolarizability.

The microcellular pad material is said to be "completely inflated" referred to when it is up to a volume -? on at least

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about 95 ie of the maximum achievable volume is inflated. This maximum volume can be calculated from the maximum diameter observed after extrusion. The maximum diameter can also be determined from the observed micro-cell-shaped thread after immersing it in the soot cooler in the bath, which consists of a plasticizer and a blowing agent which is incapable of penetration, and heating in an air oven. In all cases, pasting is sufficient for the purpose of immersion for 5 minutes in a bath made up of equal parts of the volume of methylene chloride and 1,1,2-trichloro-i, 2,2-trifluoroethane and then heating in air to about 80 ° C.

Although you can make threads with different cross-sectional shapes can, threads with a circular cross-section are preferred «

Suitable thermoplastic adhesives should (1) adhere to the microcellular material with the formation of elastic bonds, (2) be _{flexible and not brittle at normal room temperature, ie o} at about 15 to 40 C, (3) normally white, i.e. at temperatures below about 50 ° 0, be solid and (4) can be activated at temperatures above the temperature at which the cushioning material is to be used, but below the melting temperature of the plastic from which the micro-cell-shaped thread material is made.

109813/1642
BATH ORIGINAL

Adhesive © Particularly preferred are aqueous dispersions having ® ± nem solids content of adhesive of about 5 to 40 wt .- ^, preferably 15 to 25 wt .- # ♦ Also, dispersions or solutions in non-aqueous volatile (embossers can be prepared, "provided ,, that! Präger on d © n plastic nielit plasticize! acts, or that he has already evaporated before it can plasticize the mikroselXehförmigan threads. a longer Piastifizierung leads to loss of required to λ inflation gases or any part thereof.

A thermoplastic adhesive is one such here to understand who lets you activate your eyes repeatedly by means of high heating «An adhesive is activated when it is softened to the point that he is touching others with others file the same adhesive fuses, so that after the Cooling is achieved in a strong adhesive bond.

The melting temperature of the plastic is the temperature at which a sample of the plastic melts and leaves a line on a hot metal surface over which it is pulled under moderate pressure. Details on the determination of the softening points of plastics can be found in the work "Preparative Methods of Polymer Chemistry" by W ₀ R. Soreneori and T. Wo Campbell, Intersoienoe Publishers, Inc., New York, 1961, pages 49 and 50.

109813/1842 ^ original

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The term "planar orientation" is used here in the same sense as in the field of textile fiber technology. One can assume collapsed or partially collapsed threads, provided that they can only be fully inflated before cooling the fleece for the purpose of stabilization in the compressed state. Bas thread material can be produced in a fully inflated form right from the start »and in this case it is necessary. neither to contain a non-penetrative blowing agent nor to be subsequently inflated; however, it can also be produced in a collapsed or partially collapsed state, with a slowly penetrating inflating agent being located in the cells; ultimately, a slowly penetrating blowing agent can also be introduced at any point in time before the thermoplastic adhesive is deposited. If a collapsed thread material is used which contains a slowly penetrating blowing agent, it will expand completely at the latest when the fleece is heated for the purpose of drying or activating the thermoplastic adhesive. The known methods for introducing blowing agents into closed cells of microcellular foams either weaken or completely dissolve the adhesive bonds if the blowing agent is applied stubbornly after the adhesive . The thermoplastic adhesive can be applied either before or after the fleece is laid down _o The fleece can be heated to activate the adhesive and then duroh

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v BACLOBlGJNAt.

prieieren compressed between cold surfaces and are wobbles stabilized "or compressing and heating can" as shown in Example 1 below, are carried out simultaneously, provided »that the Kompressionsdruok is maintained, cooled to the nonwoven fabric and the adhesive is sufficiently deactivated so that the Fleece retains its compacted state after the compressive force has been released * There are also x other modification options. The presence of a throughput λ dringungsunfähigen blowing agent in the closed cells leads to a number of advantages. First, the blowing agent provides a permanent osmotic gradient for air to diffuse in, so that the thread "even if air is lost during compression" later spontaneously re-inflates when exposed to air. Secondly, the blowing agent delivers a superatmospheric internal equilibrium pressure * so that the inflated threads are inflated and lead to a high degree pneumatically *. The non-penetrative blowing agent leads to permanent _Λ pneumatic properties and unlimited maintenance of the upholstery properties.

Suitable blowing agents which are incapable of penetration are sulfur hexafluoride and saturated aliphatic or cycloaliphatic compounds with at least one covalent fluorine-carbon bond and preferably one is the number of carbon atoms

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NP7-11 β.

Exceeding number of chlorine atoms. These blowing agents which are incapable of penetration are preferably perhelogenalkanes or perhalocycloalkanes in which at least 50% of the halogen atoms consist of fluorine atoms. Although these blowing agents may contain ether oxygen bonds, they preferably contain koine nitrogen atoms, carbon-carbon double bonds or reactive fractional groups. Examples of blowing agents that cannot penetrate are sulfur hexafluoride, perfluorocyclobutane, 1,2-dichloro-1,1,2,2-tetra-luoroethane, perfluoro-1,3-dimethylcyclobutane, mixtures of perfluozdimethylcyclobutanes, 1,1,2-trichloro-1,2 , 2-trifluoroethane, CF, CF ₂ C? ₂ OCPHGi ^l ₅ , monochlorotrifluoromethane, diohlordifluoromethar ,, and monochloropentafluoroethane. Perfluorocyclobutane and monochloropentafluoroethane, which boil at -6 ° C and -39 ° S at atmospheric pressure, are particularly preferred because of their indifference, their considerable molecular size, their very low permeation rate and their non-toxicity.

The amount of permeation absorbed in the cells The blowing agent is easy to determine. In a foam thread, which in its cells has an incapable of penetration Contains blowing agent, which is in osmotic equilibrium with the air, the internal partial pressure of the air is about 1 at. The total internal line pressure exceeds the atmospheric pressure.

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spherical pressure around the partial artery of the durohdringungsisnbaren blowing agent. Under these conditions, corrections to the weight in the air, taking into account the air buoyancy, are at best of two-day importance. The weight W _{1 of} an inflated sample in the air is determined. Uatrn is ung © the sample between heated Brueloralzen below a fixed ^ - compressed foamed sheet and weighed again at the "Fragrance} this weight is W" Beaeionnet "Di ©]) ruoksmlzentQiapera <door may naturally nicnt so high be.. that sin ßewlolttsirerlust through the dismantling of the Eeamatsto.ffa & oioii®B team, D @ r Genalt I an, penetration unfSliigeia blowing agent in g -yes 10Og plastic can then.according to the equation

100

to calculate. The concentration of pervasive blowing agents can also be done using other physical methods, e.g. determined by gas chromatography will. . f

There is a big one? Number of Poljsieriaations- and Polykondeneationprodukten, ä @ n®n ä ± @ isikroselleaföriaiges Wääen nit this essential Eigensohaften b®stehen; -can "? S jpiaohs plastics are Kohlenwasserstoffpolyffierieät ©» wi® polyethylene, polypropylene and. Polystyrene, polyethers, such as Polyformald @ hyd, Tinylpolyaerisate, such as polyvinyl chloride w & ä Poly-.

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vinylidene fluoride, polyamides, such as Polyeaprolaetara, Polyh @ xalaethylenadipinsäureaisid and Poly-m-phenylenisophthalaäiargaEäid, Polyurethane, such as the polymer made from ethylene-Ms-ehloraiaeis © » acid esters and ethylenedisnine, polyester, such as polyhydrocyteimathylaosetic acid umä polyethylene terephthalate, seter how

de © K ¹ SIaStstoffa in outer cell strength w & ä impermeable

äahes ¹ ii®J @ aig®n plastic © _s you on the Öriantierrag ämtiassh aaspr © @ hesi ₂ that they are western and more solid w @ rd®s, _o This includes linear polyethylene,

terephthal & t, polyrinyl chloride, and the like. Continue to be Such © Kunststoff® preferred, which are highly resistant to resistance are known against the diffusion of oil, such as Polyätliylantrephthalat and polyvinyl chloride «

in? orü γόη Bndlosfädeii or in 7orm of staple fibers det w @ rS @ n | Stack length ron completely ^ ufgebliht®si

the other aasis & len Qiierabaeeemng)

109813/1642

ORIGINAL

HFr-11 i £

The micro-cell-shaped thread material is laid down randomly to form a tangled fiber fleece or a tangled fiber fleece. Bi © preferred gluttony the surface weight of the microcellular thread material is only obtained if the fleece consists of at least three thread layers, preferably four or more thread layers, so that the microcellular filaments are physically less than Take up about 25 # the volume of the fleece.

The thermoplastic adhesive is usually applied to the threads by dipping, spraying or other known methods. Usually, dilute liquid solutions or dispersions of the adhesive in a volatile carrier are used to spread the adhesive well over all the thread surfaces without adding too much Adhesive solids are absorbed. Depending on the adhesive and the Durohmesser the fully inflated filaments to adhesive solid shots of about 10 to 200 percent have. ~ 4> of the micro-cellular FAE

This has been found to be satisfactory and an adhesive pick-up of about 15 to 50% is preferred, if another method is used Powdery solid thermoplastic adhesive can be dusted onto the threads.

Typical satisfactory adhesives are the known dispersions of vinyl resins, such as copolymers of ethylene and vinyl acetate or of ethylene and methacrylic acid, and the

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same. Also polyesters, polyolefins and polyamides with a correspondingly low melting point (below the melting temperature of the material from which the microcellular threads exist) can be used. Dispersions or solutions of elastomers are particularly effective for these elastomers include, for example, certain polychloroprenes, polyurethanes, and the like. Thermoplastic natural resins with suitable melting temperatures can also be used

The adhesive can be mixed with the usual additives such as plasticizers, finely divided, inert solid scattering agents, flame-repellent Agents, antioxidants and the like, are mixed in a known manner.

In the process according to the invention, the microcellular Threads fully inflated before compaction. Plasticizers and non-penetrable blowing agents can loosen or weaken the thermoplastic adhesives. Therefore, when introducing blowing agents into threads or nonwovens, the If the adhesive is already bound, this can destroy the compression. Even if the threads in collapsed If states are stabilized by the adhesive, they can no longer be expanded to their full volume afterwards.

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BATH ORIGINAL

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The threads are dried atxr evaporation of the volatile carrier. If the adhesive is applied to threads which aind already deposited to form a flowing / _s, the drying takes place simultaneously with the often Terfahrensstuf © in which the adhesive thermoplastic adhesive © dureh Warne is activated. If the threads contain gaseous adhesive, but are not sufficiently old , air has been brought into balance in order to achieve the fully inflated state of the corresponding volume, this heating also leads to "re-inflation" by air up to the maximum ¥ olura @ a _e Bas Brhitsen can in any suitable way; done _o Babei has the 'temperature sufficient-to activate thermoplastic E.ebßtoff, but they arass below ¹ Söhmelgtemperatur ά @ Β plastic lie mikroaelienföriaig from the Sas © Thread consists »

By compressing the fleece between cold surfaces, the threads are inevitably twisted around one another, as a result of which the area of mutual contact of the threads is significantly increased. Pie cold surfaces lead äazu ₉ that the molten thermoplastic adhesive again solidifies ;, whereby the nonwoven fabric in its Terdiohteten state is stabilized. The ease with which this stabilization is achieved depends on several factors Hb ₉ namely a (1) on the difference in temperature.

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BATH ORIGINAL

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Substance and its first stage _? (2) from the Semperatur the cold surfaces, (3) äes on the thickness of the fleece "is" cold "as here the leaperatsr of the compression surfaces effecting relative aar temperature of the nonwoven fabric; vos? ier denotes compression “In reality, these surfaces can often be higher than this

There are ^ ahlrsieh © - M8glicite © it @ ffi _g ® ± w, ® auf riedenteilende? © ^ - diehtrag and Abidfelu & g aerfeeisufffesiu Bsr simplest way bs ~ stands ± m compressing <ä © s Vllesas swisshen smooth »flat» cold \ mä parallel . Surfaces »Piping surfaces or one of them ki $ im & £ abes? amch deeply engraved to a lofty ite ^ tone see cutting Maies ₃ ^ ₉ Be a mainant pattern ,. © rs ^ iigen. If the b @ id © n surfaces or one of them have or has at least a deeply engraved pattern, since @ serves as a shape, this five-fold method can be used., Toys, sB <filling @si for toy animal © » hBTzuet & llen» You can also go to the Q & tin & w & gsgm & Bem Verfaisren ®tn Vlie © as Sohio &i; Compress the object © h @ rum »the oil nap. Schute by require. . . .

If you have a% erM3 Küiuvmg mUm bei
can be achieved as is Sola

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the HindiEcehf clock en by the mm & lot f satisfies cold Eäiasiderwalzen "Longer Vsrweilzeiten achieved Sßan _s when fffhrt the slit between a conveyor belt and a cold Walz® Msdurc &, vobei the conveyor belt over © inen large © n part of Walzerasiafa & gave away firmly to the WaXsenoberfläch © is pressed, Tf © leiie letstare can be smooth or deeply engraved. The goods to be treated are preferably guided through the equally wide gap sv / isGh © n extended ropes of two endless conveyor belts 6.exn l? .Indiircage · Usually an additional support on the back side of these conveyor belts is via the whole contact stable ©. This is necessary to generate enough pressure for the test line of the Ylieee and to keep the gap between the conveyor belts constant _o You can work with smooth conveyor belts, but preferably one of the two conveyor belts is made up of links made of engraved or latticed metal.

After it has been compacted, the fleece can be heated to form the adhesive activate again, whereupon it continues to © ine larger Thick © (lower density) expanded and then chilled again can be »to deactivate the adhesive again and that Stabilize fleece in its new thickness »M® resolidification can then be done with the new, permanent tile thickness. Highly compacted nonwovens, in which the volume of the micro-

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cellular thread material is more than 80 # of the fleece, can be sent less expensively and can then be inflated to the desired larger bead at the point of use will"

The fleece can go through and through with small sizes of silencers, such as talc, dusted or by hitting or spraying, with lubricants such as detergent or silicone containing liquids and then dried. These Silencers reduce the noise that can occur when the fleece is periodically compressed. Preferably the The silencer is dispersed together with the adhesive before it is applied to the micro-cell-shaped Padengut.

In a further stage of the process according to the invention, layers of other materials can be applied to one or both surfaces of the microcellular material are bound. Such layers are e.g. knitted, non-woven, dioht-woven or reticulated fabrics, foam rolls, metal foils and cohesive plastic films. The binding of these layers can be done in a separate post-treatment; preferred However, if these substances are applied to the fleece surfaces, while the thermoplastic adhesive is activated and then together with the fleece dsm compaction process subjected so that they look firmly to the Vllesoberflachen tie.

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BATH ORIGINAL

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There is also the option of one or both surfaces of the compressed fleece © ®, foamable with a doctor blade © Hassan or an incompletely cured foam from a blastomer to apply «In this way one gets self-bound Layers of polyurethane «, polychloroprene -

In the following example © »see rope © and Prosent information, Unless otherwise stated, on sewing quantities.

B e is ρ ie 1 1 ■,

According to the invention, a carpet underlay is produced.

Ultra-microcellular polystyrene terephthalate filaments by extrusion of a uniform, mutable solution from a 3 l cylindrical pressure vessel through an opening 0.305 mm wide and 0.152 mm long into the surrounding area Atmosphere created. 3) the bridge vessel is connected to the the following components?

Dried polyethylene terephthalate (E ¥ * = 50) 1485g dried methylene chloride (^ 25 ° O) 942 ml dried!, I.S-IEriohlos-US.S-trifluor "

ethane (^ 25 ° 0) 162 nl.

* see page 22.

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ORIGlNAL BATHROOM

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* The relative viscosity (RV) is the ratio of the absolute viscosity of the polyester solution to that of the solvent at 25 ° C. The solvent is a solution of 70 parts of 2,4,6-trichlorophenol in 100 parts of phenol. The polyester _{solution contains 8 f} 7 £ polyethylene terephthalate in the solvent -

When extruding through the nozzle opening, the solution in the Dsmckgefäß is kept at 190 ° 0 and a Jfeuok of 36.9 atmospheres. A rotating blade arranged behind the string opening cuts the pressed threads in stacks of 12.7 - * 2.5 cm.

Complete inflation is achieved by immersing the staple fibers in a constant-boiling bath of methylene chloride and at least 9 % perfluorocyclobutane for several minutes. This! The bath boils under 1 atm pressure at -6 ° C. The staple fibers are then heated to 125 ° C for 15 minutes in an air oven. They inflate fully to a au Durohmesser won 1.90 mm, a density of 0.015 g / om ⁵ country containing durohdringungsunfähigem blowing agent (Perfluoreyolobutan) of 14 g per 100 g polyester, (specified here content of blowing agent is durohdringungsunfähigem determined by weighing the fully inflated sample, then compressing it between heated «and a solid film and weighing it again. The weight of the solid film is the polyester content,

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BADORfGtNAL

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while the difference between the "two weights" equals that Content of non-penetrable blowing agent is ·)

A dispersion © ines thermoplastic binder is durö & Yeraiischen made of the following ingredients?

Hassft weight parts

5t? 5 # aqueous dispersion of a copolymer made from 72 $>

Ethylene and 28 $> acetate

with a softening point according to the ring and ball method © (ASa? M-E-28) of 154.4 ° C 100

Talc ( $ 60 pesticides in water) 100

Extra water 245

This binder dispersion is applied in fine jets to the Stapelfaeora sprayed on, the staple fibers are in a Box placed with a 38.1 χ 63.5 cm top opening, and the box is placed in an oven at 125 ° C, until the water has evaporated from the binder. This treatment also fuses the thermoplastic Binding agent, so that the staple fibers are bound to one another at their crossing points after cooling.

The cooled fleece is placed between two flexible sheets of polypropylene foam (17 g / m ² ). The whole thing is placed on a metal stamping plate and brought between the flat flats of a hydraulic face., The stamping plate points

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CONSTRUCTION ORIGINAL

HP7-1t - HL

Diamond hair dryer pattern with diagonals of 2.5 x 5 »O em auf, di © Are engraved 1.27 cm deep into the plate. The raised embossed lines delimiting the pattern are 1.59 mm wide. the Press® panels are opened from the inside by water vapor Heated to 125 ° O; First of all, the Ylies is in an uncompacted state © held between the plates, whereby the adhesive is reactivated, and then the press is in working position

boiled, with a pressure of 2.8 kg / om on the fleece the steam supply is turned off and cold water is passed through the plates until the surface temperature is reached Has reached 50 ° E. When removing the laminated body is found that it is consistently compacted and keeps the pattern imprinted on it. The foam sheets are firmly bound to the two surfaces, whereby the foil on the embossed side has adapted exactly to the embossing pattern.

The weight per unit area of the compacted carpet underlay is

204 g / m ι the ultra-microcell-shaped staple fibers and the binder each contribute 85 g / m ² to this surface area. The maximum thickness of the rounded bosses of the diamond-shaped patterns is 0.91 cm and the minimum thickness along the embossed lines 0.18 cm. These thicknesses correspond to densities of 0.022 g / es ⁵ and 0.115 g / cm ^5, respectively.

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1098 13/164 2
fiQ Ct £ ä BAD ORIGINAL

^{B3? 7-11} is

Be 1 β ρ i el 2

ültramilgroselle-shaped polyethyleneite terephthalate staple fibers. are used for the production of another leppiohuat plant. The procedure corresponds to that of Example 1 with the following exceptions?

(1) The threads contain 15 g of perfluoroyclobutane after being inflated on each 100 g polyester? .

(2) The binder consists of the following components:

Hatred • ffewiohtateile

50 5 * strength aqueous dispersion of a Mieohpolymerisatee from 67 $ ethylene and 33 5 »vinyl acetate with a similar to the ring and Kugelidthode (Α3ΪΜ ~ Β-28) hestiismten softening point of 115.6 ° 0.590

Talc (60 £ Feetetoffs-in water) 332nd

Extra water, 1300

(3) Neither of the two sides is covered with a transparent film

(4) The Verdi ohtu & g takes place in the same way as the flat plates of a hydraulic prees · without Euhllfenahae an embossing plate.

Dan-resistant, compacted flat product is O ₉₉₂₂ whether diok has and a density of 0.0135 g / om, to which the Sohauafäden 57 i "and the binder contribute # 43. The prcba is 34.5 cm

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broad and 55 "9 cn" long. Similarly, becomes a® number γόη made fluff carpet underlays, their surfaces on top layers made of kraft paper, plastic films, foam films, net-like fabric, non-woven fabric or seppiah fabric are bound.

Example 3

This example shows that the produced according to the invention Upholstery material can be changed afterwards by simply® heat treatment inflate it to a greater thickness.

The materials and processes correspond to those of the example. The test produced is 33 »6 cm wide and 54.6 cm long. Its thickness in τ® r dense a tea condition is 0.602 cm and its density 0.030 g / eir, with the foam threads contributing 55.6 ρ and the binding agent 44.4 $. Two rigid Streckinet all plates are kept in this way! clamped that jswischen them a © 1.90 om wide opening is, and the sample is inserted between the plates. The thermoplastic adhesive is activated by heating in an air oven to 125 ° C, whereby the fleece fills the space available. When cooled at room temperature, the adhesive again acts as a binding agent, and the stabilized sohlleselioh obtained "Probt has a" Bioka Ton 1.90 om and "ine Seht" of 0.0096

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BATH ORIGINAL

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Example 4

Completely inflated staple fibers according to Example 1 are sprayed with an adhesive dispersion, laid down by hand to form a 7.6 cm wide and 61 cm long tangled fiber fleece and dried. The total weight per unit area of the dried fleece is 187 g / m 2, to which the adhesive solids contribute 34 g / m 2.

The adhesive dispersion consists of the following components:

Hate parts by weight

42 # aqueous emulsion of a mixed

polyaeriDates from $ 83> ethylene,. 6.9 i> methacrylic acid and. 10.1 f>

Vinyl acetate made with caustic soda

partially new to an ionomer has been neutralized 476

33 # aqueous emulsion of ethylene bis-stearic acid amide (Melting point 142 to 144 ° C) 45

3? Alkum (60 ^ ige dlepersion in water) 166 Additional waeeer 576.

Bas bound fleece is made by passing it through a an orphan and a conveyor belt existing pressing device EU condensed into a stable structure. The roller, its diameter 30.5 cm is on its surface with two each characterized by 8 parallel, helical ribs

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NF7-11 Rf

that is 0.79 on radially outwards! what trek and Are 0.16 cm wide. The two rib aggregates intersect such that they have a diamond-shaped pattern with 8 rows of Form diamonds with diagonals of 5 x 2.5 cm. The roller is located to room temperature, and the conveyor belt: is arranged so that it is about half the circumference of the orphan is close to this.

Immediately before being fed to the gap between the roller and the conveyor belt, the fleece is blown out of a circular air blower supplied air is heated, creating the thermoplastic Adhesive is activated. The circumferential speed of the roller is 6.1 m / Hin, and ~ the contact time in the space between the roller and the conveyor belt for 5 seconds. When passing the Fleece between the roller and the conveyor belt takes place a stable compression, and a permanent, deeply embossed diamond pattern is created on the surface of the fleece.

B. 9 i β ρ ie I '5

Fully inflated microcell-shaped staple fibers according to Example 1 are further cut to staple lengths of 2.5 cm. They are sprayed with the adhesive dispersion gemäes Example 4, below the üeiie in this case, but A eineε blue dye have been added. The weight balance

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NP7-11 519.

Fibers to the solids of the adhesive is 10 s 1 A layer of fibers moistened with glue is put on placed on the bottom of a cardboard box, and on top of this layer are placed an Erlenmeyer flask, bottle and metal funnel put on. The box with the rest will be spell-bound wet fibers completely filled, and the top is locked. It comes in a sealed box Luftofan heated to 125 ° C until all the water evaporates is, whereby the adhesive is activated at the same time, laugh that When the fleece cools down, a permanent Poleterblook has formed, which has the shape of the interior of the box. Huh removing the glass and metal objects shows that the fleece has adapted to the shapes of the same exactly. This results in the commercial usability of the according to the invention manufactured products for shaping life jackets, toys, pillows, packaging, etc.

Example 6 .

A highly compressed bonded fleece produced according to Example 2 is 0.82 Ω thick and has a weight per unit area of 93j 3 β / π »», to which the solids of the adhesive contribute 25 g / a ² . This fleece is inserted between a net-shaped linen and an ordinary cotton fabric and intersecting with each other by yards over its entire surface

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Provide seam lines, the diamonds with diagonals of 5 x 5 cm "Form" when heated in the air at 125 ° C for 1 minute. The Yli © s bulges in the areas between the seams like a quilt on, while the thickness along the seam lines remains practically unchanged.

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Claims (6)

1R356Ö6 Ed. du Pont d © Nemours 28. Deseafcer 1967 and Gorapany HFf-11 Pat e η t a η s ρ r ü e h © 1. A process for the production of products which can be used as coarse cushioning material, characterized in that (a) © in V tangled fiber fleece or tangled fleece made entirely bloated, randomly arranged, closed-cell, mikrozellformiggm thread material, preferably from a planar oriented plastic, in which a normally solid thermoplastic is used as a binder on the thread Adhesive is deposited at a temperature below that the melting temperature of the plastic from which the threads are made can be activated, (b) to a temperature sufficient to activate the adhesive heated below the melting temperature of the plastic, (c) it is compressed by compression, preferably between rollers and / or belts, and cooled under compression for the purpose of deactivating the adhesive and stabilizing the fleece in the compressed state, the volume of the thread material being at least 40 ί> the volume of the compressed fleece. - 31 1 O 9 8 1 37 1 6 4 2 NP7-11 Sä 2. The method according to claim 1, characterized in that a Fleece made of ultra-micro-cell-shaped thread material, the closed cells of which are 6 to 40 g of durohdringungsunfäliiges blowing agent each Contains 100 g of plastic, heated to such an extent that the thread material puffs up completely β Method according to claim 1 or 2, characterized in that · that a protective layer is created around a product, placing the fleece between the product and an external one Barrier layer is compressed. 4. The method according to claim 1 or 2, characterized in that questioning the fleece with a raised cough of intersecting lines by compressing it between surfaces, at least one of which is deeply engraved is. 5. The method according to claim 2, characterized in that a Knitted, non-woven, tightly woven or net-like textile material, a foam film, a metal foil or a coherent plastic film when the adhesive is activated brought into contact with the fleece and firmly bonded to the fleece surface by compacting together with the fleece 6. The method according to claim 1 to 5 »characterized in that . the volume of the thread is at least 60 pounds of the volume of the twisted fleece is. 1098 ^13/3 f 6 * 42