DE1934835A1 - Flexible web material - Google Patents

Description

Flexible web material

The invention relates to flexible web materials moderate plastic and fiber or fadiene material.

It has been found that a flexible web material, especially solphes, can be used as a substitute for natural leather can, expediently a pressed. Web made of cellular art contains fabric that is on a non-woven layer of fibrous material is applied adhesively. Liability can vary in many ways. achieved four times, for example by means of an adhesive compound or: Flame lamination. It is also known: that fiber material: Adhesively applied to cellular plastic by means of needles can be, with the fibers prior to pressing the assembly

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needled into the cellular plastic.

It has now been found that flexible tape material, particularly suitable for use as a substitute for natural leather, can be made by rubbing a layer of nonwoven fiber onto a sheet of cellular. Plastic is thereby applied in an adhesive manner, since the layer of fiber material is applied to a surface of the web of cellular plastic and the fiber layer is needled so that the fibers are drawn through the surface of cellular plastic to the opposite surface, so that this arrangement under such conditions gepre-SST, when the pressure is removed in that the web of zellförinigem plastic in the compressed state constant-t, and that a further pressed sheet of cellular plastic on the opposite surface of the first-mentioned web adhesively of cellular plastic, applied.

The flexible sheet material is preferably made in such a way that a layer of fiber material as described above is adhered by needles to a sheet of cellular plastic, and that another sheet of cellular plastic is then applied to the opposite surface of the first-mentioned sheet of cellular plastic and that the entire assembly is pressed under conditions in which the sheets of cellular plastic It, remain compressed when the pressure is removed.

The layer of fibrous material contains staple fibers and / or filaments that are either crimped or non-crimped. The layer can optionally be solidified prior to needling onto the web of cellular plastic by needling and / or impregnation with a binding agent. Examples of suitable fiber materials are propylene fibers POL3 ^r>

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Uylon, polyethylene terephthalate, rayon, cotton and wool. The fibrous layer may, if desired, contain a band of staple fibers such as polypropylene or nylon and a band of crimped filaments such as nylon. The fibers preferably have a denier between 0.5 and 60 and a length between about 1 cm to about 15 cm (0.25 to 6 inches), the weight of the fibrous layer is conveniently from about 1 to about 406 g / m ² (0.5 to 12 oz / sq.yd.).

The two sheets of cellular plastic can be the same or have different properties. The cellular If desired, plastics can have different - compression moduli, d. H. Compression resistance, so that a flexible Bahr.material with graduated flexural modulus can be produced from one surface to another, that has properties similar to that of natural leather. This ab- j

ι grading of the flexural modulus can be reinforced by the fact that i different amounts of heat on the during compression opposite surfaces "of the assembly applied will. The cellular plastics can have closed cells, but are preferably open-celled Plastics used. Particularly preferred cellular material is crosslinked or reticulated or reticulated or reticular foam. Preferably, at least one plastic is made of polyurethane, although other cellular plastics are also used can be used, for example foams made of natural and synthetic rubber; Paly vinyl chi ο rid, Polyätiiylsn, Polypropylene and polystyrene. The cellless eater of the cellular one The plastic is expediently between before compression VQO and SOO / u, especially between 100 and 200 / u. If so desired at least one cellular plastic can contain an adhesive which, under the compression conditions. is activated and that hardens so that it "contributes to

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helps to keep the web in the compressed state. Preferred · However, the cellular plastics are wisely free from adhesive impregnation. If desired, at least one cellular plastic can contain other components, for example fibers, which are dispersed in the plastic are. '.

The fiber layer can be attached to the cellular plastic web on a conventional needle machine, for example. The needles are commonly barbed, for example size 41 needles with three barbs are used. The stitch density for attaching the fiber layer to the cellular plastic web is expediently between about 77 and about 1,550 stitches / cm (500 to 10,000 punches / sq.in.), for example between about 310 and 620 stitches / cm ² (2,000 to 4,000 stitches / cm 2) 000 punehes / sq.in.). .

The Kpmpressionsbedbedingungenn of .Arrangement should expediently be chosen so that the zellföriuige plastic or the cellular plastics remain in the compressed state, when the pressure is removed. The compression temperature should be chosen so high that the cell-shaped Plastic softens without destroying the cell structure. It depends in particular on the melting point of the material. is the wedge-shaped plastic should be thermoplastic Temperature of the material during compression preferably not below the Vicat softening point of the material are in the solid non-cellular state as described in ASTM D 1525-65 T: The opposing surfaces of the assembly can be pressed at different temperatures, so that the cellular plastic sheet or tracks, have different densities. It is the Dielite ^ the warmer.n surface larger, '

A typical compression of the originally uncompressed plastic sheet is so high that the strength at least is reduced in a ratio of 10: 1, for example about 20: 1, the density of the cellular plastic is after the compression, for example, 0.5 to 1.2 g / cm. That Material "can be used, for example, in a press with separate moldings, a press with an infinite belt, a converging gap or a device with a movable, to be compressed around a heated drum revolving belt like a "Rotocure". If desired, the material can needled and in a continuous "in-line" process be compressed. "Optionally, one or more additional sheet materials before, during or after the fastening according to the invention or compression can be introduced into the flexible sheet material. Examples of suitable additional railway material are another cellular plastic sheet, a sheet made of textile fibers and a non-cellular sheet Plastic sheeting. -

The textile fiber web consists of a layer of textile fibers, for example knitted, woven or non-woven or in the form of "Arachne" fabric. A preferred woven fabric is nylon fabric *, in particular a tear-resistant fabric such as "rip-stop" fabric. The yarns used in the woven or knitted layer should preferably have a minimum denier of 5O ₉ preferably not have a maximum denier of 1000 at 100, and.

An example of a non-cellular plastic sheet is a sheet of thermoplastic or curable plastic, for example a thermosetting acrylic polymer, nylon or

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Polyurethane. This web can, for example, with the help of a Film transfer technique can be applied.

The additional web material can be attached, for example, by means of an adhesive compound such as rubber latex, by means of a solvent or flame treatment of the surface to be bonded, or, if a fiber material is to be applied in an adhesive manner, by means of needles. Adhesive compositions are preferably applied in a discontinuous pattern, for example by spraying, in order to preserve the permeability of the product. J) . Alternatively, often also preferably, the adhesion is achieved by means of heat and pressure alone. ·

The compressed arrangement can, if desired, with a suitable binders are impregnated, for example with a heat-sensitive, carboxylated acrylonitrile copolymer latex, this binder preferably with different Distribution is applied.

The compressed matter. is optionally marked with an or several surface coatings coated, for example with polyacrylate, nitrocellulose and / or polyurethane compounds. If desired, the coating has graduated degrees of hardness, "One or both surfaces can be embossed. \

The inventive attachment of the fiber layer to the cellular plastic web by needles causes a "hairy" opposite surface of the cellular plastic web as a result of the above "fibers Fibers would not protrude from the opposite surface. However, if the sheet of cellular plastic with a conventional '' ■ leather finish coated, it is found that the coating

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because of the protruding fibers, if the material, is bent. It has been found, that by the Applying a compressed cellular plastic sheet to the hairy surface not just a smooth surface to accommodate the finish that is not created when bending breaks up, but also a higher strength of the connection between the .Faserschicht and the cellular Plastic sheeting to which it is attached. After this Flexible sheet material produced by the method according to the invention has an excellent strength of the interlayer connection and a high permeability for water vapor, at the same time it is impermeable to liquid water. Flexible manufactured according to the inventive method Bahnmaterialieii can be used as. Replacement for natural leather in whose predominant application cases are used, for example .ft ^ r Schuhp ^ ertgils, Schuhfytter, upholstery items, Clothing and Haxiätas.phen, especially cbnn, if the cellular Plastic sheet or sheets between the one oil surface and the opposite surface, there are different ' Have density.

The invention will be explained in the following on the basis of the next few years Examples explained in more detail.

example 1

Using a conventional carding machine and a "cross-wise overlap technique will create a band of approximately 3-denier nylon staple fiber, 6.35 cm (2 inch) long Weighing approximately 172 g / W (16 g / sq. ft?). The tape is reticulated to the upper surface of a web Polyester-Pplyxirethan-Sciiaum type a thickness of 6 mm and a weight of about 196 g / m (18.2 g / square feet)

and put the whole thing through a needling machine and needled at about 620 stitches / cm (4,000 stitches / sq.in.). The needles used are size 41 with three barbs. The needle tips penetrate the assembly completely and penetrate to about 9.5 mm (τ ¼ inch) below the top surface of the base of the machine. The band pulls itself during the needling. together, the total weight of the foam /. Tape connection is about 460 g / m ² (42 g / sq..ft.). The fibers stand out from the uncovered surface of the foam. The tape is attached to the foam sufficiently firmly for handling without any visible damage. However, the tape can easily be peeled from the foam, leaving no trace of nylon fibers on the foam.

The sliver is moistened with a fine water sprayer and another web of networked! Polyester polyurethane foam similar to the first one is placed on top of the foam surface of the put together and the whole is through a "Rotocure" out, whereby the foam surface with the hot Drum and the sliver is in contact with the belt. Of the Pressure "is about. 316 ke / cm. (About" 2.8kg / cm on the layer material), the Troir.meltemp'eratur is 250 ° 0 and the belt speed is about 1.1 m / min (3? J ft / min). The total thickness is before compression about 15 mm (0.08 inches) and after compression about 1.5 mm

(0.060 inch). The bundle weight is about 650 g / m ² (61.2 g / sq.

The tape cannot be peeled from the compressed foam will. Separation of the tape from the foam is only possible if the fibers are torn. ,

A bath-sensitiveΛ latex compound is made from the following components:

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Breon 1571 - 250 g

Igepal OA 630 in £ Qjilger aqueous solution 20 g

Water Dispersion v ^ Zihkoxyd (50 ^ ige weight concentration) 10 g Dispersion of Melustral carbon black PS 5 g

Water 105 g

Catalyst H 7 - 10 ml

Breon 1571 is a carboxylated acrylonitrile mixture of latex and Igepal OA 630 a non-ionic surfactant. Middle. The O-catalyst Ή7 is a material of unknown composition, manufactured by Pirma Röhm & Haas. .

The aqueous solution from Igepal OA 630 is used in the Breon 1571 latex touched. Then in this order the water, the zinc oxide dispersion, the dispersion of Melustral carbon black PS and the catalyst, or H 7 stirred into the latex. The latex composition is then placed in a shallow dish and a Sample, approximately 9.3 dm (1 sq.ft.) of the compressed laminate with the foam layer on top of the mixture let swim. The latex mixture quickly goes "through the tape" up into the compressed foam, but comes off does not go through it and wets the surface of the compressed foam does not. The excess latex is made of -the base of the layer material removed by the same is pulled over the edge of the shell. The layer material is then placed on a support made of a metal grid for 30 minutes in a steam-heated oven, so. that the impregnating agent gels and hardens. The laminate is then washed by rinsing it with water., And then dried at 90 ° in an oven with air circulation. The final weight is about 974 g / m (90.4 g / sq. Ft.).

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The dry layer material is transferred with the aid of a film transfer process provided with an acrylate finish. the Layers of the resulting flexible sheet material can cannot be separated from each other without at least one the layers tear and the finish is resistant to bending. It feels like leather and is permeable to water vapor. -; ..

Example 2. '

On a conventional carding machine, a band is made from about 6,35 cm (2 ^ 5 inch) long, 3 denier staple fibers of polyethylene terephthalaf fibers weighing approximately 97 g / m (9 g / sq.ft.). Two strengths of this bond will be on the surface of a web of cross-linked polyester-polyurethane foam with a thickness of 4 mm. and a weight of about 130 g / m (12.1 g / sq.ft.) and put the whole thing through a Needle machine guided and needled with a total of about 310 stitches / cm (2000 stitches / sq ^ .in.). The blames used are of size 41 with 3 barbs. The needle tips penetrate '■ the arrangement down to a plane that is about 3.17 mm, (w inch) above the top surface of the machine base. The other surface is checked to see if. . . "the fibers stick out.

The fiber layer is finely sprayed with water and moistened and the sheet of hardened polyester-polyurethane foam from a thickness of 8 mm placed on the upper foam surface of the needled structure. The whole thing is carried out by a "Rotocure", the foam surface being in contact with the tape. The press pressure. _ is about 316 kg / cm (about 2.8 kg / cm on the layer material), the drum temperature is 240 ° C and the belt speed is about 1.1 m / min (3 ^ ft./min). the Adhesion of the fiber layer to the foam is checked qualitatively. ......

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A sample of approximately 9.3 dm (1 sq.ft.) 'of the compressed sheet material is made with the heat-sensitive latex mass from example 1 impregnated. The layer material is furthermore impregnated, washed and dried as in example 1 (layer material A). ^ '.

In a similar manner, two further coating materials (B and C), with the exception that when needling the needle tips the arrangement up to a distance of about 3.17 and about 9.5, respectively mm (^ inch or g inch) below the upper surface of the base plate penetrate. ■ -

In a similar way there are two more series of layered materials (D, E, F, and G, H, I) produced, except that once the fiber layer in 6 mm thick foam needle "and before .dem Passing through the "Rotocure" a further 6 mm thick foam layer is added and that the other the fiber layer in 8 mm thick foam is needled and a foam layer 4 mm thick is added before it runs through the "Rotocure".

The adhesion of the fiber layer to the foam in the impregnated sheet materials is measured by on an Instron machine a peel stress test was performed with the jig advancing at about 10 inches / min will. The pull-off load is in the direction of travel of the Tape _ through the needle machine and measured at right angles to it.

The results listed in Tables II and II A show that the adhesion between the fiber layer and the foam is measured to be too low if the fiber layer is needled onto 8, 6 and 4 mm thick foam so that the needle tips are up to a advance about 3.17 mm (rx inch) above (-3.17 mm) the top surface of the baseplate

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Foam surfaces show no fibers after needling, so the needles are adjusted so that their tips are up to "a level about 3.17 mm (w inches) below (+3.17 mm) the upper surface of the base plate '' .-rich case, the adhesion of the fiber layer is sufficiently to the foam by derKompression, however, the peel-stress is very small of the final coating material. If so needled, that the needle tips to about 9.5 mm (^ inch) below (+ 9.5) When the upper surface "of the base plate is reached, a large amount of fibers appear on the foam surface and the layer of polyethylene terephihalab fibers cannot be separated from the foam after compression unless the fibers are broken. The peel-off load of the impregnated layer material with a needle penetration of about + 9-5 mm is two to three times higher than that with a needle penetration of about + 3.17 mm. With a layer material (I). the fiber layer cannot be separated from the foam.

For the sake of clarity, the following abbreviations are used in Tables II and IIA:

Sch = coating material

G (1) = total weight of the fiber layer made of polyethylene terephthalate in g / m (g / 3q.ft.)

S (1) = initial thickness of the foam sheet to which the fiber layer is attached needling is in mm

T = depth of needle penetration in mm (inch)

F = On the back surface of the foam, on the the fiber layer is needled, fibers appearing

S (2) = initial thickness of the foam sheet, which is needled on the back surface of the fiber layer Adhesive foam sheet is applied in mm (inch-)

S (3) = thickness of the compressed layer material before Impregnation in mm

G (2} = weight of the compressed layer material of the impregnation in g / m (g / sq.ft.) ~

Adh = foam / fiber foam adhesion of the compressed

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G (lmp) = impregnating agent absorption in g / m (g / sq.ft.) S (4) = thickness of the impregnated layer material in mm A (1) = foam / fiber layer peel load across the needle ■ direction of the fiber layer in the needle machine in

kg / cm ² (lb / sq.in.)
A (2) = foam / fiber layer peel load at right angles to it in kg / cm ² (lb / sq.in.)

G (D

Table II

S (1.)

S (2)

A. 194 (18) 8th ~ 3y 17th (-1/8): no 101 (4) B. 194 (13) 8th +3, 17th (+1/8) no 10 * 4 (4) 0 194 (18) 8th +9, 5 (+3/8) much 101 (4)

D. 194 (18) 6th -3.17 (-1/8) no 152 (6) E. 194 (18) 6th +3.17 (+1/8) no 15ä (6) F. 194 (18) 6th +9.5 (+3/8) ■ much - -1.5SC6) G 194 (18) 4th ■ -3.17 (-1/8) - no 203 (8) H 194 (18) 4th +3.17 (+1/8) no 203 (8) I. 194 (18) 4th +9.5 (+3/8) much 203 (8)

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S; (3) G (2) Table IIA 603 S (4) A (T) ". 0.232 0V204. 0, 162 NS 0.178 559 (56) (3.3) (2.9) (2.3) A. (0.070) (51.9) ■ Adh G (Imp) 393 ■ -. A (2) 0.565 0.57 0.528 0.157 550 very low (36.5) very low (7.9) (8.1) (7.5) B. (0.062) (51.0) 372 2.34 adhesion very low very low • 0.152 602 sufficient (34.5) 0.225 adhesion adhesion O (0.060) (55.9) 524 2.81 (3.2) 0.225 0.134 0.165 551 no tearing (48.6) 0.549 (3.2) (1.9) D. (0.065) (51.2) 463 (7.8) 0.535 no 0.165 -575 very low (43.0) 2.88 (7.6) Tear B- (0.065) (53.4) 298 0.142 559 sufficient (27.6) 1.93 P. (0.056) - .; (51.9) 660 0.178 563 no tearing (61.2) mm ' G (0.070) (52.3) 431 0.165 557 very low (40.0) 2.99 H (0.065) (51.7) 316 0.147 563 sufficient (29.3) 2.03 I. (0.058) (52.3) Example 3 no tearing

A tape weighing about 248 g / m (43 g / sq.ft.) Is made from approximately 6,35 em (2ο ^{1 inch) long nylon staple fibers of 3 denier.} The tape is applied to the top surface - a sheet of crosslinked polyester-polyurethane foam of a thickness

of 3mm and a weight of about 98 g / m (9.1: g / sq, .ft.) and the whole thing passed through a needle machine and with about

310 stitches / cm (2,000 stitches / sq. In.) Needled. There are ^ size 4T needles with three barbs used. The needle tips penetrate the assembly to a level below about 3.17 mm (-g ineh) (+3.17 mm) of the surface of the base plate of the machine. The back surface of the foam is checked to see if any fibers are protruding.

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The sliver is moistened with a fine water sprayer and a second 3 mm thick sheet of the same foam laid the top foam surface of the needled structure. The whole is passed through a "Rotöcure", with the foam side is in contact with the tape. The pressure is about 211 kg / cm (about 1.87 kg / cm on the layer material), the drum temperature is 240 ° C and the belt speed is about 1.52 m / min (5 ft./min). The adhesion of the tape the foam is examined qualitatively.

An approximately 9i3 dn (1 sq.ft.) sample of compressed laminate material is made with the "heat-sensitive latex compound Example 1 impregnated. The layer material is impregnated, washed and dried as in Example 1 (layer material J).

A second layer material K is produced in a similar way, except that the needle tips are about 9.3 mm (77 inches) below (+ 9.5 mia) the top surface of the base of the needle loom advance. In a similar way to the layer material. J a third layer material L is produced, except that the tape is needled onto 6 ram thick foam so that the needle tips are about 3.17 mm (g inch) below the the upper surface of the base plate. The needled construction is guided through the "Rotocure" without further addition of foam.

The adhesion of the tape to the foam in the layer material is measured in the manner described in Example 1. The results are given in Table III. Yfird the tape on a 3 mm strong Schauabahn needled so that the needle tips by about 3.17 mm below the baseplate of the needling machine, the fibers stand slightly from the rear surface of the foam. The adhesion of the foam to the tape in the final Layer material J is low. Will the tape be like that on a

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3 mm thick foam web needled so that the needle tips now penetrate by about 9.5 below the base plate, so a large amount of fiber protrudes from the rear surface of the foam and the adhesion of the foam to the tape in the final - layer material K is two- up to five times larger than with laminated material J. If the tape is needled directly onto a 6 mm thick foam web so that the needle tips penetrate about 3.17 mm below the base plate, no fibers protrude from the rear foam surface and the foam adheres to the Band in the final layer material L is very small.

The same abbreviations are used in the following table as in Tables II and HA.

Table III F. S (2) O, A. (O , 7) 0, A (2) (0 f- NS Very little 76 (3) 0, 112 '(I, 0, 042 (3 , 6) J much 76 (3> 0, 267 0, 232 (1 , 3) K no no additional
lichen foam,
train 12th 077 , D L. , 6) (3.8) (1

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Claims (10)

PATENT APPLICATION A method for producing flexible sheet material, characterized in that a layer of non-woven fiber material is attached to a sheet of cellular plastic by placing the layer of fiber material on a surface of the sheet of cellular plastic and the fiber, _ita - ^,! layer is needled so that the, \. Pas _> ern ,,. bis; --- z _: ui ^ -: ig _; e; gentJl ^; b-er,. lying surface, the web of cellular plastic are drawn that the assembly is pressed under such conditions that .the web of cellular plastic remains in the compressed state when the pressure is removed, and that another compressed web of cellular plastic to.der opposite surface of the first-mentioned web of cellular plastic material "is attached. · 2. The method according to claim 1, characterized in that the Another compressed web is made by placing a web of cellular plastic on the opposite surface of the first-mentioned web of cellular plastic is applied after the former sheet of cellular Plastic is attached to the fiber layer by needles, and that the entire arrangement under such Conditions is compressed that the sheets of cellular plastic remain in the compressed state when the pressure is removed. 3. Method according to claim 1 or 2, characterized in that that at least one of the cellular plastics is open-celled is. 4. The method according to one or more of the preceding Claims, characterized in that at least one cellular Plastic made from a cross-linked or reticulated ■ There is foam. 9098 8,37.1 55 5 BAD ORlGlNAU 5 method according to one or more of the preceding claims, characterized in that at least one cellular Plastic is made from polyurethane foam. 6. The method according to one or more of the preceding claims, characterized in that the fiber material Contains staple fibers. 7. Method according to one or more of the preceding claims, characterized in that the fibers of the fiber material have a denier of 0.5 to 60 and a length of about 1 cm to about 15 »3 cm. 8. The method according to one or more of the preceding claims, characterized in that the fiber layer is needled at about 77 to about 1,550 stitches / cm. 9 · Method according to one or more of the preceding claims, characterized in that the opposite of each other = lying surfaces of the arrangement have different temperatures during the compression. · 10. The method according to one or more of the preceding -Sayings, characterized in that the strength at least a plastic sheet by the compression of the arrangement is reduced in a ratio of at least 10: 1. 909833/1555 ÖAP ORIGINAL