DE1955673A1 - Web-shaped textile structure with a new configuration, as well as process for its production - Google Patents

Description

Patent attorneys ι

Olpl.-lng.Lf, * n «;; bsr ■ '

Dipi-ir ⁷ 'τ.;I;, inn 1955 673

Tel. 2-31989

Toyo Rayon Company Limited , Tokyo (Japan)

Nov 1969

Web-shaped textile structure with a new configuration, as well as a process for its production

The present invention relates to the production of a web-like textile structure, in particular but on the production of a textile structure with a new configuration, which consists of numerous and extremely fine Individual fibers are made, which change characteristic factors over the thickness of the web to this configuration are summarized.

Numerous attempts have been made to produce artificial leather with a configuration which is similar to that of natural leather. It has been proposed to determine the density of fibers which form a fibrous mass to make variable, and it has also already been indicated, the density of an insert which is added to the fibrous mass will, to change, so that one has the natural leather-like configuration receives. Because of the need to use such a liner and the difficulty of using single fibers extremely To obtain small fineness, it has been very difficult to manufacture a synthetic leather, which the handle and the softness of the

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natural leather.

⁽ It is the most important object of the present invention to propose a web-shaped textile structure which has a novel configuration which, together with other functional properties, comes very close to those of natural leather, as well as a process for the production of the new textile structure.

According to the invention, the web-like textile structure contains two or more kinds of extremely fine fibers of different fineness, or two or more kinds of fibrous ones Bundles which have different numbers of extremely fine fibers, or two or more types of fibrous bundles which a different number of extremely fine fibers with different Exhibit subtleties. In this novel web-like configuration, the fineness of the extremely fine fibers changes and / or the number of fibers in the fiber bundle across the thickness of the web. This change can either be continuous, or it can be achieved in layers, i.e. discontinuously »over the thickness of the web,

To produce the novel web-like textile structure, a composite fiber is first produced from at least one type of island component and at least one type of matrix component. The material of the matrix components is chosen differently from that of the island components. These two components are now combined in such a way that after the subsequent removal of the matrix component from the island components, a fiber bundle is created which is composed of numerous fine fibers. A web is then formed from a large number of such fiber bundles. In forming this web, it is necessary to mix fiber bundles of two or more different kinds, namely, the fiber bundles to be mixed should be different in at least one of the following properties: (a) fineness, (b) fineness or the number of island components in cross section of the fiber bundle, and (c) weight ratio of the island component with respect to the matrix component, In addition, the specified proper ^;

Change shafts across the thickness of the web to be formed. To ■■ ..-. 2 -

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To form the web, remove the matrix component as follows is specified in detail, and a sheet-like structure is obtained which consists of a fibrous mass which is made up of composed of numerous bundles of extremely fine fibers, these fine fibers corresponding to the island components found in the original composite fiber were present.

In the drawing, which shows a preferred embodiment of the invention, represent?

1 shows the cross section through a device according to the invention composite fiber used,

2 shows a cross section through an embodiment of a web-like textile structure according to the invention,

Fig. 3 shows a cross section through natural leather, and

Figure 4 is a cross-section through another composite fiber used in accordance with the invention.

In Fig. 1 there is shown an embodiment of the composite fiber as used in the invention. The composite fiber 1 is composed of a matrix component 2 and a plurality of island components 3, the island components are isolated from one another by the connecting matrix component 2 over the cross section of the composite fiber 1. A big A number of such composite fibers are combined to form a web, and several such webs 4, 6 and 7 are placed on top of one another, as shown in FIG. With this combination, it is necessary to unite paths that come from different ones Composite fibers are made. In the preferred embodiment according to FIG. 2, the outer layers 4 and 7 are made of composite fibers provided a relatively fine configuration, the one obtains, that one (a) composite fibers with relatively coarse Fineness, (b) composite fibers with relatively very fine island components or (c) composite fibers having a relatively large weight ratio of island component to matrix component are used. In contrast, the inner layer 6 consists of a relatively coarse configuration, which is obtained by (a)

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Composite fibers with relatively large fineness, (b) composite fibers with relatively coarse island components or a relatively small one Number of island components or (c) composite fibers with one relatively low weight ratio of island component to matrix component is used.

The tracks 4, 6 laid one on top of the other in this way

7 and 7 are then needled to one another, and the sheet-like structure thus obtained can then be given an external configuration that comes close to that of natural leather, as shown in FIG. 3, for example. As can be seen from this figure, which is a vertical cross-section through natural Leather shows, a surface layer 8, a reticulated layer 11 and an intermediate layer 9 are present, which through layers 8 and 11 are covered on both sides. If one superficially compares the configurations according to FIG. 2 and FIG. 3, so corresponds to the top layer 4 of the inventive web-shaped textile structure of the surface layer 8 of the natural leather, the intermediate layer 6 of the intermediate layer 9 and the lowermost layer 7 of the network-like structure 11. Accordingly the web-like structure according to the invention has an internal configuration, that is similar to that of natural leather, and the textile structure according to the invention has preferred functional ones Properties such as a pleasant feel and excellent softness are those of natural leather is almost the same, and you can use the structure according to the invention " Use as an excellent substitute for natural leather.

The above-mentioned advantage of the textile structure according to the invention is based mainly on the use the composite fiber, which is composed of island components and matrix components, and this material is completely different from the fabrics previously used to make synthetic leather different. The extremely fine fibers obtained by removing the matrix component from the composite fiber are very similar to the collagen fibers that make up natural

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Composed of leather. Since the web-shaped according to the invention Textile structure composed of extremely fine fibers, this structure is characterized by a beautiful natural leather-like handle, which is missing in the synthetic leathers known up to now.

Another characteristic feature of the invention Textile structure is the variable fineness and density of the extremely fine fibers mentioned about the thickness of the item. If you have an elastic layer made of high polymers as the top layer of the dense intermediate layer provides, you can use the inventive textile structure superficial irregularities, which are in the natural Leather is found when the surface of the novel structure is subjected to a bulking process. If you are natural

.that. Leather deformed by bending, such an open surface layer becomes convex, its flexural strength is stronger than its resistance to reverse bending, and when it is repeated Creases form obtuse angles in the surface, whereas acute angles form when you turn the leather upside down Bends senses.

With conventional artificial leather, they develop

the surface disturbances exactly opposite to those of natural leather, and the appearance of the so disturbed surface resembles that of paper or plastic sheets, whereas in the case of the present textile structure the resistance to kinking is the same as that of natural leather and that due to kinking disturbed surface behaves like the corresponding leather surface, which is contrary to the previously known artificial leathers is.

The web-shaped textile structure according to the invention can also be used as a dust filter cloth, whereby it is possible to hold back dust with different grain fineness, without the risk of clogging

Another advantage of the invention

Textile structure is the fact that the solidification of the various layers before the removal of the matrix component

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is made so that the relatively large composite fibers withstand the mechanical stresses during the union and the finished textile structure can be produced from numerous extremely fine fibers after removal of the matrix component can. In the case of synthetic leathers known to date, the greatly reduced resistance of very fine fibers to mechanical attack represent a great difficulty in production.

As mentioned above, it is a fundamental one When practicing the present invention, it is necessary that the composite fibers are in the formation of the inventive Structure must differentiate over the thickness of the web in at least one of the following properties: (a) Fineness the composite fiber, (b) the fineness and number of island components in the composite fiber, and (c) weight ratio of the island component regarding the matrix component. The configuration of the textile structure obtained must reflect the fineness of the individual fibers and / or differentiate the number of individual fibers that form a fiber bundle, either continuously or but from layer to layer across the thickness of the web. In the present invention, two or more types are used Composite fibers that differ in at least one of the three properties mentioned. Preferably three are used to six kinds of such composite fibers.

Composite fibers selected in accordance with this are now combined to form a web and two or more, in particular, are laid three to six, such. Tracks on top of each other and then needled them. If it should be difficult that Laying individual strips on top of each other can be done by needling each strip beforehand or connecting it in some other way. You can use the Connect individual lengths with chain stitches. It is also possible bind the fibers together using flexible resins such as polyacrylonitrile or polyurethanes.

In a preferred Ausfühitungsart the ER ·> invention the process according to ^one forms the tracks on a known carding or similar devices of two ■. . ".. - 6 - -

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or more types of composite fibers of similar fineness, however, various delicacies of the island components. These tracks are now placed on top of each other in such a way that the fineness of the island components, i.e. the fineness of the fibers after removal the matrix component, from one surface to the other of the sheet-like The structure varies, and webs that are superimposed in this way then become a three-dimensional consolidation of the fibrous Configuration subject to needling. After this Solidification is carried out by removing the matrix component. When removing the matrix component, it is beneficial to use a Use a solvent that dissolves the matrix component, however, does not attack the island components of the composite fiber. :

Assuming that the island component is made of polyethylene terephthalate and the matrix component is made of nylon 6, formic acid, hydrochloric acid, or a mixture of calcium chloride and methanol can be used as the solvent. Pass the islands component of nylon 6 or polyethylene terephthalate and the matrix component of polystyrene, it may be as a solu- - solvents trichlorethylene or toluene used with advantage. In some cases it is not necessary to completely remove the matrix component. =

The configuration of the composite fiber that is invented; is used properly is described below. The ι composite fiber should over the cross section, two or more islands. \ Components include, but preferably at least five islands _ '■ components. The fineness of the island component should be 0.8 denier or less, especially Q, S denier or less. The ; Composite fibers generally have a strength of 1-20 denier, preferably 3-10 denier, and should have such physical properties that they can absorb external forces without deformation during the production of the web-like structure. The length and type of fine fibers are selected in accordance with the desired nature of the textile structure and depending on the manufacturing process.

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The island component can be made of polyamide, polyester, polyolefin, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, Polyurethane or copolymers of the corresponding monomers exist, with the obvious requirement that that the material must have fiber-forming properties.

The matrix component must consist of high polymers that differ from the material of the island components. It can consist of high polymers that are chemically similar to, but different from, the island components differ in molecular weight, crystal structure or resistance to chemical solvents. It is only strictly ensure that the island component is not attacked or damaged during the removal of the matrix component will.

In Fig. 4 is a further embodiment of the

Composite fiber used according to the invention shown. At this Embodiment are at least some of the island components 3 partially in the outer surface of the composite fiber 1, so that a better dissolution effect of the matrix component 2 is achieved will.

The following examples are intended to explain the invention further.

example 1

Three types of composite fibers were made from polyethylene terephthalate as an island component and polystyrene as a matrix component. Sample (a) had a composite fiber fineness of 6 denier, Sample (b) of 5 denier, and Sample (c) of 3 denier. The fineness of the islet components was 0.05 that in sample (a) _; 0.1 den in sample Qo) and 0.3 den in sample (cj. In all three cases the fiber length was 51 mm.

Using these three composite fibers were

produced three types of nonwovens with an m weight of 200 g. The three fleeces were then placed on top of one another in such a way that the fleece from sample (a) came on top, the fleece from sample (b) in the middle and the fleece from sample (c) came to the bottom .

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After laying them on top of each other, the three-dimensional consolidation of the fibers was done six times needled from both sides. The weight ratio of the island component to the matrix component was in the original Composite fibers 1: 1.

The web solidified in this way was then placed in a bath which consisted of a 10% polyvinyl alcohol solution. The web 151 took its weight in polyvinyl alcohol. After impregnation with the polyvinyl alcohol, the web was now the matrix component in order to completely remove the polystyrene brought in trichlorethylene. After this treatment

igen

the web was impregnated with a 201 dirnethylformamide solution Coagulated in a water bath to remove the polyvinyl alcohol Treated for 30 minutes in a water bath at 90 C and finally dried. The weight ratio of extremely fine Fibers to form polyurethane int the web-like structure obtained was 100:60.

If you get the web-like structure of a Undergoes a bulking operation, the very fine fibers near the surfaces rise, and the sheet-like structure is preserved a superficial handle that comes very close to that of goatskin. After removing the matrix component of the web, the top web layer of the article was composed of fine fiber bundles, each of which had 60 fibers 0.05 den: the intermediate layer consisted of fine fiber bundles each with 25 fibers of 0.1 denier, and the bottom layer consisted of fine fiber bundles each with 5 fibers of 0.3 denier. Because of this different configuration, the density was the Fibers in the top layer higher than in the bottom layers, and the appearance of wrinkles when bending the sheet-like The structure was very similar to that of natural high-quality leather,

For further investigation, the sheet-like structure was cut into three layers, each of which original. Layers (a), (b) and (c) corresponded. Each cut off Layer was made of polyethylene terephthalate to remove it treated with a 90 $ ^ phenol solution, and the

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Polyethylene terephthalate content in each layer was measured. A content ratio of the layers of 10: 8: 5 was established, given for (a) :( b) :( c) and the configuration properties of the individual layers was very similar to that of the corresponding layers in natural leather according to FIG. 3. A Such a result is not obtained with previously known artificial leather, which is not in the configuration over the thickness changes. Due to the fact that the web-like structure obtained is composed of a large number of bundles of extremely fine fibers was, and that the individual fibers and the added resins were not connected to each other, each fiber could be inside move the configuration, whereby the softness and the beautiful feel of the web-shaped textile structure comes about.

If you have different high polymer solutions or emulsions by coating or spraying onto the surface of the textile structure or colors the surfaces in a suitable manner, an artificial leather with significantly improved properties is obtained Qualities.

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Example 2

Using polyethylene terephthalate as the island component and polystyrene as the matrix component three types of composite fibers are made with a strength of 6 denier (Composite fiber d, e and f). The composite fiber (d) contained 42 island components with a thickness of 0.1 denier Composite fiber (e) 12 island components of 0.3 denier each and the composite fiber (f) 6 island components of 0.5 denier each. From these Composite fibers were produced on a carding machine.

represents. The basis weights were 50 g / m 2 of the fleece

2
Composite fiber (d), 200 g / m of the fleece made of composite fiber (e) and

250 g / m of the composite fiber fleece (f). After each other the fleeces were needled six times from both sides to achieve a firm bond. The solidified Web was then impregnated with a 25% dimethylformamite solution, which contained a polyurethane and a copolymer of acrylonitrile and butadiene in a weight ratio of 1: 1, and dried. The weight ratio of fibers to binder was 100:60. After impregnation with the binder it was the web in a mixture of trichlorethylene and methanol to completely remove the matrix component from polystyrene brought. .

After this treatment, the web was pressed at a temperature of 120 ° C. and bulked during the pressing. Imitation leather obtained in this way had a very good, soft and pleasant feel, and shoes made of this artificial leather developed superficial wrinkles, which are very similar to those made of natural leather looked similar. ■

Example 3

-There were again three composite fibers (g, h, i) with a thickness of 6 den, with polyethylene terephthalate were used as the island components and polystyrene as the matrix component. The weight ratio of these two

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the components was 1: 1. The composite fiber (g) contained 30 fine fibers of 0.1 denier each, and the composite fiber (h) contained 10 fibers of 0.3 denier each and the composite fiber (i) 6 fibers of 0.5 denier each. These three composite fibers became three nonwovens with one Weight per unit area of 200 g / m produced, superimposed and the bond from both sides ten times to achieve this needled to a solid consolidation. After needling, the solidified web was at 65 ° C for the removal of the Polystyrene immersed in trachlorethylene. After removing the matrix component, the web became to achieve a lateral Contraction dampened and finally calendered at a roller temperature of 180 ° C. The textile structure obtained possessed had a very smooth surface and was advantageously suitable for use as a dust filter with an improved filtering effect. By the application of heat treatment to the polyethylene terephthalate fibers the web possessed excellent dimensional stability which makes it suitable for use in filters.

Example 4

Two types of composite fibers of 10 den each

(j, k) were made using polyamide as the island component and polystyrene as a matrix component. The weight ratio of the two components was 48:52 for the composite fiber (j) and 24:76 for the composite fiber (k). The composite fiber (j) contained 48 island components of 0.1 denier each and composite fiber (k) contained 24 island components of the same strength. With these

2 composite fibers were fleeces of 300 g / m thickness on a carding machine produced, placed on top of each other and for the purpose of solidification needled. The apparent density of the sheet obtained was 0.12 g / cm. The web was then washed with a 50% vinyl alcohol solution impregnated, dried, placed in trichlorethylene at 70 ° C to remove the polystyrene matrix component and treated with hot water to remove the polyvinyl alcohol. The web-like structure obtained with an apparent

3
Density of 0.3 g / cm had an extremely soft and pleasant feel and was suitable as a material for hats and

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outer garments.

. Example 5

Two kinds of composite fibers (1, m) were prepared using polyethylene terephthalate as an island component. Polystyrene produced as a matrix component. The strength of the composite fiber (1) was 6 denier and the composite fiber (m) was 3 denier. The composite fiber (1) contained 6 island components of 0.6 den and each Composite fiber (m) 6 island components of 0.3 denier each. The weight ratio of the two components was 60: 4 ^ 0 in both cases. Nonwovens were made from these two composite fibers, these placed one on top of the other in such a way that in the middle a fleece of the Type (m) and a fleece of type C1) arranged above and below was. This three-layer sheet was needled for consolidation, treated with polyvinyl alcohol solution for removal brought the polystyrene matrix component in Trihloräthylen, on calendered in a hot calender and cut horizontally into two thin sheets. The thin leaves thus obtained had a cut surface that was very soft and was extremely easy to print on.

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Claims (12)

Claims Web-shaped textile structure, characterized in that that it consists essentially of a fibrous mass made up of numerous bundles of extremely fine fibers composed, and that the fineness of the fibers and / or the number of fibers per bundle variable over the thickness of the web is. 2. Web-shaped textile structure according to claim 1, characterized in that the fineness of the fibers and / or the number of fibers per bundle in layers, i.e. discontinuously, is changeable. 3. Web-shaped textile structure according to claim 1, characterized in that the fineness of the fibers and / or the number of fibers per bundle is continuous across the thickness the path, is changeable. 4. Web-shaped textile structure according to claim 2, characterized in that the individual layers are connected to one another by needling, sewing or the like. 5. Web-shaped textile structure according to claim 1, characterized in that it has bulged surfaces. 6. Web-shaped textile structure according to claim 1, characterized in that the fineness of the individual fibers is 0.6 denier or less. 7. Process for the production of the web-shaped Textile structure according to claim 1 to 6, characterized in that composite fibers are first produced from different matrix components and island components, the matrix components consisting of a high polymer and the island components, which are separated from one another inside the matrix, consist of another high polymer the island components are stretched lengthways so that a web is formed from the composite fibers, that the web is consolidated in such a way that the fineness and / 009823/1659 or the number of island components per composite fiber over the The web thickness changes, and that the matrix component is finally removed from the solidified web. . 8. The method according to claim 7, characterized in that the number of island components per composite fiber ·. selects variable over the web thickness. 9. The method according to claim 8, characterized draws that mand is the number of island components per composite fiber selects variable over the web thickness from layer to layer. 10. The method according to claim 7, characterized in that that the fineness of the island components can be seen in the measure decreases how to increase the number of island components per composite fiber. . 11. The method according to claim 7, characterized in that the web is solidified by needles. 12. The method according to claim, characterized in, that after removal of the matrix components, the surfaces of the web are bulged. - 15 - 009823/1659 At Empty soap