DE19804940A1 - Compound fabric structure for filters, etc. - Google Patents

Abstract

The compound textile fabric material has at least two identical or different textile layers, bonded together without a bonding agent. One layer is a random-laid nonwoven. The other layer is a textile fabric with projecting loops of filaments or fibers or particles which lock into the other layer at their contact points so that both layers are bonded together. The compound textile fabric material has at least two identical or different textile layers, bonded together without a bonding agent. One layer (1) is a random-laid nonwoven. The other layer (2) is a textile fabric with projecting loops of filaments or fibers or particles which lock into the other layer (1) at their contact points (3) so that both layers are bonded together over their whole facing surfaces without hollow zones. The nonwoven layer (1) has a cross-section structure with a higher density and the fabric structure a lower density cross-section structure than at the start before bonding. An Independent claim is included for a manufacturing process where a web of fibers or filaments is formed into a random-laid nonwoven layer (1) by high pressure media jet streams directed at it at right angles or diagonally. At the same time, fibers or filaments are forced out of the layer (1) into the adjacent layer (2) at the contact surfaces (3) between them, wholly or partially. Or filaments or fibers of the second layer (2) are drawn into the first layer (1) to bond with it over the whole of their contact surfaces (3). The fibers and/or filaments at the pores of the second layer (2) are overlaid and intermingled to give a compression at the layer (2) surface without changing the surface cross section of the layer (2).

Description

The invention relates to a textile layer composite made of at least two identical or different textile layers without the use of additional binders are interconnected, and a method for producing this layered composite. Priority areas of application for such composites are in vehicle construction, in Filter and separation technology, in construction, in medicine and in the hygiene sector.

It is already known to have two or more fabrics with the same or different appearance, usage or functional properties by sewing, To connect needles or glue together. The disadvantage of sewing is the formation of Seams on both surface sides of the composite, the geometric longitudinal distribution of the Connection points, the additional effort of suture material as well as piercing markings. The use of alien or identical adhesives adversely affects use necessary passage of air, water, water vapor or the like. Negative and lead to a undesirable stiffening of the composite material.

In terms of process engineering, there are solutions, solidified or unconsolidated fiber or Filament fiber fleeces with a textile fabric as a carrier spell by needles or Sewing mechanically to connect, elements of these nonwovens through the carrier web pulled through or pushed and arranged on the back as a flat support. The disadvantage here is the formation of a large number of holes for certain areas of application by inserting the needles, which make the surface cross-section or the surface very porous shape or in particular the reorientation of a multitude of Fibers. In addition, the optical change in the back surface of the carrier web disadvantageous for certain purposes.

Another disadvantage for the applicability in the intended areas of application are in the case of untreated single-layer nonwoven fabrics, the tendency to curl and the large-pore or fibrous surfaces.

The invention has for its object to eliminate the disadvantages listed and one Layered composite of several identical or different textile layers create that are connected to each other without additional binders, without doing so to significantly change the structure and bulk of the composite. Furthermore should the processing or use for use in a wide variety of applications areas without separating the individual textile layers of the layered composite be guaranteed and a process for the economic production of such Layered composites are developed.  

According to the invention the object is achieved by the features described in claims 1 and 8 solved. Advantageous further developments are contained in the subclaims.

With the solution according to the invention, a textile layer composite is created, which constantly new demands regarding the properties, the usage behavior and the economical and environmentally conscious production for a wide range of applications becomes. The layered composite according to the invention has good processing properties due to its high gliding ability, the combination of different fabrics is possible properties through variable layer structure and fiber combination without mixing. The Pores of the fabrics used can be reduced in size in this way by the compression be that the applied nonwoven layer can perform protective functions and for example smallest particles can be separated during filtration.

The fiber / fiber, fiber / filament or filament / filament bond achieved between the layers to be joined can be based on the use of additional non-specific binders or adhesives. The mechanical connection using needles structural and surface changes that occur due to the reorientation of fibers or the formation of a variety of puncture holes that are suitable for certain areas of application prove to be extremely disadvantageous is also avoided. The use of a wide range of Textile fabrics that are arranged according to the invention with one or both sides Fiber layer are equipped, enables a targeted improvement of the characteristic Properties such as textile feel, bulkiness and softness depending on the intended application.

The invention can be made from a variety of materials or combinations thereof realize, so that the use in many different industrial sectors is possible. Both for the vortex nonwoven and the fabric used as the carrier material all types of fibers including special fibers can be used. Beyond that through the use of single and multi-layer fabrics, which are based on the known Process technologies can be manufactured, the most diverse cross-section manufacture structures.

Embodiment

The invention is illustrated below with the aid of a number of drawings Exemplary embodiments described. Show in the accompanying drawings

Fig. 1 shows the cross-section of the textile layer composite of the invention,

Fig. 2 shows the cross-section of a page on the mesh compacted nonwoven stitchbonded fabric Malifleece for use as a replacement for foam seat cushion,

Fig. 3 shows the cross-section of a page on the mesh needled pile stitchbonded fabric densified Kunit for a filter material in the wet and dry filtration,

Fig. 4 shows the cross section of a single-sided nonwoven stitchbonded fabric densified Multiknit for an insulation material,

Fig. 5 shows the cross-section of the pile side of needled pile stitchbonded fabric densified Kunit for use as shoulder pads,

Fig. 6 shows the cross section of a double-sided compressed non-woven fabric Multiknit for an absorbent article in medicine or hygiene.

As shown in FIG. 1, the textile layer composite according to the invention consists of the layer combination with a fiber layer 1 and a flat structure 2 . The fiber layer 1 is formed from a fiber or filament nonwoven and is consolidated by means of high-energy gaseous or liquid high-pressure media jets to form a fluidized nonwoven fabric that has a high structural density. Depending on the field of application of the layered composite, a sheet with the greatest possible volume and low structural density is used for layer 2 , such as pile fabrics, knitted fabrics or knitted fabrics, preferably single and / or multi-layered nonwoven sewing fabrics, nonwoven fabric Struto or a diluted needlewoven fabric . The non-woven fabric 1 and the sheet 2 are firmly connected to one another in the contact area 3 , in which they lie directly against one another without the formation of cavities, the composite having a high separation resistance. The bond is made without additional binders only by fibers, filaments or parts thereof from the non-woven fabric 1 , which are intertwined with the fibers, filaments or parts thereof located on the surface of the fabric 2 . By intertwining the fibers or filaments of both layers 1 and 2 in the contact area 3 , the pores on the surface of the fabric 2 are reduced and evened out.

Depending on the intended use of the layered composite, the non-woven fabric 1 and the flat structure 2 can be produced from the same or different fiber material, it also being possible to use special fibers, such as, for example, electrically conductive fibers. In order to further increase the strength of the layered composite material, a flat structure 2 reinforced with additional non-woven fabrics made of fibers or filaments, non-woven materials, flat structures or threads or thread layers made of textile or non-textile materials can be used.

Example 1: Foam replacement for seat cushions

Referring to FIG. 2 Malifleece 2 is used as a cushioning component for vehicle seats or seating a nonwoven sewing knitted fabric, the nonwoven fabric mesh of a cross-laid and after the stitch bonding is made. Instead of the cross-laid nonwoven, a nonwoven provided by the card and knitted directly after the "Kunit" sewing process can also be used. In order to achieve the highest possible recovery capacity, the use of fiber blends of different fiber finenesses between 3.3 and 12 dtex, including a proportion of bicomponent fibers, is advantageous. To achieve the necessary stability in the longitudinal and transverse directions and the lubricity required for further processing, a non-woven fabric 1 is arranged on the stitch side MS of the nonwoven sewing fabric 2 (Malivlies or Kunit). The vortex nonwoven fabric 1 consists of an aerodynamically formed random web which is compressed and consolidated by means of high-energy water jets. In the contact area 3 of the non-woven fabric 1 and the non-woven fabric 2 , fibers of the non-woven fabric 1 are connected over the entire surface to the fibers lying on the surface of the non-woven fabric 2 , without cavities being formed. As a result, the composite has a strong and permanent bond with a high separation resistance, which is retained both during manufacture and in use as a cushioning component.

2nd embodiment: depth filter for wet and dry filtration

The filter composite shown in FIG. 3 consists of a Kunit 2 non-woven fabric, which is formed from a non-woven fabric made of synthetic fibers with finenesses between 1.0 and 12 dtex and a mass per unit area of approx. 60 g / m ² , by means of a vibrating device with 12 up to 34 mm stroke is folded and meshed with pusher needles. This nonwoven Kunit 2 nonwoven fabric with surface weights between 50 and 500 g / m ² and a thickness between 5 and 12 mm is then submitted to a system for water jet consolidation in order to compact the stitch side MS. In front of the hardener, a tangled fleece of fibers with a fineness of 0.8 to 1.7 dtex is placed on the stitch side MS of the Kunit 2 nonwoven sewing fabric and guided together through the hardener. Consolidation is carried out with at least five nozzle bars and water jet pressures between 0.2 and 18 MPa, the water jet pressure of the first nozzle bar should be as low as possible. A drying and fixing process follows the composite production in the area of contact 3 of the vortex nonwoven fabric 1 with the nonwoven sewing fabric Kunit 2 by means of high-energy water jets. The drying temperature and the dwell time depend on the selected fiber type and the mass of the composite.

The filter composite produced by this process is high-volume, has through high porosity of the inflow side A and the compressed outflow side B the ability to high Absorb dust capacities and separate even the smallest particles (up to 0.3 µm in size). The filter composite is cut edge resistant, so it is easy to assemble, e.g. B. to bags filter media. The use can for fine filtration u. a. for gas filtration up to filter class F9 respectively. If such filter composites are made from or with hydrophilic fibers, these composites are particularly suitable for use as car filters.

3rd embodiment: insulation material

For the insulation material according to FIG. 4, a fiber pile of approximately 100 g / m ^{2 is} formed from synthetic or natural fibers with finenesses between 3.6 and 15 dtex, folded and knitted on one side. The resulting high-volume fabric has a large-pore mesh side MS and a fluffy fiber pile side. In a further operation, the fiber pile side that forms the stitch side MS1 is also meshed. Thereafter, the two mutually meshed fabric Multiknit 2, a nonwoven fabric 1 having a basis weight between 50 and 300 g / m ² of standard or special fibers such. B. high-temperature-resistant, flame-retardant or plastic fibers and connected by means of high-pressure water jets to the Multiknit 2 fabric meshed on both sides in the contact area 3 . The water jet pressure of the first nozzle bar should be chosen to be as low as possible. The water jet pressure of the following nozzle bars depends on the mass per unit area of the nonwoven layer 1 to be applied and can be selected between 5 and 40 MPa. After bonding, the composite is dewatered, dried and fixed by vacuum suction or using padding rollers. Depending on the requirements, additional treatment with textile auxiliaries, e.g. B. flame retardants, stiffeners, can be integrated into the process.

The composite produced by this process is dimensionally stable, has a large-pore surface on the mesh side MS1 and an opposite smooth side with fine pores. The pores on the mesh side MS are compressed in such a way that the air permeability of the fabric Multiknit 2 is reduced to 1/3 to 1/4 by means of the processed nonwoven fabric 1 . The volume, breathability and insulation of the Multiknit 2 fabric are retained. Due to the compression on one or both mesh sides MS, MS1, the composite can also perform special functions.

4. Example: shoulder pads

Of FIG. 5 is a needled pile stitchbonded Kunit 2 is from 20% PES-bonding fiber (4.4 dtex / 50 mm) 40% PES (4.4 dtex / 60 mm) and 40% PES (7.0 dtex / 60 mm), a mass per unit area of 250 g / m ² , a stitch length of 2.5 mm and with pile folds, which are formed by an oscillation stroke of 34 mm, on the pile side PS with a non-woven fabric 4 made of 15% PES binding fibers (4th , 4 dtex / 50 mm) and 85% PES (1.7 dtex / 38 mm) and a basis weight of 80 g / m ² . This nonwoven fabric 4 is connected by means of water jets to the nonwoven sewing fabric Kunit 2 on its pile side PS. The bond is thermally consolidated at a temperature of approx. 160 ° C. When solidifying in a predetermined shape, for. B. shoulder pads with the given thickness profile. The vortex nonwoven fabric 1 on the one hand and the mesh structure MS on the other hand result in a closed surface on both sides, which is still consolidated by the thermally dissolved binding fibers. Such nonwoven bodies do not require any further textile cover.

5. Example: Absorbent body for use in medicine or in the hygiene area

The composite material shown in FIG. 6 is made from a voluminous knitted fabric 2 (Kunit, Multiknit, KSB) with a basis weight of 200-500 g / m ² and a hydrophilic fiber, e.g. B. viscose or Lyocell fiber (1.0-3.3 dtex, 22-90 mm) or a mixture thereof, which on its front VS with a nonwoven fabric 1 made of the same fibers of the fineness 1.0-1.7 dtex and 22-60 mm fiber length is connected on one side by means of water jets in 1 to 4 passages with increasing pressures of 3 to 18 MPa in the contact area 3 . Instead of the nonwoven fabric 1 , a pre-consolidated nonwoven fabric can also be used. By using the lyocell fibers that fibrillate under the action of high-energy water jets (<10 MPa), the inner surface of the nonwoven composite is increased, the pores are reduced and the absorbency of the composite is increased. The use of exclusively cellulose-based fibers ensures that the products made from them rot. On the rear side RS of the stitchbonded nonwoven 2 used , a second nonwoven or a prefabricated nonwoven 1 a is placed on top and bonded with 1 to 2 passages and water pressures of 3 to 15 MPa in the contact area 3 a with the knitted fabric 2 . If this fiber layer 1 a z. B. from hydrophobic fibers, such as polypropylene, this side RS of the composite forms the "dry" side.

There is also the possibility of splittable fibers of the conjugated polymer combination type, e.g. B. PES- / PE-F, PES- / PA-F in the fineness 3.4 dtex and a fiber length of 3 to 51 mm for the fiber layer 1 a on the back RS of the knitted fabric 2 to use. These fibers also split into triangular segments with a fineness of approx. 0.22 dtex under the action of high-energy water jets <10 MPa. The same effect occurs as when using the fibrillating Lyocell fibers with regard to improving the absorbency by increasing the nonwoven fabric density and reducing the pores in the nonwoven composite.

Claims (11)

1. Textile layered composite of at least two identical or different textile layers, which are firmly connected to one another without the use of additional binders, characterized in that the layer ( 1 ) is formed by a fluidized non-woven fabric, which with the layer ( 2 ) consisting of a There is textile fabric, by mutual entangling of fibers, filaments or parts thereof in the contact area ( 3 ) of the layers ( 1 , 2 ) is firmly connected over the whole area without the formation of cavities, the layer ( 1 ) having a cross-sectional structure of high density and the layer ( 2 ) has a lower density cross-sectional structure like the initial structure before joining. 2. Textile layered composite according to claim 1, characterized in that the vortex nonwoven ( 1 ) on the front and / or back (VS, RS) of the fabric ( 2 ) is arranged. 3. Textile layered composite according to claim 1 and 2, characterized in that the vortex nonwoven ( 1 ) is formed from a fiber or filament nonwoven. 4. Textile layered composite according to claim 1 to 3, characterized in that the fabric ( 2 ) made of a woven fabric, knitted fabric, knitted fabric, a single or multi-layer nonwoven fabric, for example sewing nonwoven, Kunit, Multiknit, Kunit layer composite (KSB), non-woven fabric Struto or a diluted needle punched nonwoven fabric. 5. Textile layered composite according to claim 4, characterized in that the fabric ( 2 ) has one or two stitch sides (MS, MS1). 6. Textile layered composite according to claim 4 to 5, characterized in that the fabric ( 2 ) is reinforced by additional non-woven fabrics made of fibers or filaments, nonwovens, fabrics or threads made of textile or non-textile material. 7. layered composite according to claim 1 to 6, characterized in that the fabric ( 2 ) and the vortex nonwoven fabric ( 1 ) consist of the same or different fiber material. 8. A process for the production of a layered composite material from at least two identical or different layers without the use of additional binders according to claim 1, characterized in that fibers or filaments of a layer ( 1 ) are compressed and consolidated into a fluidized nonwoven fabric by means of vertically or diagonally running high-pressure media jets , simultaneously fibers, filaments or parts of these from one layer ( 1 ) with the fibers, filaments or parts of these located in the contact area ( 3 ) of the layers ( 1 , 2 ) to be connected from one layer ( 2 ) and the Layers ( 1 ; 2 ) are uniformly and firmly connected to one another throughout the entire surface, fiber and / or filament parts being incorporated and deposited in the pores on the surface of the layer ( 2 ), which result in a densification of the surface on the Layer ( 2 ) lead without the structure of the surface cross-sections s of layer ( 2 ) is changed. 9. The method according to claim 8, characterized in that a liquid or gaseous Medium for which rays are used. 10. The method according to claim 8 and 9, characterized in that the media rays can be used on both sides. 11. The method according to claim 8 to 11, characterized in that after connecting the layers ( 1 , 2 ) one of the known thermal treatments, optionally using textile auxiliaries, for example flame retardants or the like.