DE19804940B4 - Layered textile composite and process for its production - Google Patents

Abstract

Textile layered composite made of at least two textile layers, which are connected to one another without the use of additional binders, characterized in that one layer is formed by a fluidized nonwoven fabric (1) which is combined with a second layer consisting of a voluminous textile fabric (2), by intertwining fibers, filaments or parts thereof in the contact area (3) of the layers without the formation of voids, the entire area of the non-woven fabric (1) has a cross-sectional structure of high density and the flat structure (2) retains its initial structure with lower density ,

Description

The invention relates to a textile Layered composite of at least two textile layers, the without the use of additional Binders are interconnected, and a method of manufacture this layered composite. Priority areas of application for such Composites are used in vehicle construction, in filter and separation technology, in Construction, medicine and hygiene.

It is already known two or also several fabrics with the same or different appearance, usage or functional properties by sewing, To connect needles or glue together. This is disadvantageous when sewing Formation of seams on both sides of the surface of the network, the geometric longitudinal distribution of the connection points, the additional Suture expenditure and puncture marks. used Adhesives of a different type or of the same type impair the passage of air required in use, Water, water vapor or the like. Negative and lead to an undesirable Stiffening of the composite material.

Technically, there are solutions consolidated or non-consolidated fiber or filament fiber fleeces with a textile fabric as a carrier web by needles or sewing mechanically connect, whereby elements of these fleeces through the support web pulled or pushed through and on the back as flat Edition to be arranged. This is disadvantageous for certain Areas of application are the formation of a large number of holes by piercing of the needles covering the area cross section or the surface very porous shape or in particular the reorientation that occurs when needling a variety of fibers. Moreover is the optical change the back Surface of the support web for certain Uses of disadvantage. Another disadvantage for applicability in the for that The intended areas of application are untreated single-layer Nonwoven fabrics have a tendency to curl and the large-pore or fibrous surfaces.

US Pat. No. 5,290,628 describes a process for producing a fluidized nonwoven fabric from two different fiber layers, in which no composite material is produced, but only two different fiber layers ( 2 . 5 ) one after the other to a vortex nonwoven ( 10 ) are solidified. The connection of the fiber layers ( 2 . 5 ) takes place in two successive identical process steps using water jets ( 4 . 9 ), whereby according to the process-related tape guide in the second consolidation process, part of the fibers from the first consolidated layer ( 2 ) in the second fiber layer ( 5 ) is introduced and with the fibers of the fiber layer ( 5 ) devour. This procedure serves, in particular, to use special fibers in a proportion in a fluidized nonwoven in order to modify the properties of the fluidized nonwoven for certain areas of use.

The situation is similar DE 89 16 164 U1 known non-woven, non-elastic fiber material which has an essentially homogeneous mixture of non-elastic melt-blown fibers and other fiber material, the melt-blown fibers being hydraulically intertwined with the other fiber material. The nonwoven fabric can be hydraulically entwined with additional reinforcement material to improve the tightness. The reinforcing material is arranged between the different fiber layers and the hydraulic interlacing of the fiber material creates a homogeneous fabric.

Furthermore, composite materials from the DE 27 37 703 A1 . US 4 144 370 and the publication E. Schmalz, A. Meyer, G. Ritscher "New nonwovens / metal composites for dust separation" in DE-Z Technical Textiles vol. 40, August 1997, pp. 176-178 - known, in which a fabric as Carrier or reinforcement layer is integrated in a fiber layer. The bond is made by entangling and matting individual fibers from the fiber layer with the protruding fibers of the fabric inside or on the back of the fabric, so that the components of the fabric, for example the warp and weft threads of a fabric, are almost completely wrapped in fibers are and a homogeneous, relatively thin composite is achieved. The sheet-like structure enveloped by the fiber layer acts as a reinforcing component within the fiber layer, the open-pore sheet-like structure used, such as woven, knitted or knitted fabrics, being compacted by incorporating fibers. Both components, the fiber layer and the fabric, form a homogeneous bond here too.

The production of mechanically strengthened, voluminous nonwovens is known from the literature, which according to claim 3 of the solution according to the invention is used as a layer ( 2 ) are used. These voluminous nonwovens have flat cross-sections with low density due to their strengthening process using the Malimo technique. Due to the arrangement of stitches on one or both sides, these fabrics also have an often-porous surface structure, which proves to be disadvantageous for the application examples given (P. Plesken "Experience in the mechanical consolidation of fiber webs and non-woven fabrics" in DE-Z General Nonwoven Report 2 -1992, pp. 54-58 and Dr. J. Tröger "Kunit and Multiknit for technical applications" in DE-Z Technical Textiles, 39th June 1996, p. 70,71).

The invention is based, which listed Eliminate disadvantages and a composite of several layers to create textile layers that cover the entire surface without additional binders are connected without losing the structure and bulk of the composite material to change. Furthermore, the processing or use in a variety of ways Areas of application without separating the individual textile layers of the layered composite guaranteed be and a process for the economical production of such Layered composites are developed.

According to the invention, the object is achieved by Features described in claims 1 and 7 solved. Advantageous further training are in the subclaims contain.

With the solution according to the invention created a textile layered composite that is constantly changing Claims regarding the properties, the behavior in use and the economic and environmentally conscious Production for the diverse areas of application justice. The layered composite according to the invention has good processing properties due to high lubricity, allows the combination of different fabric properties through variable layer structure and fiber combination without mixing. The Pores of the fabrics used can can be reduced by the compression in such a way that the applied nonwoven layer Fulfill protective functions can, for example, separate the smallest particles during filtration can be.

Due to the fiber / fiber Fiber / filament or filament / filament bond between those to be connected Layers can be based on the use of additional non-binding agents or adhesives. The mechanical connection Changes in structure and surface caused by needles due to the reorientation of Fibers or the formation of a variety of puncture holes that for certain areas of application as extremely disadvantageous turn out to be avoided. The use of a wide range of textile fabrics, the invention with a fiber layer arranged on one or both sides, allows a targeted improvement of the characteristic properties, like textile handle, bulkiness and softness depending on the intended application.

The invention can be of a variety of materials or their combinations, so that the use is possible in many different industrial sectors. Both for the vortex nonwoven as well as the carrier material fabrics used can all types of fibers including Special fibers are used. In addition, the use of single and multi-layer fabrics, which according to the known process technologies can be manufactured, the produce a wide variety of cross-sectional structures.

embodiment

The invention is described below with reference to several Described schematically illustrated exemplary embodiments. In the associated Show drawings

1 the cross section of the textile layer composite according to the invention,

2 the cross-section of a non-woven knit fabric compacted on the stitch side for use as a foam substitute for seat cushions,

3 the cross-section of a nonwoven Kunit knitted fabric compacted on the stitch side for a filter material in wet and dry filtration,

4 the cross section of a one-sided compressed nonwoven multiknit for an insulation material,

5 the cross section of a Kunit nonwoven sewing knit compacted on the pole side for use as a shoulder pad,

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

Like in the 1 shown, the textile layer composite material according to the invention consists of the layer combination with a fiber layer and a textile fabric. The fiber layer is formed by a fiber or filament fleece and is transformed into a fluidized non-woven material by means of high-energy gaseous or liquid high-pressure media jets ( 1 ), which has a high structural density, solidified. Depending on the area of application of the layer composite, a flat structure ( 2 ) used with the greatest possible bulk and low structural density, such as pile fabrics, knitted fabrics or knitted fabrics, preferably single and / or multi-layer non-woven fabric, knitted non-woven fabric Struto or a diluted needled non-woven fabric. The vortex nonwoven 1 and the fabric 2 are in the touch area 3 , in which they lie directly against one another without the formation of cavities, firmly connected to one another, 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 that with the on the surface of the fabric 2 fibers, filaments or parts thereof are intertwined. By intertwining the fibers or filaments of both layers in the contact area 3 are those on the surface of the fabric 2 pores are reduced and evened out.

Depending on the intended use of the layered composite, the fluidized nonwoven can 1 and the fabric 2 are made of the same or different fiber material, the use of special fibers, such as electrically conductive fibers, is also possible. In order to further increase the strength of the layered composite, a flat structure reinforced by 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 2 be used.

1. Example: foam substitute for seat pads

2 shows a textile composite layer, which is used as a cushioning component for vehicle seats or seating; it consists of a non-woven fabric made of Malivlies 2 , which is made of a cross-laid nonwoven fabric that is meshed after the sewing process. Instead of the cross-laid non-woven fabric, a non-woven fabric presented by the card and knitted immediately after the "Kunit" sewing process can be used. To achieve the highest possible recovery, 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, MS of the nonwoven sewing fabric is on the stitch side 2 (Malivlies or Kunit) a vortex nonwoven 1 arranged. The vortex nonwoven 1 consists of an aerodynamically formed tangled fleece, which is compressed and consolidated by high-energy water jets. In the touch area 3 of vortex nonwoven 1 and non-woven fabrics 2 are fibers of the vortex nonwoven 1 with those on the surface of the non-woven fabric 2 lying fibers connected over the entire surface without creating voids. 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 in 3 Filter composite shown consists of a non-woven Kunit knitted fabric 2 , 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 , is folded by a vibrating device with a stroke of 12 to 34 mm and is meshed by means of pusher needles. This non-woven fabric Kunit 2 with masses of between 50 and 500 g / m ² and a thickness of between 5 and 12 mm, a system for hydroentangling is subsequently submitted to compact the mesh side MS. Before solidification, Kunit is sewn onto the stitch side MS of the non-woven fabric 2 a tangled nonwoven made of fibers with a fineness of 0.8 to 1.7 dtex is put on and guided together through the consolidation. 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. To the composite production in the contact area 3 of the vortex nonwoven 1 with the Kunit non-woven fabric 2 A drying and fixing process follows using high-energy water jets. The drying temperature and the dwell time depend on the selected fiber type and the mass of the composite.

The one made by this process Filter composite is high-volume, has A due to the high porosity of the upstream side and the compressed outflow side B the ability high dust capacity and to separate even the smallest particles (up to 0.3 μm in size). The filter composite is cut edge resistant, so easy to assemble, e.g. B. to pocket filter media. The use can for fine filtration u. a. in gas filtration up to filter class F 9. Such filter composites Made of or with hydrophilic fibers, these are composites especially for suitable as an auto filter.

 3rd embodiment: insulation material

For the insulation material according to 4 a fiber pile of approx. 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. Then Multiknit is applied to the double-sided mesh 2 a non-woven fabric 1 with a basis weight between 50 and 300 g / m ² of standard or special fibers, for. B. high-temperature resistant, flame-retardant or plastic fibers and by means of high-pressure water jets with the fabric knitted on both sides Multiknit 2 in the contact area 3 connected. The water jet pressure of the first nozzle bar should be chosen as low as possible. The water jet pressure of the following nozzle bars depends on the mass of the non-woven layer to be applied 1 and can be chosen between 5 and 40 MPa. After bonding, the composite is dewatered, dried and fixed by vacuum suction or using padding rollers. Depending on requirements, additional treatment with textile auxiliaries, e.g. B. flame retardants, stiffeners, can be integrated into the process.

The Ver Bundstoff is dimensionally stable, has a large-pore surface on the mesh side MS1 and an opposite smooth side with fine pores. Due to the processed vertebral nonwoven 1 the pores of the mesh side MS are compressed in such a way that the air permeability of the Multiknit fabric 2 reduced to a third to a quarter. The volume, breathability and insulation of the Multiknit fabric 2 remain intact. Due to the compression on one or both mesh sides MS, MS1, the composite can also perform special functions.

4. Example: shoulder pads

To 5 is a non-woven knit fabric Kunit 2 made of 20% PES binding fiber (4.4 dtex / 50 mm) with 40% PES (4.4 dtex / 60 mm) and 40% PES (7.0 dtex / 60 mm), a basis weight 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 nonwoven fabric 4 made of 15% PES binding fibers (4.4 dtex / 50 mm) and 85% PES (1.7 dtex / 38 mm) and an area of 80 g / m ² . This fleece 4 is made by means of water jets with the Kunit 2 connected to the pole 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 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 solidified 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 hygiene

The in 6 Composite shown is made of a voluminous knitted fabric 2 (Kunit, Multiknit, KSB) with a basis weight of 200-500 g / m ² and a hydrophilic fiber, e.g. viscose or lyocell fiber (1.0-3.3 dtex, 22-90 mm) or a mixture thereof, which VS on the front with a fleece 1 made of the same fibers with a fineness of 1.0 - 1.7 dtex and 22-60 mm fiber length on one side using water jets in 1 to 4 passages with increasing pressures of 3 to 18 MPa in the contact area 3 is connected. Instead of the fleece 1 a pre-consolidated vortex nonwoven can also be used. By using the lyocell fibers that fibrillate under the influence 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 can rot. On the back RS of the sewing nonwoven used 2 is a second nonwoven or a prefabricated nonwoven 1a laid on and solidified in the contact area with 1 to 2 passages and water pressures of 3 to 15 MPa 3a with the knitted fabric 2 connected. If this fiber layer 1a 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 1a on the back RS of the knitted fabric 2 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 (10)

Textile layered composite made of at least two textile layers which are connected to one another without the use of additional binders, characterized in that one layer is composed of a 1 ) is formed with a second layer consisting of a voluminous textile fabric ( 2 ) exists by intertwining fibers, filaments or parts thereof in the contact area ( 3 ) of the layers is firmly bonded over the entire area without the formation of cavities, the non-woven material ( 1 ) has a cross-sectional structure of high density and the fabric ( 2 ) maintains its lower density initial structure. Layered textile composite according to claim 1, characterized in that a layer of a non-woven fabric ( 1 ) on the front and / or back (VS, RS) of the fabric ( 2 ) is arranged. Layered textile composite according to claims 1 and 2, characterized in that the non-woven fabric ( 1 ) is formed from a fiber or filament fleece. Layered textile fabric according to claims 1 to 3, characterized in that the flat structure ( 2 ) consists of a woven fabric, knitted fabric, knitted fabric, a single or multi-layer nonwoven in the form of mali fleece, kunite, multiknit, kunite layer composite (KSB), non-woven or needle-punched nonwoven. Layered textile composite according to claim 4, characterized in that the fabric ( 2 ) has one or two stitch sides (MS, MS1). Layered textile composite according to claim 4 or 5, characterized in that the flat structure ( 2 ) is compacted by additional non-woven fabrics made of fibers or filaments, fabrics or threads made of textile or non-textile material. Process for the production of a textile layer composite material from at least two textile layers according to claims 1 to 7 by means of vertical or diagonal high-pressure media jets, characterized in that during the formation of the vortex nonwoven ( 1 ) at the same time fibers, filaments or parts thereof from the non-woven fabric ( 1 ) with those in the contact area ( 3 ) fibers, filaments, or parts thereof of the fabric to be connected ( 2 ) are intertwined so that both layers are firmly bonded uniformly over the entire surface, fiber and / or filament parts being inserted into the surface of the fabric ( 2 ) pores are stored and deposited, which lead to a densification of the surface of the fabric ( 2 ) lead without the structure of the cross-sectional area of the fabric ( 2 ) is changed. A method according to claim 7, characterized in that a liquid or gaseous Medium for the high pressure media jets is used. Method according to claims 7 and 8, characterized in that the media jets can be used on both sides. Method according to Claims 7 to 9, characterized in that after the layers ( 1 . 2 ) a thermal treatment takes place.